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Copy Exactly!: What Is It All About and How Is It Used For Technology Transfers?
Copy Exactly!: What Is It All About and How Is It Used For Technology Transfers?
Copy Exactly
From Wikipedia, the webs free encyclopedia
The ultimate acknowledgement of being adapted.
http://en.wikipedia.org/wiki/Copy_Exactly
Copy Exactly is a factory strategy model developed by the computer chip manufacturer, Intel, to build new manufacturing facilities with high capacity practices already in place.
Copy Exactly Definition: Copy Exactly! (CE!) methodology is a process of technology development and transfer, into high volume production, which seeks to eliminate any changes or variables that impact the product output or quality.
Copy Exactly!
Intel introduced the Copy Exactly! strategy in the mid 1980s. There were rapid productivity and financial gains. Productivity increased dramatically: Estimated revenue per manufacturing employee:
- $114,000 in 1985 - $461,000 in 1995
Copy Exactly!
Fab, Sort, Assembly, & Test all follow a Copy Exactly philosophy. Enables delivery of identical products from multiple sites which operate as a Virtual Factory.
Product can be partially completed at one factory and transferred to another for completion.
Product:
-Yield -Reliability
Module:
-SEM -Visual - Die Bond -Electrical
Process:
-Etch/Dep Rates -Particles -Thicknesses -Film Comp - Temperature -Equipment
Physical Inputs:
-Recipes -Facilities -Chemicals -Gases
CE Transfer Results
It is now routine for new Intel factories or new technologies to obtain equivalent yield starting with the first check-out wafer. Production quantities of products are started immediately since there is such confidence the product will be good. 11
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# of Months
30
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60
Copy Exactly!
New Equipment Differences: Each new piece of equipment in the factory is treated as a change, and is subject to change control. Audits are conducted and an Equipment Difference Form is prepared for each. This form documents the actual difference, what risks it might pose, and the corrective action plan. This is formally reviewed by management in the JET meetings.
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Copy Exactly!
Audits: An audit is a formal procedure whereby engineers from R&D and from production, audit both lines. These audits are required and scheduled as part of the technology transfer and are ongoing for a lengthy period thereafter. A report is written for each audit, detailing plans to correct all differences found.
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Factory #1
Factory #1
Factory #2 Factory #3
TD Dev Site
TD Dev Site
Model for bringing up several factories on same process at different or staggered times. Allows TD site to move onto next generation products. 16
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Copy Exactly!
Management Issues
The system has many steps and requires negotiation skills by the originator. The system can seem overwhelming, that it discourages innovation, or encourages undercover changes. While issues directly impacting factory indicators get addressed quickly, other types of issues may be deprioritized. Rapid yield improvement in CE! virtual factories proves the system can and does work, but it may need adjustment from time to time.
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Copy EXACTLY!
Work Around
Simply stated: Everything which might affect the process, or how it is run. is to be copied down to the finest detail, unless it is physically impossible to do. Sometimes there are issues that prevent an exact copy being made:
For example, in Europe the supply voltage and frequency can be different than the U.S. Some countries do not allow the some chemical types to be imported.
In these cases, specific DOEs are run to correlate the impact and thoroughly evaluate what this input has on the resulted product.
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Summary
Copy Exactly! :
Higher yields immediately. Product delivered to market faster. Lower training and engineering costs.
Larger worldwide group of trained engineers available quickly.
Resulting in: More profit for company & lower cost to consumer.
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Further References
Intel Quality System Handbook
http://www.intel.com/intel/quality/isyh.htm
The Evolution of Intel's Copy EXACTLY! Technology Transfer Method, Chris J. McDonald, Intel SEMATECH Several articles on the www.Intel.com web site on Copy Exactly!.
Duplicate a masterpiece
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