Post on 24-Apr-2015
ABSTRACT
Industrial Training has been undergone at X-FAB Sarawak Sdn Bhd, attached to
the Quality Department. The company is known to be the world’s leading analog/mixed
signal foundry group manufacturing silicon wafers for analog-digital integrated circuits.
This report will show an overview about the company structure of management,
activities, historical background and some of its achievement. Details on the tasks that
have been carried out will be explained thoroughly according to the given training
schedule along with the on-going project.
Some of the explanations include the problem faced, planning, observation, ways
of handling and problem-solving. Some attachments on full report on the research and
project that had been conducted are shown in the appendices. Other related information
is also attached.
Here, I would like to express my heartfelt thanks to X-FAB Sarawak Sdn. Bhd for
given me an opportunity and also permission to undergo my industrial training. My
sincere appreciation goes to:
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Main supervisor: Mohammad Shahril Bin Ramli
Quality System Engineer-in-charge (Mentor): Lavinia Pua Chuk Yih
Project supervisor: Ng Hong Seng
Assisting my routine tasks: Jacqueline Geoffery
Assisting my project: Willie Teo Teck Yan (Mentor/FA staff), Lee Eng Leiong (IT)
and all the staff and colleagues in the Quality Department who have given me an
undivided attention, providing advices, assistance and support during my training.
Finally, I’d also like to thank UNIMAS faculty of Engineering, LI coordinator, Mr
David Bong Boon Liang and my visiting lecturer, Miss Shafrida Sahrani.
2
TABLE OF CONTENTS
Pages
1. Abstract 1-2
2. Table of Contents 3-4
3. List of Notations and Symbols 5-6
4. Introduction 7
5. Background of Company/Organisation 8
5.1 Approach Towards Customers 9
5.2 Milestones
5.3 Technologies by X-FAB 10
6. Management Team of X-FAB 11
7. X-FAB Sarawak Organizational Chart 12
8. Quality Department (Organizational Chart) 13
9. Overview on Quality in X-FAB Sarawak Sdn. Bhd. 14
9.1 Quality Management System in X-FAB 15
10. Summary of Duties 16-19
11. Working Experience
11.1 Routine Task: Utilizing the use of DMS 19-20
(Document Management System)
11.2 Side Task I: Clean Room Protocol and ESD Control 20-21
11.3 Side task II: Attending training offered by different module/section 22-23
11.4 Project: Designing FA Job Request Form using the cuteflow system 24-30
12. Problems faced and solved 31
13. Summary 32-33
14. Appendices
Appendix A: Wafer Process Flow 33-34
Appendix B: FA Job Request Guide for DCS 35-47
3
Appendix C: Flow chart of the current FA System
(FA Job Submission Procedure) 48
Appendix D: New System for FA Job Request -
Document Circulation System (Using Cuteflow) 49
Appendix E: Interface of the New Database
(Cuteflow Storage and Conversion Engine) 50
15. References 51
4
LIST OF NOTATIONS AND SYMBOLS
CMOS Complementary Metal-Oxide Semiconductor
BiCMOS Bipolar Complementary Metal-Oxide Semiconductor
BCD Binary Coded Decimal
SOI Silicon on insulator
MEMS Micro Electro Mechanical System
ITRS International Technology Roadmap for semiconductors
RF Radio Frequency
M/S Mixed Signal
NVM Non-volatile memory
VP Vice President
COO Chief Operating Officer
CFO Chief Financial Officer
CTO Chief Technology Officer
QA Quality Assurance
EHS Environment, Health and Safety
DMS Document Management System
CMP Chemical Mechanical Planarization
FA Failure Analysis
VBA Visual Basic Application
ESD Electrostatic Discharge
MBO Management By Objectives
ISO International Standards Organization
CVD Chemical Vapor Decomposition
WAT Wafer Acceptance Test
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ESDS Electro Static Discharge Sensitivity
PFA Physical Failure Analysis
EFA Electrical Failure Analysis
IE Industrial Engineering
FEOL Front End of Line
OPC Optical Proximity Correction
DCS Document Circulation System
MYSQL Open Source Database
CSV Comma Separated Values
TBD To Be Determined
LDAP Lightweight Directory Access Protocol
SM Specification Manager
WLR Wafer Level Reliability
DOE Design of Experiments
[1]
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INTRODUCTION
An industrial training for a total of 16 weeks is a compulsory and also a
requirement for UNIMAS students in attaining Bachelor of Engineering (Hons). By
undergoing industrial training, students are given the chance to get involved in the line
of work of engineering.
Experience and knowledge obtained are crucial for the job applied in the related
industry in the near future. The experience itself is certainly worth more than what had
been taught in ordinary lecture class. In fact, students can even apply and implement the
knowledge learnt from engineering courses in a real-life working situation.
Thus, students will then be able to troubleshoot technical problems, enhance their
problem-solving or present an effective solution for the problems encountered
throughout the training period. Besides, students are able to communicate with their
colleagues and also employer by getting involved in tasks, project or meeting. This has
certainly presents an opportunity for students to mix in the circle or social network
within the company.
In conclusion, students can get an overview and idea on what their future line of
work would be and can therefore choose an appropriate job upon graduation based on
these industrial training experience and knowledge.
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BACKGROUND OF COMPANY/ORGANISATION
X-FAB is known as the world’s leading analog/mixed-signal foundry group
manufacturing silicon wafers for analog-digital integrated circuits. X-FAB combines
solid, specialized expertise in advanced analog and mixed-signal process technologies
with excellent service and support which as a whole, provides a clear alternative to
typical foundries services. Thus, X-FAB continues to maintain the flow of products
development as well as the supply chain for customer’s semiconductor products.
This multinational firm manufactures wafers in automotive, electronic industries,
consumers’ products, medical devices and also services such as design kits and
prototyping with the use of ultra-modern modular CMOS and BiCMOS processes of
technologies ranging from 1.0 to 0.13 µm, as well as special BCD, SOI and MEMS
long-lifetime processes. Unlike most of the conventional semiconductor foundries, X-
FAB not only sticks to the ITRS road map (a guideline), but also continue to evolve by
developing even smaller and faster CMOS process technologies. X-FAB, however, aims
to enhance and expand CMOS and BiCMOS technologies with the additional, special
analog functions and modular options.
With a total of five manufacturing sites all around the world, X-FAB has managed
to achieve a combined capacity of around 70,000 eight inch equivalent wafer starts for
an average in each month. 2,600 personnel are employed worldwide for all the sites.
Numerous sales representatives spread all around the world, with the majority in Asia,
Europe and USA to establish a close contact with the nearest customers available.
8
Approach towards Customers
X-FAB builds long-term relationships with the customers based on stability,
reliability and confidence in its own expertise by emphasizing on the wafer
manufacturing processes as well as the quality and the value of the wafer produced.
Customers are provided with full technical support, simple, effective and flexible
foundry access.
The product development cycle is stable and of proven quality. From the early
development phase through to batch production, customers are given aid with complete
online support – including full access to technical documentation, process design kits,
electronic design automation, and up-to-date product status on the production lines.
X-FAB customers benefit from high-performance technologies, excellent technical
design and prototyping services; and fast, easy and flexible foundry access worldwide.
The company’s steady growth year over year often has exceeded that of the industry.
9
Milestones
X-Fab was first established in the year 1992, residing in Erfurt, Germany. Business
soon flourished, and in the year 2000, the company took over the waferfab from Texas
Instruments which locates in Lubbock, Texas with a total available capacity of 23,000 8-
inch equivalent wafer, starts per month.
After two years, the company acquired another waferfab from Zarlink in
Plymouth, UK. This waferfab has the available capacity up to 28,500 8-inch wafer starts
per month. It was until year 2006 that the company took another step in advancing the
business by successfully merged with 1st Silicon in Kuching with the total available
capacity of 55,500 8-inch equivalent wafer starts per month.
Technologies by X-FAB
X-FAB creates a wide variety of new mixed-signal process families for
applications in various areas of application, such as the automotive, medical, industrial,
communication and also consumer electronics.
The state-of-art CMOS and biCMOS platforms can be complemented with
specialties ranging from analog mixed-signal functions to high voltage, embedded non-
volatile memories, optical, RF and bipolar elements, or the implementation of,
microelectromechanical sensor technologies.
[2]
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11
12
QUALITY DEPARTMENT
(ORGANIZATIONAL CHART)
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OVERVIEW ON QUALITY IN X-FAB
X-FAB provides its customers with products and services of best-quality in order
to sustain a lasting customer satisfaction which will then guarantee X-FAB’s success on
a long-term basis. This is parallel with X-FAB’s achievement in becoming the world’s
leading independent mixed-signal foundry.
Thus, X-FAB continues to maintain its policy in improving its systems and
processes in relentless effort to meet and surpass customers’ expectations.
This can be strived by:
Focusing on customers’ needs
Benchmarking performance to specific standards
Aiming to achieve demanding goals
Rigorously reviewing the data
Continue to improve all the processes
Involving all employees in improvement activities
Realizing the policy throughout the organization
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Quality Management System in X-FAB
X-FAB’s Quality Management System is an integrated process-oriented system
into which all quality, environmental and safety management procedures have been
fulfilled and achieved. The goal is to continue to uplift as well as to ensure the best
quality and the reliability performance of all the technologies through a systematic yet
effective approach that is emphasized on the quality at every phase of the product
development through manufacturing.
Thus, this can truly allow X-FAB to control the entire manufacturing process in a
proactive manner, with quality being designed into the process as a built-in-feature and
not merely acquired through inspection and observation.
X-FAB triumph and achievement rely heavily on the trust and loyalty shown by its
customers. The task of fulfilling the customers’ needs and satisfaction presents as a
permanent challenge for X-FAB group. This requires the continuous improvement not
only of technology quality and performance but also of management, key and support
processes.
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SUMMARY OF DUTIES
Week Task/Description
1 Guided by Sandie Uding from the Human Resource Department.
Given briefing on the company’s policies and regulations.
Reporting to supervisor, Mohammad Shahril of the Quality
Department
Given brief overview on X-Fab Sarawak Quality System by Lavinia
Pua
2 Understanding Document Management System in the Company
Attending EHS briefing (Environmental, Health and Safety)
3 Attending Radiation Safety briefing.
Hands on the DMS (Document Management System)
(Migrating company’s procedures to the X-FAB Sarawak
Documentation Server)
4 Attending Orientation; understanding X-FAB
Chemical Safety
Electrical Safety
5 Continue uploading procedures using DMS
Given a tour in the FAB. Helping colleague, Khoo Eng Ann to
measure electrostatic discharge level at the photolithography area as
well as CMP area
6 Chinese New Year Holidays
7 Briefing on the project of creating FA job request form online using
the cuteflow system
Understanding and learning to use the cuteflow system.
Given tour in the FA lab and Chemical lab by Khoo Eng Ann.
8 Given a sample form on reliability (the form is failed to be built
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because cuteflow contains no functional field type for table creation)
Help colleague, Jacqueline Geoffery in document classification in
the document control room
9 Learn to use ‘Lotus Notes’ in migrating and uploading products
specifications.
Attending Toastmaster meeting
10 Concentrating of data conversion using excel VBA
Complete finalizing FA Job Request Form
11 Attending ESD briefing (Electrostatic Discharge).
Was given raw data by IT staff, Lee Eng Leiong for the use of
conversion.
Building out a prototype version of the data conversion
12 Continue with the routine tasks
13 Further discuss with Willie Teo on the flaws of the FA job request
form created.
Planning to remodify the form for a much effective use
14 Helping out Willie by preparing proposal on the part involving the
usage of database system in the project and also some of the part on
the user’s guide on how to use FA job request form with the cuteflow
system
Was briefed by Ng Hong Seng on the add-ons for the project;
building pivot tables and chart for the use of MBO purposes
15 Engage in a meeting of reviewing the cuteflow project with project
partner, supervisor and managers.
Attending advance training of Wafer Acceptance Test
Attending advance training of CVD film properties
Attending toastmaster meeting
16 Attending advance training on FA (Failure Analysis) theory
Submission of industrial training report to UNIMAS Engineering of
Faculty. (To Training Coordinator, David Bong Boon Liang)
17 Was assigned task to update revision history for each specifications
17
in the DMS System.
Finding ways to convert csv files to xls files (obtaining the source
code)
18 Attending the training course on IE Capacity Introduction
Awaiting extraction of a set dummy circulation data from Lee Eng
Leiong. (He needed to remap the query of the SQL Database with
each changes to the form)
19 Attending Advance FEOL (Front End of Line) Oxide Process
Training and Advance Implant Process Training
20 Attending SPACE workshop throughout the week. (witness the
discussion held between vendors and each representative from
respective module.
Attending Advanced Poly & Trench Etch Process Training
21 Recreating FA-Job Request Form in the Production Site (Exactly the
same format as the finalized one in the development site)
Raise a few dummy circulation to be extracted and used for excel
database creation.
22 Attending SPACE meeting.
Reviewing previous Database for FA Job Request. (Extraction of
data from Cuteflow Database should conform to the format of the
existing Database)
23 Finishing the creation on database.
Reviewing the project with Ng Hong Seng . (Some adjustments and
modification are needed to be done to conform exactly to the format
of the existing database)
Troubleshooting the coding using the PC in FA lab.
24 Completed project pass down to Willie Teo (excel database
cuteflow)
Presenting the overall tasks and projects that were given and have
been done during the course of my training.
Submission of report to HR.
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WORKING EXPERIENCE
Routine Task: Utilizing the use of DMS (Document Management System)
DMS is a computerized environment which enables and facilitates operations
such as creating, capturing, organizing, storing and retrieval and approval of a
document. According to the requirement stated in ISO 9001: 2000, quality systems
should be documented by developing documents to implement the quality system and
also to reflect what the organization do. X-FAB has managed to achieve this
certification in 2001.
Quality system manual is also created and prepared to document all the procedures
in describing how the processes interact. This manual can also define the scope of the
quality system. Quality system documents should also be controlled from time to time,
ensuring them up-to-date. The methods of controlling the documents are listed as below:
Documents are approved before distribution
The correct version of the documents is provided at points of use
Documents are reviewed and re-approved whenever they are updated
The current revision status of the documents is specified
Documents which are originated from external sources are monitored
Accidental use of obsolete documents are prevented
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The identification of the quality documents are preserved
[5]
Quality system records are also vital because these records can be used to prove
that the requirements have been met. These records are ensured usable and a procedure
is developed to control the records.
Side Task I: Clean Room Protocol and ESD Control
During the course of my training, I get a chance to attend a course regarding Clean
room Protocol and ESD Control. Clean room protocol is implemented and practiced by
all personnel in X-FAB Sarawak including visitors and vendors. The purpose of the
implementation is to control and maintain the cleanliness of the clean room as well as
the good quality of the products.
Clean room is defined as an environment with a low level of environmental
pollutants or contaminants such as dust, airborne, microbes, aerosol particles and
chemical vapors. The implementation of this environment is commonly found in the
fields of scientific research and manufacturing. It has a specific allocated level of
contamination that is of number of particles per cubic meter at a specified particle size.
Clean room is very large and the entire operation and manufacturing facilities are
contained within it. The air entering clean room from outside is filtered and is constantly
recirculated through high efficiency particulate air and also ultra low penetration air.
This is to get rid of the internally generated contamination. All employees enter and
leave through airlocks (or even air shower stage), and wear protective clothing such as
hats, face masks, gloves, boots and cover-alls
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Clean room has its own standard classification. They are grouped according to the
number and size of particles permitted per volume of air. X-FAB follows two of the
clean room standards and they are US FED STD 209E and ISO 14644-1. [3]
Nevertheless, for the training on ESD control, I managed to acquire sound
knowledge on controlling and preventing ESD event in the areas with ESD Sensitive
(ESDS) devices. ESD (Electro Static Discharge) is known as a sudden transfer of charge
between bodies at different electrical potentials (from high to low) and also at different
charges (positive and negative charges) such as the lightning phenomenon. ESD can
result defect in the semiconductor devices because of the high energy discharge. It may
also disrupt the electronic system, causing equipment to malfunction or failure.
Therefore, ESD control strategies are introduced to neutralize the charges by either
grounding or ionizing. Isolation or shielding can also be done by isolating either the
product or electrostatic source. With prevention been done on the accumulation of
charges, there will only be a low level occurrence on ESD event or not at all.
I managed to get a chance to help Mr Khoo Eng Ann, who is also one of my
colleague/mentor in performing the in-house ESD control monitoring through
conductivity check on clean room floor and wall. This is done half a year using an
equipment known as 3M 701 Test Kit Conductivity Meter. [4]
Side task II: Attending training offered by different module/section
21
During the period of my training, I have also taken the initiative to participate in
the advance training courses offered by X-FAB. The training courses offered are
conducted by trainers who are the employees from various module/department/section.
The courses are mainly related to the operations and various processes of wafer in
the line. These intermediate/advance courses are only available from the month April till
June. Therefore, I have taken into consideration to extend my training so that I have the
opportunity to attend those training courses that I have opted to know more about.
Some of the courses that I have chosen to attend are shown in the table below:
Date Training Description
9 April Wafer Acceptance
Test
Learn about various testing methods and relate test
parameters to process parameters
10 April CVD film
properties and
process control
items I & II
Detail properties for CVD films
Detail application for CVD films
Process trend for CVD films
Monitor control items for CVD films
14 April FA (PFA & EFA)
–Theory
Learn about the various methods used to search for
product failure: e.g: delayering, etching, manual
benching, liquid crystal testing etc.
28 April IE capacity
Introduction
Introduction of capacity planning.
7 May Advance FEOL
Oxide Process
Training
Introduction to various types of etch methods along
with a case study.
8 May Advance Implant
Process Training
Explains details on Ion Implantation versus
theory.
Details on Ionization and filament physics,
Extraction and Suppression physics, space
22
charge considerations, 23nalyzer assembly,
acceleration, channeling and projected range.
13 May Advanced Poly &
Trench Etch
Process Training
Introduction to Poly & Trench Etch Processes
Different Scheme of Poly Etch Processes
Different Scheme of Trench Etch Processes
Design of Experiments (DOE) & Process
Tuning
Dry Clean & Seasoning Requirement
Case Study
Project: Designing FA Job Request Form using the cuteflow system
(Major Role: Data conversion from cuteflow database into excel using VBA)
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This project has play a role in introducing new, easy yet effective system for FA
Technicians when performing their task upon the submission of Job Requests. It
eliminates the needs of manually getting an approval from the person of a higher level to
accept the submission of every FA job request on inspecting, scraping or analyzing a
scrap (defect wafer).
In this system, cuteflow, a document circulation software aids in automating
circulation of the FA job request form (which is also created using the software itself)
among Job Requestor, Managers and FA technicians hierarchically (according to
different mailing slots).
After the job is completed, or in other words, the circulation is done, all the
information which is inputted into FA job request form is extracted, converted into
readable format and stored in FA very own excel database.
The details on the next few pages are the proposal showing the information on the
‘cuteflow’ software as well as the overall purposes of the project.
New FA System – Document Circulation System
Main Objective:
24
The main objective of upgrading the current system is:
Effective validation of details and clear description for job request
Consistent and effective authority level of approval through Document
Circulation
Reduce Verbal Communication Error
Improve job pass-down
Improve automation
Assist in MBO summarization by data collection.
Brief Introduction of “CuteFlow”
CuteFlow is an Online or web based Document Circulation System (DCS). The
system will distribute a user-customized form throughout a defined group of people
by E-mail (mailing list) at a “step-by-step” basis.
These documents distributed can be observed by these people and can act as a
notification or highlight to higher levels of management. At the same time, DCS can
capture important details and act as a simple online form to collect data.
Here are some of the main features and facilities of the DCS:
User can built customized forms
Each event of circulation progress will be indicated in progress bar and
percentile
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Allow file attachments for reference purposes
Check the progress of the circulation online
View the details of circulation
Change receivers or route for a substitute for a specific circulation*
Stop a circulation*
Search for Circulation
*It is advisable that whatever abnormalities happened during the circulation need to be justified
Advantages:
Promote consistent data entry and input validation
Abolish the need to obtain approval signatures from higher authorities by
replacing with Personal Email Notification and approval
Reduce Communication traffic between Requestor and FA Staff
Job Requestors and FA Staff can work effectively after they are taught on how to
implement this system through guidelines and training
Provide better Data Compilation capability for MBO summarization
New Features:
General:
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Input validation for important fields
Online Check for Job Progress Upon Web Logon
Advanced Filtering options which will allow search of specific circulation based
on user selected fields
For FA Staff:
Maintainable and flexible form design method (for DCS) for future changes
Conversion of data from mysql database to Excel (extraction requires IT
Assistance)
Immediate Email Job Notification when job request is done
Limitations:
Performance of System will depend on Network traffic and utilization frequency
of user
System operation will be dependent on company server (Centralized system)
Require Manual and monthly Data Extraction from IT
Facilities:
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In General, any interaction with this system will require a PC with Intranet/Local
Area Network (LAN) connectivity. An internet browser (Internet Explorer 6.0 or higher
with Java Plug-ins installed) is required to access the System along with a valid
company’s system user account and a company email address.
For maintenance purposes, Trained FA Staff will be given super
user/administrator right for future changes or fine-tuning on the cuteflow system. The
same goes to the source code in the excel database which may also subject to changes if
there are any changes occurred in the FA job request form created in cuteflow.
Database: Records from the cuteflow system:
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The records in the cuteflow system are the actual inputs in the form after it
undergoes submission and circulation.
Originally, the cuteflow system itself is using mysql database.
Records inputted into the FA job request form (created by cuteflow) will be
stored in the mysql database.
However, IT staff would only need to extract out the data of the fields from each
slot and compile them all into several ‘.csv’ files.
Each slots in the form will be extracted into its own single .csv file
These data will then be handed over to the FA staff for conversion and storage in
excel.
The conversion of data into readable format is done using VBA (Visual Basic
Application) within excel whereas the storage for the converted information is
the excel file itself (the main file containing the macro)
The raw data from each of the slots are to be classified into a single sheet in the
excel file
The information for each record is classified neatly and accordingly with each
column stating the type of fields.
Pivot tables and charts/graphs can then be built from the information collected
for the use of presentation in MBO review.
The main file is then created from the raw data, taking out only the important
fields (columns). Extra columns are created for the use of pivot table and
chart/graph.
Data will be extracted routinely (say monthly) from time to time by IT staff from
the cuteflow database itself.
FA staff will then take the extracted data, allocate and converted it into the FA
excel database. With a click of a button all the ‘extracted’ raw data are converted
in readable form and aligned properly.
The database will be maintained from time to time (source code will be subjected
to changes with each additional new field)
The allocation and conversion of data is built by creating macro using VBA
excel.
29
Advantages
Eliminating the hassle of keying-in the data manually for each record.
It is a semi-automated system. With just a quick click of the button, data are
converted and stored in the excel file.
Disadvantages
The source code will subject to change if FA job request form within the
cuteflow is modified. Therefore, maintenance is the required to be done by FA
staff if the need arise.
Still inflexible because of the routinely needs of acquiring raw data extracted
from IT staff.
Currently, this project is still in prototyping period. The project will finish upon the
completion of my training on the 13th June.
PROBLEMS FACED AND SOLVED
30
During my training, I encountered several problems that I have found quite hard to
handle at beginning of the first few weeks of my training. I was very vague on what the
organization actually did along with the operations and processes that happens within
the FAB and also the responsibility and tasks carried out by my surrounding colleagues.
This, however, was immediately dispersed after I was briefed by the engineer in charge
of me, Miss Lavinia Pua through her invaluable guidance and some softcopies on the
training materials.
I have also learn that time organization is crucial when handling multiple tasks. At
first, I found it hard to complete the routine task and the project, both at a same time. I
committed almost entirely on my daily tasks while struggling to find time to cope with
my on-going project. However, I chose to prioritize my daily tasks in finishing them all
first before I fully committed to the progress of my project. I chose not to multitask all
of them at once. The completion of the tasks at hand, one at a time has certainly made
me gave more of my personal time and concentration more on the upcoming task.
I learnt that knowledge on some of the engineering principles and terms was
essential when performing the tasks. With the lack of knowledge, the progress on my
task became slow as I constantly need to seek aid and guidance from my colleagues as
well as browsing for some vital sources through the internet. Luckily, for the on-going
project on cuteflow that I am still doing, I only face a few minor problems associated
with the use of VBA as I already have the basic knowledge of using Visual Basic.
SUMMARY
31
Throughout my training period in Quality Department at X-FAB Sarawak, I
was given the opportunity to handle tasks and projects, which in turn, letting me gain
new ideas and experiences which cannot simply be learned in the courses attended in
university.
I found that teamwork is crucial in the company. Each of my colleagues has
their own role to play and responsibility to contribute towards attaining the company’s
goal. They share ideas, opinions and function as a team when dealing with any matters
that arise.
I, myself, have the chance to cooperate with some of my colleagues in
completing the project. Reviewing and troubleshooting have been done continuously
along the process of completing the project, where cooperation and communication are
required and essential in decision-making. I have learnt that decision-making in a team
provides much easier, precise and time-saving approach in solving matters and
sometimes even present an alternative path when handling problems.
Working with my colleagues who have years of experience in the company has
also given me the privilege to learn from them as they are extremely capable and know
very well their line of work in engineering. I have learnt a great deal from them when
dealing with routine tasks and project.
Continuous learning is important not only in the sense of acquiring knowledge-
based theory, but also through observation and experience. No matter how high our
education background is, learning through experience gained is still the top priority
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because the working environment and tasks given are all more on the practical aspect
which cannot be experienced within the confined in an ordinary lecture class.
In conclusion, a proper working attitude, and good knowledge can aid in
performing our job better. Besides, diligence and the passion to learn continuously is an
ongoing process of a lifetime and shall never stop. As the saying goes, “Learning is a
never-ending process and also a process of a lifetime.”
APPENDIX A: WAFER PROCESS FLOW
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The process flow for semiconductor manufacturing is best considered in two
sections, the “front-end” and the “back-end”. The flow chart in the next page shows the
semiconductor front-end manufacturing process flow chart.
The “front-end” is wafer processing which is performed in a Wafer Fab area. The
process of wafer fabrication consists of a series of 16 to 24 loops, each defining a
conductive or insulating layer on the device. Each loop comprises of some or all of the
major steps of photolithography, etch, strip, diffusion, ion implantation, deposition and
chemical mechanical planarization.
At each stage, there are various inspections and measurements performed to
monitor the process and equipment. Supporting the entire process is a complex
infrastructure of materials supply, waste treatment, support, logistics and automation.
The Fab has the cleanest environment in the world – many times cleaner than the
best hospital operation theater. A Fab is one of the most complex industrial facilities to
be found anywhere. A state-of-the-art Fab, costing over US$ 1 billion, has a denser
capital expenditure per square foot than any other industry.
34
APPENDIX B: FA JOB REQUEST GUIDE FOR DCS
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Objective:
To educate FA Job Requestors on how to submit a proper and complete FA Job Request
(circulation) and provide the relevant details to support FA task.
Steps to create a circulation:
Part 1.0 - Basic startup
1.1 Open Internet Explorer and enter Document Circulation System main site (TBD)
1.2 Logon with you valid LDAP Username and password at X-FAB Document
Circulation System Login as per Figure 1.1.
1.2.1 If you are not listed in the user database, please contact IT staff to get a
username and password
Figure 1.1
1.3 After successfully logged on, you will se a page similar to Figure 1.2.
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Figure 1.2
1.4 To show the listing of circulation, click on the “Circulations” link provided on the
left menu as per pointed in Figure 1.2
1.4.1 The Circulation list will show the entire listings of circulation for FA Job
as Figure 1.3
1.4.2 Here you can check your FA Job request status, whether it’s still waiting
for approval, or already in progress.
1.4.3 FA Staff will not need to serve phone calls for job status queries.
Figure 1.3
Part 2.0 – Creating a circulation/ Job Submission
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2.1 To start a new circulation, click on the “New Circulation” link provided at the left-
top position of the circulations listings.
2.2 You will be required to enter information of the FA job submission as per the
Figure 2.1.
Figure 2.1
2.3 At “Step 1/3: New circulation” form:
2.4 For Circulation name, Select QRA-FA JOB REQUEST FORM
2.5 For Mailing list, select your own department on the ‘Select Mailing list’ pop-up
box (Figure 2.2). E.g.:
2.5.1 Etch is ET/ALL;
2.5.2 Photo-litho is LT/ALL;
2.5.3 Diffusion is DF/ALL;
2.5.4 Quality is QRA/ALL;
2.5.5 OPI and YE Manufacturing is OPI/ALL;
2.5.6 Thin-Film is TF/ALL;
2.5.7 R&D is RD/ALL
Click OK when done or Cancel to close without selecting
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Figure 2.2
2.6 At ‘Attachment’, it is recommended you attach supporting documents or
information regarding your submission for FA Reference.
2.6.1 Click on the browse button and a typical “Choose file” window (Figure
2.3) will show.
2.6.2 Select your file attachment and click on ‘Open’ to attach the file.
2.6.3 The DCS allows attachment up to 4 files.
Figure 2.3
2.7 ‘Description text’ is optional to fill. You can enter your remarks here.
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2.8 A completed Step 1/3 would typically look something like Figure 2.4. Click on
Next to proceed with submission or Cancel to discard this submission
Figure 2.4
2.9 For Step 2/3 (Mailing List), Please Follow instructions as per below and ASSIGN
ONE APPROVER ONLY for each ‘Slot’:
2.9.1 Slot 1: Job Request – Please ignore this slot. (It is to prevent circulation
back to the sender’s email)
2.9.2 Slot 2: Originator’s Manager Notification – Choose your respective
manager for notification purposes.
2.9.3 Slot 3: Approval by Dept/Module Manager – Select your respective
Dept/Mod manager if the job priority is High/Urgent. Please remove all
if job priority is Normal
2.9.4 Slot 4: Approval by FA Manager – Also required if job priority is
High/Urgent. Please remove if job priority is Normal
2.9.5 Slot 5 to Slot 7: – PLEASE DO NOT CHANGE THESE. FA Technician
is made default for these slots. (Reference in Figure 2.6)
2.10 Example screen for Slot 1 to Slot 4 can be seen in Figure 2.5.
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Figure 2.5
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Figure 2.6
2.11 After completing the Mailing list, simply click Next to proceed to with submission
or Back to return to previous step or Cancel to discard all information.
2.12 At Step 3/3, you are required to input your job request information in the first slot
only.
2.13 Be sure to fill in correct and accurate information or else it will affect FA data
accuracy.
2.14 Field marked with a red asterisk (*) is compulsory. You are unable to proceed if
fields are incomplete.
2.15 A completed slot can be referred in Figure 2.7
2.16 After entering your details, click on ‘Complete’ to submit circulation or ‘Back’ to
return to previous page or ‘Cancel’ to discard this circulation.
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2.17 Provided that there is no server error or network problems, your Circulation should
have successfully been submitted and you should receive an E-mail of this
circulation.
2.18 Read the Email, which typically from kch-intranet@xfab.com. Make sure your
spam filter does not detect this as spam. Email should be similar to Figure 2.8
from X-FAB web mail
2.19 Approve the Email by selecting the clicking the Send button on the bottom-right
corner of the sub window.
2.20 To cancel this circulation select “I decline the content of this circulation” above
the form and click Send. Your submission will stop immediately and showed in
the circulations page.
2.21 Upon clicking Send, a message will indicate the success of transfer as per Figure
2.9
2.22 The next approver will need to follow instructions from 2.18 to 2.21 to approve a
circulation and 2.13 to 2.16 for filling the circulation fields.
2.23 The approver can click on the ‘Print View’ button on the bottom left of the sub-
window to view Job details more accurately (Figure 2.10)
Figure 2.7
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Figure 2.8
Figure 2.9
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Figure 2.10
Part 3.0 – General Features of DCS
3.1. Advanced Filter (refer to Figure 3.1 )
3.1.1. Objective for this filter is the narrow down your target of search
3.1.2. To activate this feature, click on the Advanced Filter Options check box
at the Grey title bar.
3.1.3. A form will appear and you can choose based on the filtering details by
entering them in the correct fields provided.
3.1.4. Click on the Green filter icon on the right end of the grey title bar to start
the filtering process.
3.1.5. Your search targets together with similar job details will appear in a list
below the Filter tool
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Figure 3.1
3.2. Sort view
3.2.1. Objective for this is to sort the entire list of the circulation based on a
particular field. Usually applied when general viewing or checking job
status or job queue.
3.2.2. To utilize this feature, simply click on your preferred sorting field on the
blue header bar.
3.2.3. You can sort by Ref No., Department, Name, Sending Date, or Sender.
3.3. Show Circulation Details
3.3.1. Objective is for the viewer to check or inspect the circulation information
3.3.2. Click on the Magnifying Glass Icon at the right end of the particular
circulation to open it. Help bubble will appear when your cursor is placed
on the icon. (Figure 3.2)
3.3.3. These circulation is Read only for viewers. Outcome will be almost
similar to Figure 3.3
Figure 3.2
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Figure 3.3
47
48
APPENDIX E: INTERFACE OF THE NEW DATABASE
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(CUTEFLOW STORAGE AND CONVERSION ENGINE)
REFERENCES
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[1] Abbreviations, http://www.abbreviations.com
[2] X-FAB main website, http://www.xfab.com
[3] Cleanroom, from Wikipedia the free encyclopedia,
http://en.wikipedia.org/wiki/Cleanroom
[4] Cleanroom Protocol and ESD Control, Study Material from e-learning, Rev 2.1
[5] ISO 9001:2000, Quality Management Systems, ISO 9000 families, from Wikipedia
the free encyclopedia,
http://en.wikipedia.org/wiki/ISO_9001
[6] Figure; Industry Manufacturing Processes, United States Securities and Exchange
Commission, Washington, D.C, AMTECH SYSTEMS, INC,
http://yahoo.brand.edgar-online.com
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