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Living Automotive Excellence On the way to Zero Defect products and services

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Page 1: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Living Automotive ExcellenceOn the way to Zero Defect products and services

Page 2: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 2September 10

Infineons Automotive Excellence Program is your competitive advantage

Improvement Examples: Our target of ZD is your competitive advantage:

• no quality events• defect-free product launches• low non-conformance costs• highest quality image in your market • more business due to satisfied customers

Goals:•Sustainable quality improvement•Zero Defect Culture

Measurables:•Decrease of number of customerreturns and quality spills•Increase of customer satisfaction

Our quality is clearly seen as industry benchmark by almost all of our customers

Zero Defect

Infineon established the Automotive Excellence Program in 2003

Advanced Process Control

Excellent Requirement Management

0.23

0.95 Product Quality(0km/Field)

PPM

03 04 05 06 07 08 09

Page 3: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 3Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Content

Motivation for “Zero Defect”

Excellence in Backend Production (examples)

Excellence in Front End Wafer Production (examples)

Our Zero Defect Culture

First Time Right in Product Development (examples)

Our Quality is industry benchmark

Infineon “Automotive Excellence Program”

Page 4: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 4Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Content

Motivation for “Zero Defect”

Excellence in Backend Production (examples)

Excellence in Front End Wafer Production (examples)

Our Zero Defect Culture

First Time Right in Product Development (examples)

Our Quality is industry benchmark

Infineon “Automotive Excellence Program”

Page 5: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 5Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Infineon established the Automotive Excellence Program from 2003

Living Automotive Excellence

• to create a competitive advantage through excellent quality

• to exceed your quality expectations

Too valuable to compromise

Page 6: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 6Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Zero Defect products to guarantee the highest safety possible

1ppm (1 defective part per million) is close to Zero Defect. Would 1ppm not be enough?

300ppm defect ECUs*

1 ppmcomponents

15,000 cars defect out of1,000,000 (1.5%)

CarECU*

300

Component

50

To guarantee highest safety, we need Zero Defect

*ECU: Electronic Control Unit

Page 7: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 7Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Customer Returns = FARs

failure cause of Airbag ECUs (0 km-

/Field)

up to 90% caused by supplier of

electronic components

(Semiconductor)

In the automotive industry

each failing device comes back

to the supplier as a

Customer Return

or

FAR

Failure Analysis Request

Page 8: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 8Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Why invest in Zero Defect Supply Chain ?

Devices in IFX fab

Reel label

Reel label

Plant 1

Plant 2

SV Ichon Korea

InfineonTier 1

SupplierOEM

End

customer

Failure analysis

Cost of Scrap

~ 50 k€

Cost of Scrap

Cost of Overtime

~100k€

e.g. 1 day linedown

Controlled shipping

~1000k€

e.g. recall of

10,000 cars

~10000 k€

Example : Cost Explosion in case of a supplier quality event

Failure analysis

~ 10 k€

Supplier

Page 9: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 9Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Motivation: Why zero defect?

Reliability in cars: A question of life or death!

Page 10: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 10Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Content

Motivation for “Zero Defect”

Excellence in Backend Production (examples)

Excellence in Front End Wafer Production (examples)

Our Zero Defect Culture

First Time Right in Product Development (examples)

Our Quality is industry benchmark

Infineon “Automotive Excellence Program”

Page 11: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 11Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Automotive SemiconductorsCommitment leads to success

Innovative product portfolio covering the complete control cycle:From sensing over computing to actuating

System expertise with broad application competence:Powertrain, Safety Management, Body & Convenience

Market leader in automotive semiconductors:No. 1 worldwide, No. 1 in Europe, No. 2 in USA,

Reliability through experience:High quality products and services for the automotive industry for 40 years

Automotive Excellence: Most comprehensive quality program in the industry

(Source: Strategy Analytics)

Page 12: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 12Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Quality and safety of electronics demands a well-balanced co-operation of all involved parties

Awareness

Quality Management System & Tools

Management

Products Production People Processes

Automotive Excellence

Automotive ExcellenceThe most comprehensive quality program in the industry

Page 13: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 13Copyright © Infineon Technologies 2006. All rights reserved. 13.09.2010 For internal use only

Automotive Excellence Program Setup Responsibility and Accountability in the Line Organization is key for a successful program

SponsorDr. Reinhard PlossJochen Hanebeck

Claus GeislerMichael Seitz

Program ManagerAlexander Müller

Steering CommiteeAutomotive Division Board and Operation

BoardProject Office: Dr. G. Mauckner (ATV) Dr. C. Zeller (Production)

Business Lines Production Support Functions

Body PowerT. Fitzek / K. Jauck

Standard PowerF. Schwertlein / L.A. Past

Assembly & Test CMOSW.T. GanCh. Chan

Assembly & Test PowerK.T. Ng

C.H. Yang

FrontendDr. H.D. LoeweDr. M. Polzer

Power Technology PlatformT. Gutheit

Powertrain Safety & ASICsA. Doll / W. Glawischnig

MicrocontrollerP. Schäfer / R. Petter

Sense & ControlS. Hofschen / Dr. I. Trapp

Advanced Technology Management

A. Rahm

Supply Chain ManagementS. WollenbergM. Stegherr

Sales & Marketing & Distr.A. Müller

OEM Business DevelopmentC. Preuschoff

Quality ManagementA. Müller

C. Zeller/G. Mauckner/ E. Palmeda

Cluster Zero Defect InitiativesA. Heitzer

Electric Drive TrainM. Muenzer / Dr. Eschbaumer

Page 14: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 14Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Automotive Excellence has goals and measureables

Measurables

• Decrease of number of customer returns (FARs) and quality spills

• Increase of customer satisfaction (feedback & ratings)

Goals

• Sustainable quality improvements by running projects and continuous improvement actions

• Growing towards a Zero-Defect Culture

Page 15: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 15Copyright © Infineon Technologies 2006. All rights reserved.

Our Zero Defect Policy

• Zero Defect is a strategic mindset

• Zero Defect is . . .

- embedded in our business processes, - driven by our people, and - stimulated by personal senior

management leadership

• Zero Defect mindset means ...

- No compromise on quality- No deviations from our commitments- Fast reaction on deviations - Excellence in Problem Solving –

no reoccurrences

We bring Zero Defect to Reality. Be part of it.

Page 16: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 16Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Project Management @ Automotive Excellence

• Dedicated project structure with representatives…- of all business lines, logistics, technology development and

sales of the Automotive Division - of all production units

• Almost 6 years, more than 200 Sub-Projects from all areas with an active participation of more than 1000 Employees

• Methodology: - a systematic structuring of the projects according to the „4P –approach“ into the 4 pillars „Products, Production, Processes,

People“ guarantees an holistic approach- Consequent project management for our activities- Review Meetings on working and management level - Program KPI Reviews

Page 17: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 17Copyright © Infineon Technologies 2006. All rights reserved.

Automotive Excellence Program Embracing all sites and lines worldwide

Relevant Production Sites

Frontend (FE): Regensburg, Villach, Kulim, Dresden Backend (BE): Regensburg, Singapore, Batam,

Malacca, Wuxi, Warstein

Relevant Automotive Business Lines

Microcontroller Powertrain Safety & Asics Sense & Control Electric Drive Train

Enablers

To establish and staff a dedicated AEX organization Consequent Project Management Regular Zero Defect review at sites / segments Quality Spill reviews

Standard Power Body Power

Page 18: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 18Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Requirement

Management

Examples of automotive quality measuresimplemented along the semiconductor value chain

SpecificationProduct

Development

Qualification

- Technology

(FE, BE)

- Product

Frontend Backend

Logistics

Electrical Test

Design for Quality

Design for Reliability

Design for Manufacturability

Design for Test

Enhanced

Simulation &

Character-

ization

Zero Defect

Culture

Forward &

Backward

Traceability

Design for

Testability,

Test coverage

Advanced

Process Control,

no rework

Intelligent

Outlier

Screening

(SBA, PAT, ..)

FMEA and

Risk

Management

Automotive Excellence

FMEA, Risk &

Deviation

Management

Success is enabled by cross functional approach

Customer

and

Supplier

Page 19: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 19Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Content

Motivation for “Zero Defect”

Excellence in Backend Production (examples)

Excellence in Front End Wafer Production (examples)

Our Zero Defect Culture

First Time Right in Product Development (examples)

Our Quality is industry benchmark

Infineon “Automotive Excellence Program”

Page 20: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 20Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Our Way to a Zero Defect CultureYour satisfaction has utmost importance

Zero DefectEvent Day

5S/Fuguai Program

Zero Defect Training

Zero DefectPoster

Campaign

Internal Audit

Quality Bonus

Full Management Commitment

ErrorProofing Zero

DefectCulture

Page 21: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 21Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

knowledge

quality awareness

Zero Defect Culture - Change of mind set isthe key enabler to achieve our goals

training

quality ability

motivation

quality engagement

personal

quality

ownership

Who is able to contribute to success will be proud of it

Living Zero

Defect

Source: IFX, AEP Consultant

Page 22: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 22Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

5th Birthday Automotive Excellence Program

Page 23: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 23Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Target:

Highest awareness of

all employees on quality and

and customers expectations

Actions:

Employee's training

Target group oriented infor-mation given by managers

Poster advertising

Article in employees magazine

Zero Defect exhibitions

Zero Defect as Key for our FutureMindset

Page 24: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 24Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Regensburg and Villach

Zero Defect Exhibitions at OPP FE

Page 25: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 25Copyright © Infineon Technologies 2006. All rights reserved. September 10 Confidential

FUGUAI BREAKDOWN BY CAUSES - Q1 (05/06)

0

10

20

30

40

50

Scra

tches o

n

m/c

cover

Sticker

sta

in

Magazin

e n

ot

sta

ndard

ized

Flo

or

panel

shaky

Str

ay d

ie

5S

Wro

ng

washin

g

schedule

Dirty

magazin

e

Mis

sin

g

sticker

Glu

e s

tain

Mark

er

sta

in

FUGUAI DESCRIPTION

0%

25%

50%

75%

100%

NU

MB

ER

OF

FU

GU

AIS

PE

RC

EN

TA

GE

FUGUAI BREAKDOWN BY CAUSES - Q1 (05/06)

0

10

20

30

40

50

Scra

tches o

n

m/c

cover

Sticker

sta

in

Magazin

e n

ot

sta

ndard

ized

Flo

or

panel

shaky

Str

ay d

ie

5S

Wro

ng

washin

g

schedule

Dirty

magazin

e

Mis

sin

g

sticker

Glu

e s

tain

Mark

er

sta

in

FUGUAI DESCRIPTION

0%

25%

50%

75%

100%

NU

MB

ER

OF

FU

GU

AIS

PE

RC

EN

TA

GE

FUGUAI BREAKDOWN BY CAUSES - Q1 (05/06)

0

10

20

30

40

50

Scra

tches o

n

m/c

cover

Sticker

sta

in

Magazin

e n

ot

sta

ndard

ized

Flo

or

panel

shaky

Str

ay d

ie

5S

Wro

ng

washin

g

schedule

Dirty

magazin

e

Mis

sin

g

sticker

Glu

e s

tain

Mark

er

sta

in

FUGUAI DESCRIPTION

0%

25%

50%

75%

100%

NU

MB

ER

OF

FU

GU

AIS

PE

RC

EN

TA

GE

M/C Process ProductivityFUGUAI TAG

Name:

Cell Name :

Date:

M/C #:

Location:

Abnormalities :

Corrective Action :

Resolved by :

Designation : OPR/UO/LA/SET-UP/TECH

* Delete where appropriate

Name/Shift/Date

No.___

Impact :

Together we shape the future

Shift :

PCDF raised (if Product Quality affected): Yes / No

If Yes, PCDF No. ________________

M/C Process ProductivityFUGUAI TAG

Name:

Cell Name :

Date:

M/C #:

Location:

Abnormalities :

Corrective Action :

Resolved by :

Designation : OPR/UO/LA/SET-UP/TECH

* Delete where appropriate

Name/Shift/Date

No.___

Impact :

Together we shape the future

Shift :

PCDF raised (if Product Quality affected): Yes / No

If Yes, PCDF No. ________________

Identify & Fix

abnormalityClassification of

abnormality

Process?

Equipment?

Productivity?

Tracking of

abnormalities

Man?

Method?

Material?

Machine?

Identify focus

areas

Analyze and

Identify root

cause

Eliminate root

causeHuman factor?

Poor design?

Incoming Material?

Handling Procedures?

Prevent future

occurrence of

abnormality

Abnormality Management SystemWe work to remove abnormality before it turns into defect

Not at standard condition

Different from the normal state

Any Difference in Sound, Color, feeling of

Touch, Smell, Speed

Abnormality = Fuguai

What is abnormality?

Page 26: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 26Copyright © Infineon Technologies 2006. All rights reserved. September 10 Confidential

Examples of Fuguai ……..

Wafer Colour Variation Water on the floor

Grounding Wire Not Secured Tower Light Faulty

Page 27: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 27Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Sustainable problem solving: No Reoccurrence

8D

flow

1D: Team

3D: Containment action

4D: Root cause analysis

6D: Implementation of corrective action

5D: Corrective action and verification

8D: Congratulate Team

2D: Problem verification

7D: Prevention

We follow the 8D (8 disciplines) systematics

We focus on 7.D: Permanent corrective actions and standardization

Systematic rollout of solutions to all relevant fabs and sites

Longterm follow-up of preventive actions within Automotive Excellence Program

Page 28: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 28Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Content

Motivation for “Zero Defect”

Excellence in Backend Production (examples)

Excellence in Front End Wafer Production (examples)

Our Zero Defect Culture

First Time Right in Product Development (examples)

Our Quality is industry benchmark

Infineon “Automotive Excellence Program”

Page 29: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 29Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Excellent requirement management to ensure perfect fit for customer‟s application

Data Sheet ProductChip Design Application

TLE 7259

Wake and BusComparator

Driver

Temp.-ProtectionCurrentLimit

OutputStage

Supply

TxD Input

ModeControl

Receiver

TOAEB03513_1.VSD

RxD1

Filter

6Bus

TxD4

EN2

INH87

VS

30 kW

Filter

30 kW

30 kWTimeout

3WK

GND5

5 V

An excellent data sheet is required to develop an excellent product that fits your application

Customer requirements

Page 30: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 30Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Motivation for Data Sheet ExcellenceExample of critical wording: Short Circuit Protection

„Fully protected“ : What does it mean ?

Customer Impression: „Indestructible“

But:

• Protection functions are not meant for repetitive operation

• Depending on conditions any device can be damaged

Page 31: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 31Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Data Sheet ExcellenceExample: New Short Circuit Specification

Improved Version

• Detailed description of Short Circuit protection feature

• Description of the Influence of inductance and resistance

• Showing the limits of the feature

Page 32: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 32Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Data Sheet Excellence TeamTasks

•Review existing Data Sheets•Create a guideline for writing Data Sheets•Update the AP Data Sheet Template•Define a release process for Data Sheets•Roll-Out of guideline and release process

The Data Sheet Excellence Team is:

• Tobias Otter (AIM AP M AE)

• Günter Schwarzberger (AIM AP M AE)

• Andreas Kiep (AIM AP M AE)

• Jürgen Kositza (AIM AP M AE)

• Gunther Krall (IFNA AI)

Page 33: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 33Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Data Sheet ExcellenceData Sheet Guideline Topics

• Absolute Maximum Ratings

• ESD Definition • Thermal Resistance • Operation Range• Short Circuit• Functional Description• Electrical Characteristics• Application Diagram• Legal terms

Page 34: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 34Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Only products with proof of design quality

Experiments

Customer Requirements

Generic verification, validation plan

almostautomatically

Data Sheet

Your advantage: Each of your requirements is reliably fulfilled

Stringent flow from requirements to simulation and lab measurement

Spec compliance due to full traceability and completeness of requirements

Reuse for simulation and lab verification

Automation in simulation/lab characterization and documentation

Page 35: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 35Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Our products are robust in automotive environment

A

C

B

D

Infineon OptiMOS™ 4 different competitors

No delamination even after 260°C preconditioning and 1000TC with robust package

(TC = Temperature cycles)

Total delamination already after 260°C preconditioning (red areas)

100% adhesion delaminationPackage

chip

Your advantage: High reliability in the field

Page 36: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 36Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Content

Motivation for “Zero Defect”

Excellence in Backend Production (examples)

Excellence in Front End Wafer Production (examples)

Our Zero Defect Culture

First Time Right in Product Development (examples)

Our Quality is industry benchmark

Infineon “Automotive Excellence Program”

Page 37: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 37Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Excellence in Production

• Examples of Automotive Excellence Projects

No rework

Advanced Process Control wafer fab

Advanced Process Control assembly

Via testchip and redundant vias

R2D2: Reliability Related Defect Density

Intelligent outlier screening

Page 38: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 38Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Due to our „No rework‟ principle we deliver first-time-right products

No Rework in Front End and Back End Production

A Zero Defect principle

Your advantage: You receive first-time right products

Wafer flow in production interrupted due to process instabilities and rework

Smooth and stable production flow without interruption

Our engineers focus on process stabilization

Page 39: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 39Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Excellence in Production

• Examples of Automotive Excellence Projects

No rework

Advanced Process Control wafer fab

Advanced Process Control assembly

Via testchip and redundant vias

R2D2: Reliability Related Defect Density

Intelligent outlier screening

Page 40: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 40Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Resist coating + exposure + develop

Etching metal

Resist strip

Deposition metal

SPC Statistical Process Control: Control Limits and Process Capability cpk

APC Advanced Process Control: Real-time monitoring of key process parameter

Equipment control: temperature, etching rate, deposition rate, contamination.....

Process control:

metal thickness

resist line width

metal line width

optical inspection

New

Standard

With Advanced Process Control we realize deviations before they affect the product

Page 41: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

Page 41Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

APC = Equipment Integration + Fault Detection & Classification

FDC Stage

Status Description

0 NO USAGE PDA is not ready.

1 PDA AVAILABLE

PDA is ready and accepted based on specification.

2 KN SETUP Simple Keynumbers are set in Config

3 MONITORING Keynumbers are build in Config; Systematic usage of APC trend. (includes LFA)

4 OOCAP Systematic usage of APC Trend. Limits are set, reaction on violations during office hours. (EQ FMEA required)

5 MESSENGER Same as "4" additional MESSENGER is switched on.

6 AUTO STOP Same as "5" additional LH, INL and/or Tool Stop is switched on.

7 CONTINUOUS IMPROVE

MENT

Constant usage of FDC for continuous improvement, e.g. Cpk, yield, scrap. Automatic stop reactions are set on 100% of FMEA requested Keynumbers.

In principle available from T5Operatively available from T8

T1Specification agreed & Characterization done

T2 Tested in Simulation

T3 Tested with Equipment

T4 User Acceptance

T5 FDC tested and accepted

T6 Rollout to all tool instances

T7 Stability run

T8 Final acceptance

Tool Integration Milestones

Living FDC

no use

offline FDC use

online FDC fast reaction

DefinitionsDefinitions

Equipment Integration Fault Detection and Classification

PDA = Process Data Acquisition

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Overall Appl Level by Month in RBG

6,56,56,46,36,36,16,05,95,85,74,13,1 3,3 3,6 3,6 3,6 3,7 4,5 4,8 5,3 5,5

6,5 6,6

0

1

2

3

4

5

6

7

8

JAN

/07

FEB/0

7

MAR/0

7

APR/0

7

MAY/0

7

JUN

/07

JUL/0

7

AU

G/0

7

SEP/0

7

OCT/0

7

NO

V/0

7

DEC/0

7

JAN

/08

FEB/0

8

MAR/0

8

APR/0

8

MAY/0

8

JUN

/08

JUL/0

8

AU

G/0

8

SEP/0

8

FDC Stage

Overall ShortTerm Target LongTerm Target Dynamic Target

Overall Appl Level by Month in VI

6,26,16,05,85,75,04,94,64,64,64,54,5 4,7 4,8 5,1 5,1 5,5 5,6 5,6 5,8 6,0

6,1 6,2

0

1

2

3

4

5

6

7

8

JAN

/07

FEB/0

7

MAR/0

7

APR/0

7

MAY/0

7

JUN

/07

JUL/0

7

AU

G/0

7

SEP/0

7

OCT/0

7

NO

V/0

7

DEC/0

7

JAN

/08

FEB/0

8

MAR/0

8

APR/0

8

MAY/0

8

JUN

/08

JUL/0

8

AU

G/0

8

SEP/0

8

FDC Stage

Overall ShortTerm Target LongTerm Target Dynamic Target

APC Road Map and Status Sept. 2008RBG + VIH

VIH

RBG

- Overall FDC stage slightly above target

-FDC stage on target-CR due to EI reasons (e.g. EI of ASM) and parameter availability from tool (eg. RCD Litho)

Quelle: K. Forster

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Achievement: Weekly APC Violation Review MeetingPareto Analysis: Keynumbers with most violations

Detailed analysis and reporting:Top 3 work centers per Area =>

key numbers with according equipment/recipe, defined action, status and due date

weekly limit violation review meeting with key user / UPSrunning since March 2008

detailed analysis of single violations

WORKCENT EQUIPMENT BATCHID LIMITID FEATURENAME MSG_ACTIVEINHIBIT_ACTIVEHOLDLOT_ACTIVETOOLSTOP_ACTIVEDATUM

POLY_LAM_ALLIANCE ALLIAN4 247315 2866566 INT_EP_CHANC_ME_A_M 1 1 0 0 19.01.2008

POLY_LAM_ALLIANCE ALLIAN4 247315 2866813 INT_EP_CHANC_ME_A_M 1 1 0 0 19.01.2008

POLY_LAM_ALLIANCE ALLIAN4 247315 2867195 INT_EP_CHANC_ME_A_M 1 1 0 0 19.01.2008

POLY_LAM_ALLIANCE ALLIAN2 239801 2875261 INT_EP_CHANC_ME_A_M 1 1 1 1 23.01.2008

POLY_LAM_ALLIANCE ALLIAN2 239800 2876920 INT_EP_CHANC_ME_A_M 1 1 1 1 23.01.2008

POLY_LAM_ALLIANCE ALLIAN1 247312 2870171 INT_EP_CHANC_ME_A_M 1 1 0 0 21.01.2008

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Result of APC:Continuous increase of process stability

* Target for green process steps < 100% as continuously new processes are implemented

84

,47

%

83

,42

%

82

,83

%

81

,31

%

80

,38

%

82

,01

%

84

,09

%

84

,95

%

83

,93

%

85

,88

%

86

,98

%

88

,14

%

89

,13

%

88

,92

%

89

,22

%

90

,24

%

90

,35

%

91

,64

%

92

,05

%

92

,40

%

92

,23

%

92

,58

%

92

,65

%

93

,01

%

93

,21

%

13

,14

%

13

,86

%

14

,39

%

15

,83

%

16

,38

%

15

,45

%

13

,60

%

13

,02

%

13

,89

%

12

,64

%

11

,60

%

10

,61

%

9,9

5%

10

,07

%

10

,00

%

9,0

6%

8,9

1%

7,6

3%

7,3

9%

6,8

8%

7,3

0%

6,7

2%

6,7

3%

6,2

5%

6,2

1%

2,39%2,72%2,78%2,86%3,25%2,54%2,31%2,04%2,18%1,48%1,42%1,25%0,92%1,01%0,79%0,70%0,74%0,73%0,56%0,72%0,47%0,71%0,62%0,74%0,58%

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

100%

Se

p 0

6

Ok

t 0

6

No

v 0

6

De

z 0

6

Ja

n 0

7

Fe

b 0

7

Mrz

07

Ap

r 0

7

Ma

i 0

7

Ju

n 0

7

Ju

l 0

7

Au

g 0

7

Se

p 0

7

Ok

t 0

7

No

v 0

7

De

z 0

7

Ja

n 0

8

Fe

b 0

8

Mrz

08

Ap

r 0

8

Ma

i 0

8

Ju

n 0

8

Ju

l 0

8

Au

g 0

8

Se

p 0

8

Cp

k f

ulf

illm

en

t [%

]

<1

1<=cpk<1,5

>=1,5

Kulim

Regensburg

Villach

Kulim

Regensburg

Villach

Perlach

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Excellence in Production

• Examples of Automotive Excellence Projects

No rework

Advanced Process Control wafer fab

Advanced Process Control assembly

Via testchip and redundant vias

R2D2: Reliability Related Defect Density

Intelligent outlier screening

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Page 46Only for internal use Copyright © Infineon Technologies 2006. All rights reserved.

Process Steps Test Customer

AP

C

Weeks

Electrical

Results

Customer

Returns

Inline Control

SPC

Hours

Online

Time

Months

Process

APC (advanced Process Control) means we act on process deviations online, preventing deviations of the product

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We invent innovative methods to detect deviations in the assembly fabs

Wafer Sawing:Spindle speedCutting speedCutting force

Wire Bond:Bond ForceBond PowerTemperature

Moulding:SpeedPositionTemperatureTransfer Pressure

Trim&Form:Acoustic signals

Together with the tool vendors we develop sensors to measure tool parameters that are critical for the result of the process step.

Page 48: Living Automotive Excellence - Infineon Technologies · 2018-08-17 · Sustainable problem solving: No Reoccurrence ow 1D: Team 3D: Containment action 4D: Root cause analysis 6D:

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Excellence in Production

• Examples of Automotive Excellence Projects

No rework

Advanced Process Control wafer fab

Advanced Process Control assembly

Via testchip and redundant vias

R2D2: Reliability Related Defect Density

Intelligent outlier screening

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With via testchip and via doubling for µCs we came close to Zero Defects for via-related fails

Metal x+1

Via x

Metal x

Via size: 200nm

Metal x+1

Via x

Metal x

Metal x+1

Via x

Metal x

Via size: 200nm

Silicon Substrate

Metal 1

Metal 2

Via

Co

nta

ct

Co

nt.

Polysilicon

On a typical C11 chip there may be more than 10 million vias

With our innovative via testchip and via doubling we reach a defect level for via related fails that is close to zero!

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What is via – doubling?

Metal 1

M 2

Via

1

M 2

Via

1

Metal 1

M 2

Via

1

M 2Via

1

Via

1

Automatic routine doubles vias, wherever possible

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R2D2 Test Chip – Overview C11FLA

Metal x+1

Via x

Metal x

Via size: 200nm

Metal x+1

Via x

Metal x

Metal x+1

Via x

Metal x

Via size: 200nm• 4blocks with

34 arrays(40% of area)

• other structures

• product

• 8 inch wafer• 68 chips• 12 wspw

• 512x512 vias per array

• Each via is addressable

• contact holes (CA)• all Via levels (till

VQ) connecting thin wires

• all Via levels connecting fat wires

• stacked Vias• misaligned Vias• design rule

variations• short Via chains

Concept– Measuring – Analysis Yield Improvement– Stressing – Measuring – Analysis Reliability Improvement

Overall:About 3.2 billion contacts/vias

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Excellence in Production

• Examples of Automotive Excellence Projects

No rework

Advanced Process Control wafer fab

Advanced Process Control assembly

Via testchip and redundant vias

R2D2: Reliability Related Defect Density

Intelligent outlier screening

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R2D2: Reliability Related Defect Density

Focus not only on yield -, but on reliability related defects

0

0,5

1

1,5

2

2,5

3

02/0

3

03/0

4

04/0

5

05/0

6

06/0

7

07/0

8

08/0

9

09/1

0

10/1

1

11/1

2

An essential contributor to ppm reduction is the continuous reduction of defects with impact on reliability

The continuous down-ward trend of ppm rates is the result of numerous activities:

Detection of single defects

Pareto analysis

Root cause finding

Root cause elimination

One after the other…

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Result of R2D2:

Continuous reduction of ppm rate

Jun 06 Jan 07 Jan 08N

anospra

y M

1,

M2

CM

P w

ate

r ri

nse

Veri

fication C

onta

ct

testc

hip

Passiv

ation R

PS c

lean,

CT s

cre

enin

g

Gasonic

s a

t CT

Rota

tion s

peed Z

OX C

MP,

gow

nin

g p

roc.

Meta

l depositio

n,

via

resis

t str

ip

Wate

r to

uch u

p o

xid

e C

MP

Avoid

ance o

f m

anual w

afe

r handling

Resis

t str

ip im

pro

v.

Shib

.

Scre

enin

g M

1,

M2 (

tem

p.)

HD

P im

pr.

dom

e c

ond.

& c

lean.

end p

oin

t

Via

scre

enin

g larg

e d

efe

cts

RCA Is

opro

panol supply

CM

P b

evel cle

an s

tart

FAR data : M. Schmalzbauer, based on SAP

Veri

fic.v

ia t

estc

hip

Carr

ier

cle

an C

O2

Roll o

ut

CM

P b

evel cle

an

RPS C

lean S

IOX 6

05

New

carr

ier

change c

oncept

Mara

ngoni dry

er

322,3

24

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Excellence in Production

• Examples of Automotive Excellence Projects

No rework

Advanced Process Control wafer fab

Advanced Process Control assembly

Via testchip and redundant vias

R2D2: Reliability Related Defect Density

Intelligent outlier screening

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Highest outgoing product quality by intelligent outlier screening

with Pattern Recognition

Single & stacked

X

"Normal"YieldLoss%

Yield Loss Pareto (per BIN, Test, etc.)

"Risk"

"Risk"

under SBA** controlX

*PAT: Part Average Testing; **SBA: Statistical Bin Analysis

Intelligent PAT* ScreeningX

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PATImplementation of PAT in automotive wafer fabs

Implementation level all: 88 %Implementation level suitable: 100 %

High Volume, Automotive (12,42,58)

0%

20%

40%

60%

80%

100%

0707 0108 0708 1008

0

50

100

150

200

250

300

350

PAT notimplemented

PAT implemented

# Basic Types

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Content

Motivation for “Zero Defect”

Excellence in Backend Production (examples)

Excellence in Front End Wafer Production (examples)

Our Zero Defect Culture

First Time Right in Product Development (examples)

Our Quality is industry benchmark

Infineon “Automotive Excellence Program”

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Page 59Copyright © Infineon Technologies 2006. All rights reserved. For internal use only10-09-13

Automotive Product Quality (0km + Field)

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

2003 2004 2005 2006 2007 2008 2009

Production Year

pp

m

0km Field

0.23 ppm

0.95 ppm

-76 %

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Page 60Only for internal use Copyright © Infineon Technologies 2006. All rights reserved. ConfidentialSeptember 10

Confidential

Our customers appreciate our results

“Automotive Supplier of the Year 2009” and “Supplier Performance Award” for the Year 2008

“Hitachi Quality Award” for the year 2006 for achieving customer satisfaction

“Bosch Supplier Award” for the years 2005 and 2006

German “TOPIT Award” for the year 2008 for the Automotive Excellence Program

6 quality awards in 2004, 2006, 2007, 2008, 2009 and 2010 from Toyota’s Hirose plant.

„Honor Quality Award Toyota Hirose“ received in 2010 for zero defect quality for last four years.Infineon is the First non- Japanese company that received this honour in this highest level category.

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Automotive Excellence is the differentiator for your business success

No Rework

Intelligent Outlier

Screening

Excellent Requirement Management

Product Robustness

Zero Defect culture

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Infineon’s Automotive Excellence Program is your competitive advantage

Our Quality is clearly seen as industry benchmark by almost all of our automotive customers.

Our target of Zero Defect means for you: no quality events defect-free product launches automotive product quality of 0 defect parts per million low non-conformance costs highest quality image in your market more business due to satisfied customers.

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Never stop

thinking.

and finally …

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"If there's a way to do something better,

I'll find it.“

Thomas Edison (1847-1931)