Introduction to the MIG TDP template

COMS2013, Enschede, The Netherlands 27.08.2013 – Dirk Ortloff

The MEMS Industry Groups Technology Development Process Template (TDP)Improving multi-site, multi-disciplinary MEMS development collaboration

CONFIDENTIAL Process Relations GmbH

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Negative Data

Comic by: Nik Papageorgiou http://upmic.wordpress.com/

http://upmic.wordpress.com/


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Negative Data




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Negative Data




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Negative Data




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Why do I show this? – What are the challenges behind this?

Inappropiate data management in R&D

Inappropiate collaboration methodology


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Agenda

Quick company introduction

The challenges in collaborative MEMS development

The methodological approach – MIG TDP Template

The next level – CORONA Methodology

Conclusions


About Process Relations GmbH


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Process Relations’ Mission

…is to enable you to…

Expedite your R&D with improved Methodology and flexible Software solutions

Next generation recipe and DoE management Virtual manufacturing data management Automated data collection from various sources Experimental data management, analysis and extraction

We deliver the easy to use, unique, world class Process Development Execution System (PDES) and consulting services.


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PDES Coverage of other Manufacturing Solutions

Business SystemsERP

Enterprise IT SW Infrastructure

CRMMDM

Inbound Supply Chain Systems

SCP

etc.

etc.

Operations Management

SystemePDES

MES

EMS LIMS

Operations IT SW Infrastructure

Design & Engineering Systems

Control and Automation Systems

RTD AmHS / MCS

SPC

APC

Manufacturing Tools

EI

RMS

QMS

Shipping Outbound Systems

TMS

etc.

SRM

Doc-Mgt

PLM

DwH

etc.

Doc-Mgt


The challenges in collaborative MEMS development


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The challenges

25% development projects reach the market

of those 66% fail their original expectations

20% of projects take too long and miss their market window

35% of companies experience runaway projects

40% of R&D experiments are repeated

Source: IDC “Accelerating Science-Led Innovation for Competitive Advantage” Feb. 2012


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Difficulties in collaborative MEMS development

Wealth of information / technologies / data / …

Diverse Variances, Options and Variability

Multi-disciplinary teams required

Collaboration along the value chain


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Collaboration challenges

MEMS Development Phases must include Foundry at early stages with multi-disciplinary team

Design Review must be done for a transfer from R&D Lab to High Volume Manufacturing

…

14

Fabless Houses

Design HousesDesign Centres

MEMS ProcessDevelopment

Specialists

Assembly & Test Houses

(Wafer) Foundry Services, SemiconductorContract Munufacturer (SCM)

Integrated Semiconductor(Device Manufacturer (ISM/IDM)

Distributors, Fabless Houses,

Wholesalers, Trading

Companies

X-FabBusiness Model


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Difficulties in collaborative MEMS development

Question: How to manage for fast time to market?


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Historical Collaboration between Design and Process

Microlelectronics:Clear separation between manufacturing and application development

Micro Nano Technology: Fabrication effects influence all stages

Concept Behaviour FabricationStructure Geometry

De

sig

n R

ule

s

Concept Behaviour FabricationStructure Geometry ???


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The Traditional Development Cycle for MEMS Device

IDEA

DEVICEDESIGN

EXPERIMENT

PROCESSDESIGN


The methodological approach – MIG TDP Template


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The basis for the MIG Technology Development Process Template


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Principle structure MIG TDP Template


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MIG TDP Template -- Protocols / Roles & Responsibilities

Category Concept Feasibility Prototype Pilot Production

Maturity IdeaDesign Defined

Process EstablishedDesign and

Process QualifiedDesign Frozen

Process ValidatedDesign and

Process Frozen

Lead Engineer R&DR&D /

DevelopmentR&D /

DevelopmentDevelopment /Manufacturing

Manufacturing

Layout Design Team Design Team Design TeamProcess Mapping Process Team Process TeamProcess Development

Process Team Process Team Process Team

Process Improvement

Process Team Process Team

Processing Engineers EngineersEngineers / Operators

Operators Operators

Experimental Approach

ManufacturingPOC DOE


Target specs and tolerances DOE

Process windowing DOE

Surface response DOE

Quality ProtocolsSafety and

EquipementSafety and

EquipementAdd Product

SubsetAdd Full Product Full

Process / Material /Equipment Changes

FrequentControlled Change

Qualification Required


ChargeDevelopment

ProjectDevelopment

ProjectDevelopment

ProjectLot Charge

Yielded die / wafers

POC = Proof of Concept

Protocols / Roles and Responsibillities


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MIG TDP Template -- Gating Requirement Examples






Process Frozen


DevelopmentR&D /


Manufacturing



Process Improvement



Operators Operators















ChargeDevelopment

ProjectDevelopment

ProjectDevelopment

ProjectLot Charge





Design Preliminary Test Freeze Optimize RevisionDesign Failure Mode and Effect Analysis

Preliminary FinalizeVerify

with Process

Process Failure Mode and Effect Analysis

Preliminary Finalized Adjust/ Revise

Process Flow Diagram Draft Preliminary Test Finalized FinalizedStatistical Processing Charts

DraftIdentify and

Establish ChartsPopulate/Setup

/ControlMonitor/OCAP

/AdjustEquipment Capability Study Test Identified Validated FinalizedProcess Capabilities for critical nodes

Study TestMeeting

physical specsCp > 1 Cp> 1.3

Yield Estimate Model InitialEstablish

baseline yieldsYield

improvement

Specifications DraftTarget

specificationsEstablish spec/

Acceptance criteriaSpecifications

in placeSpecifications

in placeBOM Draft Preliminary Finalize Frozen Frozen

Inventory Control StudyBuild demand

forecastInitial Plan In place

Adjust when required

Manufacturing Execution System

DraftBuild demand

forecastBuild models Models in place

Modify as necessary

Capacity/ Throughput

StudyBuild demand

forecastEstablish capacity/Identify constraints

Address constraints

Add capacity if required

Safety Study Identify Initiate Plan Rectify SustainShipping Protocols Schedule Identify Establish In place Frozen

Training Schedule Plan InitiateIssue

documentsRevised

documents

Pricing/Contract Development Development Development Manufacturing price in place

Adjust

External Vendors Establish Establish Qualify Qualified Qualified

BOM = Bill of Materials OCAP = Out of Control Action Plan

Gating Requirments


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MIG TDP Template -- Expanded Design Requirements






Process Frozen


DevelopmentR&D /


Manufacturing



Process Improvement



Operators Operators















ChargeDevelopment

ProjectDevelopment

ProjectDevelopment

ProjectLot Charge





Design Preliminary Test Freeze Optimize RevisionDesign Failure Mode and Effect Analysis

Preliminary FinalizeVerify

with Process

Process Failure Mode and Effect Analysis

Preliminary Finalized Adjust/ Revise

Process Flow Diagram Draft Preliminary Test Finalized FinalizedStatistical Processing Charts

DraftIdentify and

Establish ChartsPopulate/Setup

/ControlMonitor/OCAP

/AdjustEquipment Capability Study Test Identified Validated FinalizedProcess Capabilities for critical nodes

Study TestMeeting

physical specsCp > 1 Cp> 1.3

Yield Estimate Model InitialEstablish

baseline yieldsYield

improvement

Specifications DraftTarget

specificationsEstablish spec/

Acceptance criteriaSpecifications

in placeSpecifications

in placeBOM Draft Preliminary Finalize Frozen Frozen

Inventory Control StudyBuild demand

forecastInitial Plan In place

Adjust when required

Manufacturing Execution System

DraftBuild demand

forecastBuild models Models in place

Modify as necessary

Capacity/ Throughput

StudyBuild demand

forecastEstablish capacity/Identify constraints

Address constraints

Add capacity if required

Safety Study Identify Initiate Plan Rectify SustainShipping Protocols Schedule Identify Establish In place Frozen

Training Schedule Plan InitiateIssue

documentsRevised

documents

Pricing/Contract Development Development Development Manufacturing price in place

Adjust

External Vendors Establish Establish Qualify Qualified Qualified

BOM = Bill of Materials OCAP = Out of Control Action Plan

Gating Requirments

Responsibility Requirement Concept Prototype Pilot Production

Engineer Application Review Preliminary Finalized Review Review

Engineer / MarketingReview of competitive landscape.Is it favorable?

Finalized

EngineerProduct History (new product, derivative, cost reduction, change)

Finalized

Eng / Sales / Marketing / Purchaseing

Design to Cost Goals Preliminary FinalizedAdjust /Revise

Adjust /Revise

EngineerIntellectual Property / Patent Review

Finalized Review Review Review

Engineer / Patent Attorney

Intellectual Property Creation / Patent Disclosure Submitted

Review Finalized Review Review

Sales / PM / EngineerCustomer Schedule /Milestones Defined

Preliminary Finalized Review Review

Engineer Detailed Review of Product Design

Preliminary Finalized Review

EngineerReview of analysis completed to validate design


EngineerReview for compliance to existing engineering specifications

Preliminary Finalized Review Review

Engineer DFMEA Completion and Review Preliminary Finalized Review Review

Sales / PM / Engineer Customer Specification Review Preliminary FinalizedReview / Adjust

Review

EngineerDesign and Production Validation Test Plans


EngineerReview of Design and Production Validations Completed

PreliminaryDesign

FinalizedPilot

FinalizedProduction Finalized

Engineers(design, proc and equip)

Prototype and Production Tooling / Equipment Strategies

PreliminaryDesign

FinalizedProduction Finalized

Purchasing / Engineer Supplier Reviews Preliminary FinalizedPM / Engineer Risk Assessment Preliminary Finalized Review Review

PM / Engineer Lessons LearnedPrevious Products

Review Review Finalized

PM - Program Manager

Design Review Gating Requirments


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Benefits of the usage MIG TDP Template


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But Technology vs. Product Development


The next level – CORONA Methodology


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To be provoking …


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… with Customer Involvement

The customer is the one who has detailed product knowledge Methodology must reflect customer interaction

Customer-DrivenProduct

Engineering

Customer:Define requirements and constraints, initiate, supervise and control product realization

Spec

ifica

tion,

Con

trol

ling

Assessm

ent

Sign-Off

Implementation,

Verification

DevelopmentTurns idea into technically feasible product description guided by customer

ManufacturingProduce device fromproduct description to meetcustomer needs


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… with Customer Involvement

The customer is the one who has detailed product knowledge Methodology must reflect customer interaction

Customer-DrivenProduct

Engineering

Customer:Define requirements and constraints, initiate, supervise and control product realization

Result ValidationProduce or result assessment“to do things right”

Spec

ifica

tion,

Con

trol

ling

Assessm

ent

Sign-Off

Implementation,

Verification

Task DefinitionProduct descriptionguided by customer control“to do the right things”


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Product Engineering – Overview

Project ManagementPRINCE2

Product DevelopmentStage Gate™


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Benefits from MEMS PE

Shorter time-to-market: Reduced cycle time Fewer learning cycles

Access to knowledge-bases on design and fabrication ICT based structure

and tools Improved transfer of knowledge from design to production

Customer-lead multi-site product development

100 % product level

time

3rd 2nd 1st cycle

MEMS PE enables reduced development times, shorter cycles reduced time to market


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Documentation of this approach

TO BE PUBLISHED

OCTOBER 2013


Conclusions


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Collaboration between Design and Process 2.0

Microlelectronics:Clear separation between manufacturing and application development

Micro Nano Technology: „closing the loop“


De

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MEMS development collaboration challenges can be overcome by Putting the customer in control

Following a customer driven, thorough collaboration methodology

Adopting documented best practices

Pursue new approaches of data exchange and infrastructure