nvq level 2 business improvement - nmi...equipment engineer communicated that each individual nxe...

Seagate Confidential

Name: Richard Kernaghan Date : Sep 2016

NVQ Level 2 Business Improvement


Project title: Optimize NXE run start procedure

Project Team : Richard Kernaghan (BIT operator)

Paschal McKenna (Trainer)

Kevin Crumley (Area UM)

Alister Gourley (Lead operator)

Cain Nash (Process Engineer)

Paddy Kealy (Process Engineer)

Stephen McElhinney (Eqp Engineer)

Andrew Gillespie (IE)

NVQ Level 2 Business Improvement Techniques

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Project Lead Team Members

Problem Statement:

NVQ Business Improvement Techniques - Level 2

Project Title

Optimize NXE run start procedure

Richard Kernaghan (BIT operator)


Alister Gourley (Lead operator)


Cain Nash (Process Engineer)

Paddy Kealy (Process Engineer)

Stephen McElhinney (Equipment Engineer)

Andrew Gillespie (IE)

Project Co-ordinator

Level 3

Richard Kernaghan

Tool start process requires operator interaction to initiate cassette

mapping. The time lost is not visible on tool view.

Paschal McKenna


Project Title: Optimize NXE run start procedure

8D Action Status

D1 Define the Team Complete

D2 Describe Problem Complete

D3 Containment Plan Complete

D4 Describe the Cause Complete

D5 Choose/ Verify Corrective Actions & Solutions Complete

D6 Implement / Validate Permanent corrective Actions Complete

D7 Preventative Action Plan Complete

D8 Congratulate the Team Complete


D1 Define the Team D1 Complete 02/09/2016

Team Members:

Richard Kernaghan (BIT Operator)


Alister Gourley (Lead Operator)


Patrick Kealy (Process Engineer)

Cian Nash (Process Engineer)

Stephen McElhinney (Equipment Engineer)

Andrew Gillespie (Industrial Engineer)




D2 Describe Problem D2 Complete 10/09/2016

Current procedure requires the operator to

press Load on the SOC and then wait a

period of time for Map Cassette to become

active on the Toolset. This needs to be

clicked on before the run will commence

and currently Toolview accepts SOC as

the trigger that the tool has started and

has no visibility if this is not the case.

Toolview shows NXE_52, the run is still in

process 11 minutes after it was due to

complete. It is suspected there was a

delay in the cassette been mapped.



D2 Describe Problem D2 Complete 08/09/2016

30 Days data showing the time from Load being pressed

until tool mapping is started @ STST & NRM

Here in STST we lose out on 3 mins/run with 14000 runs

being processed during this period!!!

NRM have auto mapping already in place


Impact/ Risk Assessment

Containment Actions


D3 Containment Plan D3 Complete 30/09/2016

Velocity suffering due to Production time being lost

Trust the operators to map the cassette quickly



D4 Describe the Cause D4 Complete 06/10/2016

4 Why’s

Time lost mostly every run

Tool requires operator interaction

Delphi logbooks unable to auto start mapping

Historical Safety feature in place



D5 Choose/ Verify Corrective Actions Solutions D5 Complete 13/10/2016

SOC now has the capability to initiate auto mapping Get agreement from all parties to turn function on

Before any changes can be made the Process Engineer needs the

current MP to be re-evaluated to reflect current best practice Complete and agreed with Process Owner

Equipment Engineer communicated that each individual NXE needs this

functionality to be turned on while idle and needs monitored closely

initially Equipment group had/have a fear that this could increase the possibility of a

scrap event due to double etch. This is/was the biggest obstacle to

implementation.



D6 Implement/ Validate Permanent Corrective Actions D6 Complete 20/10/2016

• PCA has now been

distributed and has

received signoff

• This has allowed us to

start on a number of

toolsets in Fab1 ensuring

that everything is in place

before some of the more

critical operations in Fab2

are turned on

• We will revisit in 3 months

time to measure actual

improvement v theoretical.

Assuming we are able to match NRM figures

What we were able to process in 90 days we will now be able to

process in 86.3 days. An improvement of 4.2%



D6 Implement/ Validate Permanent Corrective Actions D6 Complete 20/12/2016

Preliminary data is showing an improvement

Before:

6:30 mins

Now:

4.40 mins

This is over a period of 11111 runs and includes

the process of getting each individual NXE

upgraded.

We expect these figures to improve further as the

data will reflect all Tools having the upgrade.

1:50 min/run gained which can equal = 340 hours production

opportunity gained per month across the Toolset group



D7 Preventative Action Plan D7 Complete

Ensure that this upgrade is not switched off or disabled for any

reason



D8 Congratulate the Team D8 Complete 02/11/2016


Appendices

nvq level 2 business improvement - nmi...equipment engineer communicated that each individual nxe...

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