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Introduction to the MIG TDP template
The document discusses challenges in MEMS development collaboration and proposes solutions. It describes the MEMS Industry Group's Technology Development Process template, which provides guidelines for multi-site, multi-disciplinary collaboration. It also discusses the CORONA methodology, which emphasizes customer involvement for shorter development times. The conclusions are that adopting collaboration methodologies and best practices can help overcome challenges and that new approaches to data exchange and infrastructure are needed.
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Introduction to the MIG TDP template
- 1. COMS2013, Enschede, TheNetherlands 27.08.2013 – Dirk Ortloff The MEMS Industry Groups Technology Development Process Template (TDP) Improving multi-site, multi-disciplinary MEMS development collaboration
- 2. CONFIDENTIAL Process Relations GmbH Slide2 Negative Data Comic by: Nik Papageorgiou http://upmic.wordpress.com/
- 3. CONFIDENTIAL Process Relations GmbH Slide3 Negative Data Comic by: Nik Papageorgiou http://upmic.wordpress.com/
- 4. CONFIDENTIAL Process Relations GmbH Slide4 Negative Data Comic by: Nik Papageorgiou http://upmic.wordpress.com/
- 5. CONFIDENTIAL Process Relations GmbH Slide5 Negative Data Comic by: Nik Papageorgiou http://upmic.wordpress.com/
- 6. CONFIDENTIAL Process Relations GmbH Slide6 Why do I show this? – What are the challenges behind this? Inappropiate data management in R&D Inappropiate collaboration methodology
- 7. CONFIDENTIAL Process Relations GmbH Slide7 Agenda Quick company introduction The challenges in collaborative MEMS development The methodological approach – MIG TDP Template The next level – CORONA Methodology Conclusions
- 8. COMS2013, Enschede, TheNetherlands 27.08.2013 – Dirk Ortloff About Process Relations GmbH
- 9. CONFIDENTIAL Process Relations GmbH Slide9 Process Relations’ Mission …is to enable you to… Expedite your R&D with improved Methodology and flexible Software solutions Next generation recipe and DoE management Virtual manufacturing data management Automated data collection from various sources Experimental data management, analysis and extraction We deliver the easy to use, unique, world class Process Development Execution System (PDES) and consulting services.
- 10. CONFIDENTIAL Process Relations GmbH Slide10 PDES Coverage of other Manufacturing Solutions Business SystemsERP Enterprise IT SW Infrastructure CRMMDM Inbound Supply Chain Systems SCP etc. etc. Operations Management Systeme PDES MES EMS LIMS Operations IT SW Infrastructure Design & Engineering Systems Control and Automation Systems RTD AmHS / MCS SPC APC Manufacturing Tools EI RMS QMS Shipping Outbound Systems TMS etc. SRM Doc- Mgt PLM DwH etc. Doc- Mgt
- 11. COMS2013, Enschede, TheNetherlands 27.08.2013 – Dirk Ortloff The challenges in collaborative MEMS development
- 12. CONFIDENTIAL Process Relations GmbH Slide12 The challenges 25% development projects reach the market of those 66% fail their original expectations 20% of projects take too long and miss their market window 35% of companies experience runaway projects 40% of R&D experiments are repeated Source: IDC “Accelerating Science-Led Innovation for Competitive Advantage” Feb. 2012
- 13. CONFIDENTIAL Process Relations GmbH Slide13 Difficulties in collaborative MEMS development Wealth of information / technologies / data / … Diverse Variances, Options and Variability Multi-disciplinary teams required Collaboration along the value chain
- 14. CONFIDENTIAL Process Relations GmbH Slide14 Collaboration challenges MEMS Development Phases must include Foundry at early stages with multi-disciplinary team Design Review must be done for a transfer from R&D Lab to High Volume Manufacturing … 14 Fabless Houses Design Houses Design Centres MEMS Process Development Specialists Assembly & Test Houses (Wafer) Foundry Services, Semiconductor Contract Munufacturer (SCM) Integrated Semiconductor(Device Manufacturer (ISM/IDM) Distributors, Fabless Houses, Wholesalers, Trading Companies
- 15. CONFIDENTIAL Process Relations GmbH Slide15 Difficulties in collaborative MEMS development Question: How to manage for fast time to market?
- 16. CONFIDENTIAL Process Relations GmbH Slide16 Historical Collaboration between Design and Process Microlelectronics: Clear separation between manufacturing and application development Micro Nano Technology: Fabrication effects influence all stages Concept Behaviour FabricationStructure Geometry DesignRulesConcept Behaviour FabricationStructure Geometry ???
- 17. CONFIDENTIAL Process Relations GmbH Slide17 The Traditional Development Cycle for MEMS Device IDEA DEVICE DESIGN EXPERIMENT PROCESS DESIGN
- 18. COMS2013, Enschede, TheNetherlands 27.08.2013 – Dirk Ortloff The methodological approach – MIG TDP Template
- 19. CONFIDENTIAL Process Relations GmbH Slide19 The basis for the MIG Technology Development Process Template
- 20. CONFIDENTIAL Process Relations GmbH Slide20 Principle structure MIG TDP Template
- 21. CONFIDENTIAL Process Relations GmbH Slide21 MIG TDP Template -- Protocols / Roles & Responsibilities Category Concept Feasibility Prototype Pilot Production Maturity Idea Design Defined Process Established Design and Process Qualified Design Frozen Process Validated Design and Process Frozen Lead Engineer R&D R&D / Development R&D / Development Development / Manufacturing Manufacturing Layout Design Team Design Team Design Team Process Mapping Process Team Process Team Process Development Process Team Process Team Process Team Process Improvement Process Team Process Team Processing Engineers Engineers Engineers / Operators Operators Operators Experimental Approach Manufacturing POC DOE Manufacturing POC DOE Target specs and tolerances DOE Process windowing DOE Surface response DOE Quality Protocols Safety and Equipement Safety and Equipement Add Product Subset Add Full Product Full Process / Material / Equipment Changes Frequent Controlled Change Qualification Required Qualification Required Charge Development Project Development Project Development Project Lot Charge Yielded die / wafers POC = Proof of Concept Protocols / Roles and Responsibillities
- 22. CONFIDENTIAL Process Relations GmbH Slide22 MIG TDP Template -- Gating Requirement Examples Category Concept Feasibility Prototype Pilot Production Maturity Idea Design Defined Process Established Design and Process Qualified Design Frozen Process Validated Design and Process Frozen Lead Engineer R&D R&D / Development R&D / Development Development / Manufacturing Manufacturing Layout Design Team Design Team Design Team Process Mapping Process Team Process Team Process Development Process Team Process Team Process Team Process Improvement Process Team Process Team Processing Engineers Engineers Engineers / Operators Operators Operators Experimental Approach Manufacturing POC DOE Manufacturing POC DOE Target specs and tolerances DOE Process windowing DOE Surface response DOE Quality Protocols Safety and Equipement Safety and Equipement Add Product Subset Add Full Product Full Process / Material / Equipment Changes Frequent Controlled Change Qualification Required Qualification Required Charge Development Project Development Project Development Project Lot Charge Yielded die / wafers POC = Proof of Concept Protocols / Roles and Responsibillities Category Concept Feasibility Prototype Pilot Production Design Preliminary Test Freeze Optimize Revision Design Failure Mode and Effect Analysis Preliminary Finalize Verify with Process Process Failure Mode and Effect Analysis Preliminary Finalized Adjust/ Revise Process Flow Diagram Draft Preliminary Test Finalized Finalized Statistical Processing Charts Draft Identify and Establish Charts Populate/Setup /Control Monitor/OCAP /Adjust Equipment Capability Study Test Identified Validated Finalized Process Capabilities for critical nodes Study Test Meeting physical specs Cp > 1 Cp> 1.3 Yield Estimate Model Initial Establish baseline yields Yield improvement Specifications Draft Target specifications Establish spec/ Acceptance criteria Specifications in place Specifications in place BOM Draft Preliminary Finalize Frozen Frozen Inventory Control Study Build demand forecast Initial Plan In place Adjust when required Manufacturing Execution System Draft Build demand forecast Build models Models in place Modify as necessary Capacity/ Throughput Study Build demand forecast Establish capacity/ Identify constraints Address constraints Add capacity if required Safety Study Identify Initiate Plan Rectify Sustain Shipping Protocols Schedule Identify Establish In place Frozen Training Schedule Plan Initiate Issue documents Revised documents Pricing/Contract Development Development Development Manufacturing price in place Adjust External Vendors Establish Establish Qualify Qualified Qualified BOM = Bill of Materials Gating Requirments
- 23. CONFIDENTIAL Process Relations GmbH Slide23 MIG TDP Template -- Expanded Design Requirements Category Concept Feasibility Prototype Pilot Production Maturity Idea Design Defined Process Established Design and Process Qualified Design Frozen Process Validated Design and Process Frozen Lead Engineer R&D R&D / Development R&D / Development Development / Manufacturing Manufacturing Layout Design Team Design Team Design Team Process Mapping Process Team Process Team Process Development Process Team Process Team Process Team Process Improvement Process Team Process Team Processing Engineers Engineers Engineers / Operators Operators Operators Experimental Approach Manufacturing POC DOE Manufacturing POC DOE Target specs and tolerances DOE Process windowing DOE Surface response DOE Quality Protocols Safety and Equipement Safety and Equipement Add Product Subset Add Full Product Full Process / Material / Equipment Changes Frequent Controlled Change Qualification Required Qualification Required Charge Development Project Development Project Development Project Lot Charge Yielded die / wafers POC = Proof of Concept Protocols / Roles and Responsibillities Category Concept Feasibility Prototype Pilot Production Design Preliminary Test Freeze Optimize Revision Design Failure Mode and Effect Analysis Preliminary Finalize Verify with Process Process Failure Mode and Effect Analysis Preliminary Finalized Adjust/ Revise Process Flow Diagram Draft Preliminary Test Finalized Finalized Statistical Processing Charts Draft Identify and Establish Charts Populate/Setup /Control Monitor/OCAP /Adjust Equipment Capability Study Test Identified Validated Finalized Process Capabilities for critical nodes Study Test Meeting physical specs Cp > 1 Cp> 1.3 Yield Estimate Model Initial Establish baseline yields Yield improvement Specifications Draft Target specifications Establish spec/ Acceptance criteria Specifications in place Specifications in place BOM Draft Preliminary Finalize Frozen Frozen Inventory Control Study Build demand forecast Initial Plan In place Adjust when required Manufacturing Execution System Draft Build demand forecast Build models Models in place Modify as necessary Capacity/ Throughput Study Build demand forecast Establish capacity/ Identify constraints Address constraints Add capacity if required Safety Study Identify Initiate Plan Rectify Sustain Shipping Protocols Schedule Identify Establish In place Frozen Training Schedule Plan Initiate Issue documents Revised documents Pricing/Contract Development Development Development Manufacturing price in place Adjust External Vendors Establish Establish Qualify Qualified Qualified BOM = Bill of Materials Gating Requirments Responsibility Requirement Concept Prototype Pilot Engineer Application Review Preliminary Finalized Review Engineer / Marketing Review of competitive landscape. Is it favorable? Finalized Engineer Product History (new product, derivative, cost reduction, change) Finalized Eng / Sales / Marketing / Purchaseing Design to Cost Goals Preliminary Finalized Adjust Revise Engineer Intellectual Property / Patent Review Finalized Review Review Engineer / Patent Attorney Intellectual Property Creation / Patent Disclosure Submitted Review Finalized Review Sales / PM / Engineer Customer Schedule / Milestones Defined Preliminary Finalized Review Engineer Detailed Review of Product Design Preliminary Finalized Review Engineer Review of analysis completed to validate design Preliminary Finalized Review Engineer Review for compliance to existing engineering specifications Preliminary Finalized Review Engineer DFMEA Completion and Review Preliminary Finalized Review Sales / PM / Engineer Customer Specification Review Preliminary Finalized Review Adjust Engineer Design and Production Validation Test Plans Preliminary Finalized Review Engineer Review of Design and Production Validations Completed Preliminary Design Finalized Pilot Finalize Engineers (design, proc and equip) Prototype and Production Tooling / Equipment Strategies Preliminary Design Finalized Producti Finalize Design Review Gating Requirments
- 24. CONFIDENTIAL Process Relations GmbH Slide24 Benefits of the usage MIG TDP Template
- 25. CONFIDENTIAL Process Relations GmbH Slide25 But Technology vs. Product Development
- 26. COMS2013, Enschede, TheNetherlands 27.08.2013 – Dirk Ortloff The next level – CORONA Methodology
- 27. CONFIDENTIAL Process Relations GmbH Slide27 To be provoking …
- 28. CONFIDENTIAL Process Relations GmbH Slide28 … with Customer Involvement The customer is the one who has detailed product knowledge Methodology must reflect customer interaction Customer-Driven Product Engineering Customer: Define requirements and constraints, initiate, supervise and control product realization Implementation, Verification Development Turns idea into technically feasible product description guided by customer Manufacturing Produce device from product description to meet customer needs
- 29. CONFIDENTIAL Process Relations GmbH Slide29 … with Customer Involvement The customer is the one who has detailed product knowledge Methodology must reflect customer interaction Customer-Driven Product Engineering Customer: Define requirements and constraints, initiate, supervise and control product realization Result Validation Produce or result assessment “to do things right” Implementation, Verification Task Definition Product description guided by customer control “to do the right things”
- 30. CONFIDENTIAL Process Relations GmbH Slide30 Product Engineering – Overview Project Management PRINCE2 Product Development Stage Gate™
- 31. CONFIDENTIAL Process Relations GmbH Slide31 Benefits from MEMS PE Shorter time-to-market: Reduced cycle time Fewer learning cycles Access to knowledge- bases on design and fabrication ICT based structure and tools Improved transfer of knowledge from design to production Customer-lead multi-site product development 100 % product level time 3rd 2nd 1st cycle MEMS PE enables reduced development times, shorter cycles reduced time to market
- 32. CONFIDENTIAL Process Relations GmbH Slide32 Documentation of this approach
- 33. COMS2013, Enschede, TheNetherlands 27.08.2013 – Dirk Ortloff Conclusions
- 34. CONFIDENTIAL Process Relations GmbH Slide34 Collaboration between Design and Process 2.0 Microlelectronics: Clear separation between manufacturing and application development Micro Nano Technology: „closing the loop“ Concept Behaviour FabricationStructure Geometry DesignRulesConcept Behaviour FabricationStructure Geometry
- 35. CONFIDENTIAL Process Relations GmbH Slide35 MEMS development collaboration challenges can be overcome by Putting the customer in control Following a customer driven, thorough collaboration methodology Adopting documented best practices Pursue new approaches of data exchange and infrastructure