Conclusions & Recommendations .1 Conclusions

An OEE tracking system that added little if any extra non-value added work on equipment operators was created. Such a system categorised its factors and sources of loss in a manner than allowed all PTM, PDM and HVM departments focus on their specific goals yet also allowed for correlation of performance between the phases of program life-cycle.

An utilisation tracking system was designed to interact with an equipment’s controller to capture and categorise all time spent on the equipment. It also ensured that the time the equipment spent powered down is captured. The captured data required minimal user input and was used to accurately determine the equipment’s utilisation. This utilisation indicator provided the same functionality as the Availability Efficiency and Operating Efficiency metrics as defined by SEMI E79.

An efficiency tracking system was designed to interact with an equipment’s computer-controller to capture and categorise the equipment’s cycle-time. Cycle-time was categorized as steady-state and non-steady-state such that:

 Historical steady-state cycle-times from multiple instance of Equipment-Z were used to determine Equipment-Z’s Rated Cycle-Time.

 Steady-state cycle-time, or some function of non-steady-state cycle-time to estimate steady-state, were used as Actual Cycle-Time in real time.

This efficiency indicator provided the same functionality as the Rated Efficiency metric as defined by SEMI E79.

A yield tracking system was designed to interact with an equipment’s controller to capture the number of units actually loaded and unloaded from the equipment as well as the number of defective units. It also categorised, with minimal user input as needed, the number and classification of defects detected on defective units. This yield indicator provided the same functionality as the Quality Efficiency metric as defined by SEMI.

OEE metrics are only valuable if the sources of OEE loss are prioritised for focused improvement. Rather than focus on utilisation, efficiency and yield independently these OEE losses were weighted based on opportunity and compared in the same Pareto chart.

This system was implemented on Equipment-Z on selected pilot PTM, PDM and HVM lines at Company-X. End-users of the system and the captured data approved a final refinement of the utilisation tracking software. Implementation was approved pending validation of those refinements. The same tracking systems used on Equipment-Z could be implemented on Company-X’s other equipment.

7.2 Recommendations

The following would have been developed further had opportunity allowed.

Automatic classification of efficiency loss: While the existing system at Company-X allowed for the automatic detection of steady-state and non-steady-state, it only provided the raw data from which engineering would have to infer opportunities for improvement. Ideally the system would know the conditions which constituted the equipment’s rated cycle-time, and would be able to deduce and assign causes of loss automatically. For example, if the rated cycle-time included a “waiting for upstream time” to be 1 second or less, and the signal from the upstream process occurred after 2 seconds, the monitoring software could recorded a speed loss of 1 second due to waiting for upstream equipment.

Determining Overall Line Efficiency as a function of the line’s equipment’s OEE metrics: Company-X as well as other manufacturers require the ability to correlate the current performance of individual stand-alone equipment used for batch-volume production during prototyping, to the future performance of fully coupled dedicated equipment in a high-volume manufacturing line. It was proven that the same system can work on a piece of equipment be it stand-alone or coupled, or used for batch-volume or high-batch-volume. Upon implementing this system on all equipment across the line, the various proposed formulae in Section 6.2 could be evaluated.

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Appendix – A

The appendix describes more in more detail the proposed changes to the utilisation tracking system.

Changes to Normal Run Mode (NRM)

1. User will no longer be presented option screen when they press stop {Figure A-1}.

A. Machine already logs when user selects any of the Basic functions {Figure A-2}.

B. User will have to press the Switch Mode button when the need to access