Apparatus and methods for monitoring health of semiconductor process systems
First Claim
1. A method of monitoring a process system for performing a fabrication operation on a semiconductor wafer, the method comprising:
- enabling output of a feedback from the process system and receiving the feedback, the feedback specifying a characteristic of a component of the process system, wherein the characteristic is in response to input data sent to the component;
determining whether there is an actual or imminent problem with the process system based on the feedback, wherein such determination is accomplished without analysis of the input data sent to such component; and
reporting the actual or imminent problem or sending an alert regarding the actual or imminent problem when it is determined that there is an actual or imminent problem, while physically disabling output of the input data from the process system.
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Abstract
Disclosed are apparatus and methods for monitoring an operation parameter of a process tool, independently of a process system recipe, are provided. In one embodiment, the behavior of a process device as it transitions between different states is monitored for a single cycle of operation or over time to detect trends that indicate a potential failure of the process device. When a trend that indicates a potential failure is detected, an alarm is generated. In one implementation, the time for reaching a particular stage of operation may be repeatedly monitored over a plurality of device cycles. For example, the time to open a valve or door may be monitored. In another example, the time for reaching a stable phase of gas flow after a ramping stage has commenced is monitored. When the time for reaching a particular stage begins to decline by a predetermined amount, an alarm may be generated.
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Citations
23 Claims
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1. A method of monitoring a process system for performing a fabrication operation on a semiconductor wafer, the method comprising:
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enabling output of a feedback from the process system and receiving the feedback, the feedback specifying a characteristic of a component of the process system, wherein the characteristic is in response to input data sent to the component; determining whether there is an actual or imminent problem with the process system based on the feedback, wherein such determination is accomplished without analysis of the input data sent to such component; and reporting the actual or imminent problem or sending an alert regarding the actual or imminent problem when it is determined that there is an actual or imminent problem, while physically disabling output of the input data from the process system. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 21)
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9. An apparatus for monitoring a process system for performing a fabrication operation on a semiconductor wafer, comprising:
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one or more processors; one or more memory, wherein at least one of the processors and memory are adapted for; enabling output of a feedback from the process system and receiving the feedback, the feedback specifying a characteristic of a component of the process system, wherein the characteristic is in response to input data sent to the component; determining whether there is an actual or imminent problem with the process system based on the feedback, wherein such determination is accomplished without analysis of the input data sent to such component; and reporting the actual or imminent problem or sending an alert regarding the actual or imminent problem when it is determined that there is an actual or imminent problem, while physically disabling output of the input data from the process system. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 22)
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17. A computer program product for monitoring a process system for performing a fabrication operation on a semiconductor wafer, the computer program product comprising:
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at least one non-transitory computer readable medium; computer program instructions stored within the at least one computer readable product configured to cause a processing device to; enabling output of a feedback from the process system and receiving the feedback, the feedback specifying a characteristic of a component of the process system, wherein the characteristic is in response to input data sent to the component; determining whether there is an actual or imminent problem with the process system based on the feedback, wherein such determination is accomplished without analysis of the input data sent to such component; and reporting the actual or imminent problem or sending an alert regarding the actual or imminent problem when it is determined that there is an actual or imminent problem, while physically disabling output of the input data from the process system. - View Dependent Claims (18, 19, 20, 23)
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Specification