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André van de Geijn
Collaboratism
People, Processes and Profitabilityin the Semiconductor Assembly and Test Business
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denotes a distinctive system of beliefs, myth, doctrine or theory that guides a social movement, institution, class or group.
-ism
collaborateis a recursive process where two or more people or organizations
work together on common goals.
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People, Processes and Profitability
in the Semiconductor Assembly and Test
Business.
Business Model
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PeopleDesign, test, diffusion, process, quality, assembly, packaging, IT, marketing - engineers, managers, etc.
YOU !
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Process ≠ Paperstack !But individual steps: design - production - etc., supporting the creation of a product.
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Profitability
Development Introduction Growth Maturity Decline
Sales
Profit
Loss
Money
Time
Product Life Cycle = Investment followed by a profit.Where profit is bigger than investment.
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Semiconductors = ProductsWhich end up in:Memory, Bankcards, CPU, Car-ABS etc.
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Business = Advantageover Competition
by Key DifferentiatorsFunctionality
Cost
Quality
Time-to-Market
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Key Differentiators Example
ABS Module priority:
1. Quality
2. Functionality
3. Time-to-market
4. Cost
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Key Differentiators
Influence each other!
★ Quality
★ Functionality
★ Time-to-market
★ Cost
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Sales
Profit
Loss
Money
Time
B
C
A
The story of being too late:Cost impact with a delay in time-to-market:Bigger loss, followed by less ‘sales and profit’
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Product Life Cycle
Influence each other!
★ Loss = Investment
★ Sales
★ Profit
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Package Product Life CycleNumber of connectors, package size, package technology, end-product functionality.
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Package time-to-market:
Development Introduction Growth Maturity Decline
Sales
Profit
Loss
Money
Time
A new product might first be placed in the market with available packages: to start sales......
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Sales
Profit
Loss
Money
Time
B
C
A
Package time-to-market:......and later introduced in a smaller package, to gain more market share: more sales.
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Package differentiator
Same function, but:
Different package
Means:
Different process
Different workflows
Different application
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Processes, Workflows and Applications, are not only different, but they also interact with each other!
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...and with the other aspects...
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...this needs collaboration...
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...and that is written in the book.
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WorkflowsProcesses Applications
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ProcessesIndividual steps, supporting the creation of an end-product.
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Some Process Examples
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Building a skyscraper
Design by architect
Bill of materials
Assemble the building
Processes
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Building: key differentiators
Take care of the cost, functionality, quality and time-to-market.
Is it a nomad shelter, your villa, or an office building to host 1000 employees?
Influences the processes
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Building: key differentiators
Take care of the cost, functionality, quality and time-to-market.
Is it a nomad shelter, your villa, or an office building to host 1000 employees?
Influences the processes
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B
A
Vdd
A
Z
B
Vss
Produce a semiconductor end-product
Design the product
VHDL creation
Transistor level
Test program
Lay-out
Mask creation
Processes
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Produce a semiconductor end-product
Design the product
Diffuse the circuit
Create transistors
Create connections
PCM testing
Visual inspection
Processes
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ProcessesProduce a semiconductor end-product
Design the product
Diffuse the circuit
Assembly and test
Wafer test
Die attach
Wire bonding
Etc. See book!
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Commonality:Buildings & Semiconductors
Efficiency: it is NOT likely that a single person or company can fulfill all needed process steps by itself!
It is all based on core competences.
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CollaborateA person working on a single process, needs to be aware of:
the outputs of the previous process.
the inputs of the next process.
This will improve your product and therefore business.
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WorkflowsProcesses Applications
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WorkflowsConnect the individual process steps.
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Design Di!usion Assembly/Test
Semiconductor WorkflowConnects the top-level processes.
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Design Di!usion Assembly/Test
Focus on TestTest devices, and remove fail devices.
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Test Quality
Inking
!
"
#$ %
&
Standard Test WorkflowBuild up by three processes.Different workflows possible.
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Design Di!usion Assembly/Test
Extended WorkflowDifferent processes influence each other.
Edge Die
Ugly Die
PCM Die
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Test Analysis
Quality Merge
!
"
#
$
%
&
Extended Test WorkflowBuild up by four processes, merge results of diffusion with assembly/test processes.
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Design Di!usion Assembly/Test
Focus on TestTest time reduction, by parallel testing.
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Test time reduction
Test several products at once
Reduces costly test time
For small products
For products with long test time
Think of up to 87% cost reduction with 8 products parallel testing!
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Test timereduction
This needs special hardware, to expand tester capacity.
And special software for optimized path finding.
Remember the costs Key Differentiator!
Invest to create a ‘bigger’ profit.
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Application influenceOne application for wafer test results
One application for merge
One application for analysis
One application for test time reduction
Why not one application to support all workflows !
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Design Di!usion Assembly/Test
Test-program developmentGoes over all three main processes !
Developa test
program...
...to find diffusion failures...
...and can be used by test equipment...
...to prevent use of failing
end-products.
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Test Program
Test Library
Tester Library
Tester Operating System
Test program stack
A test program relies heavily on the underlaying parts.
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Tester Library Test Library Test Program
Tester librarydevelopment
Tester libraryrelease
Test librarydevelopment
Test libraryrelease
Test programengineering
development
Test programproduction
development
Test programproduction
release
Release workflowA released test program for production, relies on a released tester library, and released test library.
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Distribution by e-mailIn many cases, a released test program, tester library, and test library rely on e-mail.
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CollaborationNeed for an application to bring different groups of engineers, internal and external, together
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WorkflowsProcesses Applications
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ApplicationsSupport the workflows:The lubricant that helps to run the processes smoothly.
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Create User Groups
Collect Process Steps Details
Collect Business Details
Group User Needs
Create Application Land-scape
Create Roadmap
Create and Roll-out Ap-plications
Application DevelopmentWorkflow
A workflow to get the needs on the table, which support the business.
Collect requirements
Create the roadmaps.
Start the implementation.
Roll-out of applications.
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For granted users only.
To collect requirements.
Discuss requests and solutions.
Accessible from different locations.
Store source code.
Distribution.
One repository
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For applications, like the wafer map application.
For test programs, test libraries, and tester libraries.
Datasheet development process.
Enables collaboration between internal and external engineers, and different locations, for different purposes.
One repository
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Collaboration applicationThe book goes into detail of TeamForge, an application that looks like CollabNet.
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Money
Time
BasicFunctionality
IntermediateFunctionality
AdvancedFunctionality
Profit
Loss
Establish applications in phases,to support the business as soon as possible.
How to establish applications
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Different packages
Basic package with pins
Followed by package with terminals
Example 1: Fab-IT
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Different packages
Basic package with pins
Followed by package with terminals
Example 1: Fab-IT
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Wafer maps
Basic functionality
Intermediate functionality
Advanced functionality
Example 1: Fab-IT
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Money
Time
BasicFunctionality
IntermediateFunctionality
AdvancedFunctionality
Profit
Loss
Business model generation in a collaborative way.It’s all about collaboration
Example 2: ReuseCan - Lin SBCFlexRay
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Collaboration is the KEY ! Between design - diffusion - assembly and test.
With subcontractors: at the begin, the end, and in the value chain.
With customers.
Define the efficient cores, and let them collaborate, towards a profitable business.
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Collaboratism
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Collaboratism
Think about the whole value chain,who should do what, who is good in what!
These all create a profitable business,based on efficiency and competitiveness.
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“Collaboratism shows us the amazingly tight integration and collaboration between
design, test, and assembly engineers and processes in the semiconductor industry.
It’s a deep-dive into a world most of us would never see - making clear just how much genius went into making the brains of devices we unthinkingly depend upon every day.”
—Brian Behlendorf, founder of the Apache Software Foundation