Adjusting manufacturing process control parameter using updated process threshold derived from uncontrollable error
First Claim
1. A computer-implemented method for controlling a manufacturing process, comprising the steps of:
- (a) inputting a model for the manufacturing process and obtaining a manufacturing recipe based on the model, wherein the model predicts at least one value for a product characteristic of at least one product processed by the manufacturing process;
(b) receiving at least one observed value for the product characteristic of the at least one product and determining a variance between the at least one observed value and the at least one predicted value;
(c) determining a value for uncontrollable error from the variance;
(d) using the value for uncontrollable error to update a process threshold; and
(e) adjusting at least one control parameter of the manufacturing process using the updated process threshold,wherein the manufacturing process includes at least one device on which the at least one product is processed, the at least one device being affected by the at least one control parameter.
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Abstract
A method, system and medium are provided for enabling improved feedback and feedforward control. An error, or deviation from target result, is observed during manufacture of semi conductor chips. The error within standard deviation is caused by two components: a white noise component and a signal component (such as systematic errors). The white noise component is random noise and therefore is relatively non-controllable. The systematic error, in contrast, may be controlled by changing the control parameters. A ratio between the two components is calculated autoregressively. Based on the ratio and using the observed or measured error, the actual value of the error caused by the signal component is calculated utilizing an autoregressive stochastic sequence. The actual value of the error is then used in determining when and how to change the control parameters. The autoregressive stochastic sequence addresses the issue of real-time control of the effects of run-to-run deviations, and provides a mechanism that can extract white noise from the statistical process variance in real time. This results in an ability to provide tighter control of feedback and feedforward variations.
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Citations
31 Claims
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1. A computer-implemented method for controlling a manufacturing process, comprising the steps of:
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(a) inputting a model for the manufacturing process and obtaining a manufacturing recipe based on the model, wherein the model predicts at least one value for a product characteristic of at least one product processed by the manufacturing process; (b) receiving at least one observed value for the product characteristic of the at least one product and determining a variance between the at least one observed value and the at least one predicted value; (c) determining a value for uncontrollable error from the variance; (d) using the value for uncontrollable error to update a process threshold; and (e) adjusting at least one control parameter of the manufacturing process using the updated process threshold, wherein the manufacturing process includes at least one device on which the at least one product is processed, the at least one device being affected by the at least one control parameter. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A computer program product for controlling a manufacturing process, the computer program product comprising:
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(a) at least one computer readable medium; (b) instructions, provided on the at least one computer readable medium, for inputting a model for the manufacturing process and obtaining a manufacturing recipe based on the model, wherein the model predicts at least one value for a product characteristic of at least one product processed by the manufacturing process; (c) instructions, provided on the at least one computer readable medium, for receiving at least one observed value for the product characteristic of the at least one product and calculating a variance between the at least one observed value and the at least one predicted value; (d) instructions, provided on the at least one computer readable medium, for calculating value for uncontrollable error from the variance; (e) instructions, provided on the at least one computer readable medium, for updating a process threshold based upon the value for uncontrollable error; and (f) instructions, provided on the at least one computer readable medium, for adjusting at least one control parameter of the manufacturing process using the undated process threshold, wherein the manufacturing process includes at least one device on which the at least one product is processed, the at least one device being affected by the at least one control parameter. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A system for controlling a manufacturing process, comprising:
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(a) means for inputting a model for the manufacturing process and obtaining a manufacturing recipe based on the model, wherein the model predicts at least one value for a product characteristic of at least one product processed by the manufacturing process; (b) means for receiving at least one observed value for the product characteristic of the at least one product and determining a variance between the at least one observed value and the at least one predicted value; (c) calculating means for determining a first portion of the variance caused by uncontrollable error and a second portion of the variance caused by controllable error; (d) calculating means for updating a process threshold using either the first or second portion of the variance; and (e) means for adjusting at least one control parameter of the manufacturing process using the updated process threshold; wherein the manufacturing process comprises at least one device on which the at least one product is processed, the at least one device being affected by the at least one control parameter. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31)
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Specification