lots received customer complaints
The semiconductor manufacturing process involves a set of complex, high speed and micro-meter ranged processes along the entire assembly line. It hence becomes increasingly challenging for the manufacturers to identify and improve the processes that lead to production defects.
Identifying the root-cause for quality defects is a big concern for manufacturers. Even after a through quality testing process, the manufacturer received multiple quality complaints from its customers over the last few months.
The manufacturer sought our help to restore the production line, identify the bottlenecks and eliminate defective outputs.
We used a combination of multi-variate statistical testing and rare-event modelling technique to determine the operating ranges of all machine parameters. We worked with all the stakeholders - Product Heads, Manufacturing Director as well as the Production Engineers to identify the processes associated with all machines in the product line.
Using a hypothesis-based approach and statistical testing, we identified the parameters critical and having a high influence on the production quality.
We worked with the engineering team to design a set of experiments with multiple parameter configurations that were tested on sample lines over the course of 1 week to validate the results. Based on the findings, the solution was then rolled out to all the lines.
By using a combination of multi-variate statistical testing and rare-event modelling technique to determine the operating ranges of all machine parameters, we achieved 99.99% quality assurance across production line.