SAS Process Intelligence for Manufacturing · Quality Manufacturing: Capacity and Volume Yield,...

Copyright © 2002, SAS Institute Inc. All rights reserved.

SAS Process Intelligence for Manufacturing

Ian Cox Gerhard HeldProduct Manager Solutions Manager Worldwide Marketing Analytical ApplicationsSAS Institute Inc. SAS International


Software Solutions Landscape and General Approach

Low High

Service Effort to Customise Software

High

Low

Effort to Understand Prospect Problem (Effort to Re-Sell)

(Our Cost)

(Customer’s Cost)

PackagedSolutions

Custom Development

SAS Process Intelligence


Automotive

SAS Process Intelligence Product Strategy

Semiconductor High Tech Chemical andPharmaceutical

CPGFMCG

NonManufacturing

SAS PRI for ManufacturingDirect SAS Sales

ENGINEERINGworksTM

Sell through Brooks-PRI Automation


Agenda! The High-Tech Manufacturing Environment! SAS Process Intelligence for Manufacturing:

Overview! SAS Process Intelligence for Manufacturing:

Summary


What Is The Defining Characteristic of ‘Manufacturing’?


Maximising Value Creation is Increasingly Difficult For High-Tech Manufacturers Today Because Of . .

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A Note On “Value Creation”

CostyFlexibilitkSpeedkQualitykValue *** 321 ++

=

Edwin Artzt of Proctor and Gamble, Quality Forum VIII, October 1st 1992.

What is “value”?

How is value delivered?Through (hierarchical) processes.

How can value creation be maximised?By using “intelligent” processes that obey all real-world constraints.


A Convergence of Multiple Processes . . .

New Product Introduction Technology Transfer

Customer Service

Quality

Factory/Supply Scheduling

Engineering Changes

Cos

t Cut

ting



Customer Service

Quality


Engineering Changes

Cos

t Cut

ting


*****

****

*****

****

********



Customer Service

Quality


Engineering Changes

Cos

t Cut

ting


*****

****

*****

****

********

Managing risks Managing risks and tradeoffs startsand tradeoffs startsfrom integrated datafrom integrated data

from Processes,from Processes,Products andProducts andEquipment.Equipment.


RequirementsCustomer:

Product FunctionSort Requirements

Final Test Requirements

Design:Design RulesSpice ModelsCell Libraries

Qualification:Reliability

Quality

Manufacturing:Capacity and Volume

Yield, Cycle Time, OEE

Risk Assessment and Resource Allocation

Electrical

ProcessDefinition

Initial ProcessSettings

Sources ofVariation

Control andCapability

Identify KeyDrivers

Set Targetsand Windows

Process Module Process Step Tool Recipe

Monitor andControl

Improve AsRequired

ProcessDefinition


Sources ofVariation


Identify KeyDrivers


Monitor andControl

Improve AsRequired

ProcessDefinition


Sources ofVariation


Identify KeyDrivers


Monitor andControl

Improve AsRequired

ParameterDefinition

Identify ControllingSubsystems

ToleranceStudy


ControlMethodology

Monitor andControl

Improve AsRequired

Difference Between Planed Versus Actual Performance Drives Activity

EquipmentEngineering

ProcessEngineering

YieldEngineering

Defectivityand Line

Monitoring

Design

TestEngineering

ProductEngineering

ProcessIntegration

Quality andReliability

Scheduling







Quality




Electrical

ProcessDefinition


Sources ofVariation


Identify KeyDrivers



Monitor andControl

Improve AsRequired

ProcessDefinition


Sources ofVariation


Identify KeyDrivers


Monitor andControl

Improve AsRequired

ProcessDefinition


Sources ofVariation


Identify KeyDrivers


Monitor andControl

Improve AsRequired

ParameterDefinition


ToleranceStudy


ControlMethodology

Monitor andControl

Improve AsRequired



ProcessEngineering

YieldEngineering

Defectivityand Line

Monitoring

Design

TestEngineering

ProductEngineering

ProcessIntegration


Scheduling

•Monitor performance

•Control performance

•Improve performance


Qualify new equipmentImprove maintenance scheduleQualify new material vendorReduce test timeReduce monitor or test productCharacterise new product designEliminate inspection operationMaverick product identificationPre-emptive scrapping before test

. . . .

Underlying Data

Analytical Objective

Analytical Task

Business orEngineering

Objective

“Objective” versus “Task” . . .


Monitor performanceControl performanceImprove performanceEstablish cause and effect relationshipFind problem root causeDevelop predictive model

. . . .


Underlying Data


Analytical Task


Objective


ANOVAEWMA ChartsCUSUM ChartsGeneralised Liner ModelLinear Mixed ModelDecision TreeNeural NetworksRegressionCapability StudyBoxplot

. . . . .


Underlying Data


Analytical Task


Objective


“Objective” versus “Task” . . .ERP dataReticle dataWIP lot history dataLot-based inline data Non-lot or tool-based inline dataPM dataPlanned recipe dataActual recipe dataMaterials dataFacilities dataPCM dataElectrical Sort dataBitmap dataFailure Analysis dataInspection dataDefect data Bench test dataWafer Sort dataAssembly dataFinal Test dataReliability data

Underlying Data


Analytical Task


Objective







Quality




Electrical

ProcessDefinition


Sources ofVariation


Identify KeyDrivers



Monitor andControl

Improve AsRequired

ProcessDefinition


Sources ofVariation


Identify KeyDrivers


Monitor andControl

Improve AsRequired

ProcessDefinition


Sources ofVariation


Identify KeyDrivers


Monitor andControl

Improve AsRequired

ParameterDefinition


ToleranceStudy


ControlMethodology

Monitor andControl

Improve AsRequired



ProcessEngineering

YieldEngineering

Defectivityand Line

Monitoring

Design

TestEngineering

ProductEngineering

ProcessIntegration


Scheduling

Across Multiple Locations . .

“Silicon 2000” Survey




Summary


What is SAS Process Intelligence for Manufacturing?

“The only packaged solution that allows manufacturing and engineering operations to maximize value creation by exploiting integrated data to institute the right problem-solving, monitoring, control and improvement actions.”


! An analytic solution infrastructure and reporting environment.

! Build around a data model and warehouse flow.

! Delivers SAS analytic tasks in a thin client web interface.

! Designed to easily add new analytic tasks and reports.

! High-technology manufacturing initially

What is SAS Process Intelligence for Manufacturing?


C-Space

etestetest

DefectDefect InspectionInspection MetrologyMetrology

Final TestFinal TestSortSort

Test SystemsTest Systems

SupplierSupplier OtherOther

Navigator

DiscovererAgent

Information Store

Know

ledge Managem

ent Interface(W

ebDA

V)

Extract, Transform and Load

Navigator(Client side)

Navigator(Server side)

SAS® ProcessIntelligence

Metadata andProcesses

Discoverer

Case ManagerAnalysis Tasks,

Components andUtility Processes

EngineeringInformation

Store

Manufacturing/operational

Data

Extraction,Transformation,

and LoadProcess

Confirm Data SetBuild and ReturnData Set Handle

RequestNew Data

Set

RequestAnalysis and

Data SetMaintenance

ReturnResults

RequestEnrichment

Data

ReturnMeasurementand Metadata

Data Sets

PublishResults as

Requested by User

AnalyzeData Sets

RequestEnrichment

ReturnAnalysisResults

ExtractLegacy

Data

Load Data toSAS® Process

Intelligence DataMart

Query/Extract D

ata

Request NewData Sets

Analyze ExistingData Sets

StoreAnalysisResults

Agent

Publish ResultsMeeting Statistical

and Business RulesReturnResults

User Interface Layer(access via HTTP) IE 5.5

sp2

Stored Processes Layer

Meta Data Layer andProcesses

Physical Data Layer

Case Manager UI -Dependant on

Customer Deployed3rd Party Technology


User Interface

! Easy to use & access! User needs only a Web Browser (thin client)! Interactive ! Complete Information (reports, data, charts)! Usable by casual and power users! Supports IE 5.5 or later


Analysis/Reporting Scenarios

“I know what I want to analyze” . . .

! Quickly retrieve data related to a specific problem

! Perform standard analysis

! Publish initial results to community of interest

! Collaborate, continue analysis

“Tell me where to look”. . .

! Batch process millions of “trends”

! Compare analytic results to engineering rules and publish exceptions to community of interest

! Responsible engineers take action

“I need to perform complex ad-hoc design and analysis”. . .

! Data discovery! Develop statistical

models of data! View many linked

interactive graphics! Share results with

community of interest

Discoverer and Data Navigator

Agent and Case Manager

DOE and Ad Hoc Analysis


I know what I want to analyze …

Navigator and Discoverer


Build Queries on the Integrated Data . . .


Extendable Web-Based Analytical Tasks


Tell me where to look …

Active Agent with drilldown


Email Notification . . .


The Agent Prioritises Issues


Click on Any Bar to Drill Down On that Problem . . .Lot A1232 is Suspect


It Starts with Consistent Working Practices and Integrated Data of High Quality . . .

Logical “Universal Data Model” (UDM) of SAS Process Intelligence for Manufacturing


Information Store

! Built using SAS Warehouse Administrator! Logical data model required for your reporting and

analysis activities. ! Designed to minimize implementation time. ! Highly scalable – uses MPConnect for batch

processing! Initially physical storage of data model in SAS,

SPDS, or Oracle! Centrally managed. ! Low maintenance.


Information Store


WebDAV Interface

to Collaboration Environment of Choice


Publish to Communities of Interest and Look for Similar Issues in the Past




Summary


Key Strengths of SAS Process Intelligence! Packaged industry-specific data model! Flexible 3-tier architecture! Interoperability and platform independence! Openness and modularity! Scalable performance! Interactive web-based user interface! Customizable analytical tasks! Active collaboration with C-Space


Key Strengths of SAS Process Intelligence (cont.)! Web delivery of results! Configurable and extensible framework! Clear commitment to industry-specific product

development (initially high-tech manufacturing).


Status of SAS Process Intelligence

! SAS/PRI 2.0 available today! Industry focus - high-tech manufacturing initially

! communications equipment, computer peripherals, comp. storage devices, electronic instruments, biotechnology/drugs, medical equipment/supplies, personal and household products

! Alliance with Brooks Automation –Semiconductor specific offering

! “Controlled availability”

SAS Process Intelligence for Manufacturing · Quality Manufacturing: Capacity and Volume Yield,...

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