The Research Of Zero Defect Management On Yield Improvement Strategy And Implementation In Company A

In semiconductor industry, ATM(Assembly and Test Manufacturing) factory has high production costs because of expensive equipment, while the product update quite rapidly. How to achieve HVM yield goal quickly and how to achieve a rapid payback of the investment cost become the focus issue in this industry. Because of the restrictions of technical level, funds, human resources, etc, yield will be encounter bottleneck, which is very difficult to stretch any more after reaching a certain level. Back to the semiconductor ATM company A where the author works, despite it is the leading manufacturer, but also encounters the situation of yield bottleneck. In the production of millions, yield increasing from 85% to 95% have been already not easy, ever more harder if want to drive it from 95% to 99%. The purpose of this thesis is going to implement Zero Defects philosophy on yield management to break through the yield bottleneck in company A. The research method of quantity analysis, experiential summary, and empirical research are employed in this thesis.Zero Defects, Total Quality Management and Lean Production are initially focusing on the quality management, but their fundamental purpose is the pursuit of defect free manufacturing, which is the same objective of yield management. Among all the management philosophies, Zero Defects looks like more customized for the yield management. The research object of this paper is the yield bottleneck issue in company A. By analyzing the culture, institutional, process, efficiency and incoming material current issue, five strategies of culture promotion, institutional adjustment, process optimization, system and tool development, and vendor quality reinforcement have been worked out for yield improvement, which are implemented in production. Integrated Module Team organization structure and six new systems and tools’ development are creatively applied in these five strategies. Large amounts of data analysis and production validation shows that the zero defect management not only benefits a lot of yield improvement and solves the yield bottleneck problem, but also improves the product quality, speeds up the working efficiency, shortens the product life cycle, and ultimately achieves the purpose of lower manufacturing costs.