Best Practices in Microtechnology for PV production effectiveness

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1 Best Practices in Microtechnology for PV production effectiveness PV meets Microtechnology Chancen und Herausforderungen Erfurt, 29./30. Oktober 2008

2 Agenda 1 Motivation 2 History of Microtechnology 3 Common understanding of MES? 4 Innovations for PV production IT 5 Executive Summary acp Information Technology AG PV meets Microtechnology 2

3 1. Motivation advanced clean production Information Technology AG Overview: Founded in 2001 as spin off of Fraunhofer Institute of Production Engineering & Automation, Stuttgart 62 employees; partner network Locations: Stuttgart, Dresden, Timisoara, Villach Active member of standardization organisations (e.g. SEMI, VDI, VDMA) Certified according to DIN EN ISO Key Accounts in the areas Semiconductor Photovoltaic Discrete Technology Manufacturing Automotive Dresden Stuttgart Villach Timisoara acp Information Technology AG PV meets Microtechnology 3

4 1. Motivation Reinventing the wheel? Saving Cost &Time on PV production-it using standards Seamless integration based on various standards regardless of vendor Use of off-the-shelf modules lessens risk and long term maintenance cost Existing solutions instead of "homegrown" implementation acp Information Technology AG PV meets Microtechnology

5 1. Motivation but just Copy-Paste is not the right approach, too Yes, a lot of standards in Semiconductor already exist Yes, implementation of standards in semiconductor proven production stability, reliability, etc. But, What does PV really need? acp Information Technology AG PV meets Microtechnology

6 1. Motivation Goal is cost reduction Increase productivity by Yield Improvement Increase Throughput Quality control Equipment Utilization, OEE (source: SEMI PV Fab Managers Forum! You can't control what you can't measure. (Tom DeMarco) acp Information Technology AG PV meets Microtechnology 6

7 2. History of Microtechnology History of Microtechnology Production-IT Fab Operation Principle Laboratory Manual Processing Automation supported Automated Manufacturing IT Operation Principle Paper & Pencil Runcards updated daily Online Tracking of lots Data Collection Recipe Selection SPC/EDA Controlled Automated Processing IT Technology Batch Processing Transaction Processing Equipment Integration WorkFlows, Control Loops Workflow Engine Production-IT Frameworks Event Handling Business Rules Material/Machine Tracking Operator Driven (no recipe) Central DB SECS defined 300 mm guidelines full automation Standard IT: Framework for Semiconductor Manufacturing 1st time Sharing Systems 1st proprietary Lot Tracking acp Information Technology AG PV meets Microtechnology

8 3. Common understanding of MES? Monitoring vs Lights-out-Fab ERP Production Definition Production Capability Production Schedule Production Performance Ressource Management Detailed Scheduling Tracking ISA 95 Functions on Production-Control-Level Dispatching Analysis Definition Management Data Collection Planning Execution Monitoring Execution acp Information Technology AG PV meets Microtechnology Plant Floor Scanners, CNC, PLC, DCS, SCADA, PC, HMI

9 4. Innovations for PV production IT Single Wafer/substrate Tracking in PV is easy because linear process flow, process steps only, no cycles?? BUT on continuous flow processing at high volume?? acp Information Technology AG PV meets Microtechnology 9

10 4. Innovations for PV production IT Product and process traceability Equipment data acquisition Process data acquisition, recipe selection / Down- and upload, etc. Equip Material identification External Scanner, Barcode Reader, RfID, etc. Operator input Additional process input, process instructions, alarms, etc. Other production line data Ad-hoc quality measurement, consumables, durables, etc. Requires Complex Equipment integration Material not always identifiable leads to challenges in new material tracking concepts process data to product correlation! Multiple input source correlation at equipment integration for reliable and full traceability of product and process history. acp Information Technology AG PV meets Microtechnology 10

11 4. Innovations for PV production IT Changing Production Paradigms!? High Volume production, but capacity loss of complete line because of one tool down-time!? Why not material exchange between cluster tools Enabling Load Balancing, Re-routing Dispatching!? acp Information Technology AG PV meets Microtechnology 11

12 4. Innovations for PV production IT Innovation flexible process flow definition Manufacturing Process defined from Wafering to Module (Installation?) Flexible process flow Linear process (cell/thinfilm) Quality needs Single Substrate Tracking Enhanced Data Collection (SPC, APC) Zero-Measurement means Zero-Control Ad-hoc measurement Rework Assembly process (module) Alternative process routes Process variations Single MES Database for multiple and distributed production lines modeling Diversification needs Recipe Management Experiment Management Versioning Process Change Documentation! Wafer, cell production (linear process flow) and Module production (Assembly flow) in one single MES database for multiple and global distributed production lines. acp Information Technology AG PV meets Microtechnology 12

13 5. Executive Summary Upcoming PV production IT requirements From monitoring to control PV History Curve will be traversed faster Rapid development in PV industry will require a fast knowledge transfer Assess and Adopt Best Practices for PV Example: SEMI PV-EIS, defines subset of existing SEMI SECS/GEM Equipment Integration Standard took 1 year for voting instead of 3 years Many libraries, trainings, and experiences exist already Business Goal Production Requirement Enabler Cost Reduction every year Increase Yield Continuous Product / Process Development While full production Detailed Process Monitoring Quality Control and Improvement Configurable Data Acquisition Advanced Sampling Experiment Management Change Management Customizable Release Management EI-Standard, EDC Release & Version Management FDC, SPC, APC Throughput Optimization Equipment Utilization / OEE Equipment /Material state model Enable re-routing of material Dispatching Advanced Planning and Scheduling acp Information Technology AG PV meets Microtechnology 13

14 5. Executive Summary Extendable/Growing Manufacturing Execution System (MES) Production-IT has to follow production needs, not the other way. Innovation/technology partner Fraunhofer IPA acp Information Technology AG PV meets Microtechnology 14

15 Optionaler Platz für Kundenlogo Thank you for your attention. Frank Bölstler advanced clean production Information Technology AG Moritzburger Weg 67, D Dresden Telefon +49 (0) Telefax +49 (0)

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