Texas Instruments Maine (MFAB)

Texas Instruments Maine (MFAB)
John Doxsey – IT Manager
About John Doxsey
• Work Experience
– “Doing computers” for 42 years, Fairchild/National/TI for last 30
– Some form of Factory Automation since 1976
• Education
– Took my 1st computer class in 1965 at the age of 14 (FORTRAN)
– B.A. in Computer Science from SUNY Potsdam
– “Almost-a-Masters” in Computer Science from RPI
• Hobbies
– Reading, sailing, skiing, re-constructing various parts of my home,
watching my three daughters grow into young women
• Personal Philosophy
– If work isn’t fun you’re doing the wrong job
• IT Philosophy
– You can’t have a good information system without a good data
collection system. Get the data right. Keep it. Use it.
2
Importance of Thinking Globally
• 95% of the world's customers live overseas
• TI ships 100,000 Products
• To 100,000 Customers
• 90% of TI’s revenue comes from overseas
• 60% of that revenue comes from Asia
3
TI’s Analog and Embedded Processing products
powering diverse and fast growing applications
Smart phones
Test equipment
Wireless
infrastructure
Medical
Smart energy
meters
Wireless LANs
Automotive
& HEV
Analog
Embedded Processing
Motor control
Digital TV
IP
phones
Computing
Digital
still cameras
Industrial weigh scales
Digital audio & radio
E-bikes
4
Digital video
recorder/server
Worldwide Manufacturing sites
LEGEND
Wafer Fabs
Assembly / Test
Bump
Greenock
GFAB
Chengdu
CFAB
150mm,
200mm
200mm
Freising
FFAB
200mm
Aizu
200mm
Miho
200mm
Hiji
150mm
Assembly and test
Portland
MFAB
200mm
Texas
Taipei
TITL
Aguascalientes
TMX
Baguio City
TIPI
Dallas
DFAB
SFAB
DHC
MEMS Heater 150mm
150mm,
Chips
200mm
Houston
DMOS6
HFAB
DMOS5 300mm
150mm
200mm
DBUMP
HBUMP
RFAB
300mm
Kuala Lumpur
TIM
Melaka
TIEM
5
Pampanga
Clark
Bump
Maine Site
Jean Hoerni &
Robert Noyce
develop IsoPlanar
process at
Fairchild
Semiconductor.
First Commercial
Integrated Circuit
TI & Fairchild
1959
NSC purchases
Fairchild
Semiconductor
4” Fab
Expansion
1963
1961
National
founded in
Danbury, CT
First Fab in
Maine
BiCMOS8
1984
1978
5” Fab
Expansion
200MM Die Fab; Nov
‘95 Groundbreaking
FSC sold to Fairchild
management team
1993
1987
1996
1995
6” Fab
Expansion
1999
1997
1st
200mm
Production
6
Texas
Transfer
2008
2001
2010
2009
CBC8
BiCMOS13
Sept
2011
What MFAB Produces ….
7
Semiconductor Manufacturing 101
• From Silicon to Wafers to Die (Chips) to Packaged Parts
• High Complexity
– 300 – 700 unique operations to fully process the wafer
– Each operation uses a different kind of equipment (tool)
• High Precision
– Every operation must be performed in the correct order
– Each must be executed perfectly - Every Time !!
– Equipment must operate within narrow tolerances
• Super Cleanliness
– Class 1 Clean Room – Class “sub-1” Pods & Mini-environments
– “Class” = # of .5 micron particles found per cubic foot of air
8
How big is a Micron?
• 1-millionth of a meter (1/1,000,000)
• Diameter of a Human Hair
40-50 microns
• Red Blood Cell
6-10 microns
• Typical Bacteria
5-20 microns
• Clean Room Particle Detection
9
.5 micron
MFAB Factory Automation System
• Software has all been developed “in-house” by our IT Staff
• We fully Automate “the Simple, but Important Things”
– Right lot, right tool, right recipe, right operator, right reticle
• Everything in the Factory gets controlled or tracked
– 100% of equipment is controlled and operated by the system
– All wafers are in Pods with Smart Tags
• Each wafer is uniquely identified via a number etched into the silicon
• The position within the pod is tracked (Slot 1 – 25)
• The Smart Tag has a unique ID burned into its EPROM
• The Smart Tag communicates with the System via Infrared (TV Remote)
• System supports all aspects of Manufacturing
– Running Wafers on Equipment
– Maintaining the Equipment (Repairs and Preventive Maintenance)
– Statistical Process Control
Link to Video
10