System and method for providing automatic qualification intervention in a manufacturing process

• US 7,826,915 B1
• Filed: 01/23/2006
• Issued: 11/02/2010
• Est. Priority Date: 01/23/2006
• Status: Active Grant

• Current Assignee: National Semiconductor Corporation (Texas Instruments, Inc.)
• Original Assignee: National Semiconductor Corporation (Texas Instruments, Inc.)
• Inventors: MacDonald, William, Francis, Edward J., Moericke, Gale, Logsdon, George
• Primary Examiner(s): Kasenge; Charles R
• Application Number:
  US11/337,928
• Time in Patent Office: 1,744 Days
• Field of Search: 700/121, 700/103, 700/108, 700/109, 700/111, 700/174, 700/175, 700/95, 702/81, 702/82, 702/84, 702/182, 702/183, 702/184
• US Class Current: 700/109
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Abstract

A system and method is disclosed for providing automatic qualification intervention in a manufacturing process that is performed by a plurality of components. At least one qualification process is associated with each of the components. The qualification processes are stored in a component/qualification matrix in a computerized database management system. The automatic qualification intervention system requires that all qualification processes for a component must be performed in conformity with the qualification processes for the component that have been stored in the component/qualification matrix. The automatic qualification intervention system significantly reduces the delays that are inherent in prior art methods.

Claims

1. A method for controlling a qualification intervention process in a manufacturing process that is performed by a plurality of components, the method comprising the steps of:

receiving a work order from a manufacturing execution system, the work order associated with a tool malfunction;

selecting one of the components for which it is desired to perform a qualification process in response to the work order, wherein the qualification process comprises at least one operation that must be performed after completion of a maintenance operation to return the selected component to an operational status after the selected component has been removed from operation in the manufacturing process;

accessing an entry for the selected component in a component/qualification matrix in a database management system;

identifying from the entry the qualification process to be performed for the selected component;

providing to the manufacturing execution system the identification of the qualification process to be performed for the selected component; and

after completion of the maintenance operation associated with the qualification process, confirming that each of the at least one operation associated with the qualification process has been performed.

2. The method as set forth in claim 1, further comprising the step of:

performing the identified qualification process for the selected component as described in the entry in the component/qualification matrix.

3. The method as set forth in claim 2, wherein performing the identified qualification process comprises the step of:

determining a course of action to be taken to perform the identified qualification process for the selected component.

4. The method as set forth in claim 2, wherein performing the at least one identified qualification process comprises the step of taking no action.

5. The method as set forth in claim 1, further comprising the steps of:

associating a plurality of qualification processes with the plurality of components;

storing the plurality of qualification processes in the component/qualification matrix; and

at least one of;

adding, deleting and altering information stored in the component/qualification matrix.

6. The method as set forth in claim 5, further comprising the step of:

providing at least one graphical user interface that is configured to access the information stored in the component/qualification matrix.

7. The method of claim 1, further comprising:

controlling performance of the qualification process in the manufacturing process by requiring the at least one operation associated with the qualification process to be performed in conformity with the qualification process.

8. A method for controlling a qualification intervention process in a manufacturing process that is performed by a plurality of components, the method comprising the steps of:

receiving a work order from a manufacturing execution system, the work order associated with a tool malfunction;

selecting one of the components for which it is desired to perform a qualification process in response to the work order;

accessing an entry for the selected component in a component/qualification matrix in a database management system;

identifying the qualification process to be performed for the selected component from the entry, wherein the qualification process comprises at least one operation that must be performed after completion of a maintenance operation to return the component to an operational status after the component has been removed from operation in the manufacturing process;

providing to the manufacturing execution system the identification of the qualification process to be performed for the component;

controlling performance of the qualification process in the manufacturing process by requiring the at least one operation associated with the qualification process to be performed in conformity with the qualification process; and

confirming that each of the at least one operation associated with the qualification process has been performed.

9. The method as set forth in claim 8, further comprising the step of:

associating a plurality of qualification processes with the plurality of components.

10. The method as set forth in claim 8, further comprising the step of:

performing the identified qualification process for the selected component as described in the entry in the component/qualification matrix.

11. The method as set forth in claim 10, wherein performing the identified qualification process comprises the step of:

determining a course of action to be taken to perform the identified qualification process for the selected component.

12. The method as set forth in claim 10, wherein performing the at least one identified qualification process comprises the step of taking no action.

13. The method as set forth in claim 9, further comprising the steps of:

storing the plurality of qualification processes in the component/qualification matrix; and

at least one of;

adding, deleting and altering information stored in the component/qualification matrix.

14. The method as set forth in claim 13, further comprising the step of:

providing at least one graphical user interface that is configured to access the information stored in the component/qualification matrix.

15. The method of claim 8, wherein the identification of the qualification process is accessible to a tool operator in the manufacturing execution system.

16. An automatic qualification intervention apparatus for controlling a qualification intervention process in a manufacturing process that is performed by a plurality of components, the apparatus comprising:

a computer processing system configured to communicate with a manufacturing execution system;

wherein the computer processing system is further configured to;

receive a work order from the manufacturing execution system, the work order associated with a tool malfunction;

select one of the components for which it is desired to perform a qualification process in response to the work order;

access an entry for the selected component in a component/qualification matrix in a database management system;

identify the qualification process to be performed for the selected component from the entry, wherein the qualification process comprises at least one operation that must be performed after completion of a maintenance operation to return the component to an operational status after the component has been removed from operation in the manufacturing process;

provide to the manufacturing execution system the identification of the qualification process to be performed for the component after completion of the maintenance operation associated with the qualification process; and

control performance of the qualification process in the manufacturing process by requiring the at least one operation associated with the qualification process to be performed in conformity with the qualification process.

17. The automatic qualification intervention apparatus as set forth in claim 16, wherein the apparatus further comprises:

a database management system configured to store a component/qualification matrix that identifies a plurality of qualification processes associated with the components; and

at least one graphical user interface that is configured to access information stored in the component/qualification matrix.

18. The automatic qualification intervention apparatus as set forth in claim 16, wherein the manufacturing process comprises a semiconductor manufacturing process.

19. The automatic qualification intervention apparatus as set forth in claim 16, wherein the apparatus is configured to determine that the at least'"'"' east one operation associated with the qualification process for the component has been performed in conformity with the qualification process.

20. The automatic qualification intervention apparatus as set forth in claim 19, wherein the apparatus is configured to return the component to the operational status after the qualification process has been performed for the component.