Macronix International Co., Ltd.

Published on 27-Apr-2012

Validated on 16 Dec 2013

Customer:
Macronix International Co., Ltd.

Industry:
Electronics

Deployment country:
Taiwan

Solution:
Application Design-Build-Manage, Automation, Industry Framework , BA - Risk Analytics, Smarter Planet, Systems & Network Management

Smarter Planet:
Smart Products, Smarter Manufacturing

Overview

Established in 1989 at the Science Park in Hsinchu, Taiwan, Macronix International Co., Ltd. (Macronix) is one of the largest suppliers of read-only memory (ROM) products worldwide. Macronix has 4,400 employees and operations in Asia, Europe and the Americas. The company’s top customers include Nintendo, LG Electronics and Hewlett-Packard.

Business need:
Macronix used its acquisition of a local company in the 300 mm wafer market segment as an opportunity to rethink its IT infrastructure strategy. Extending its existing manufacturing execution system was an option but would not adequately address a growing concern: losses caused by equipment contamination, many of which were due to human error in loading the “recipe” for any process. With cost and quality concerns vying for the top spot on the company’s priority list, the manufacturer needed a solution that would satisfy both areas while delivering a flexible framework for future growth.

Solution:
In order to effectively compete on cost while meeting the highest levels of quality control, Macronix implemented a new-generation manufacturing execution system that uses sensors to proactively prevent process errors and intervene early to help mitigate any ill effects. To reduce the possibility of equipment contamination and help keep production on schedule and within budget, an alert system was established that will automatically respond with an alarm and alert message; the suspension of a process and unloading of wafers from a piece of equipment; or suspension of an entire operation.

Benefits:
Increased process capability to 40 percent using Six Sigma system metrics Expected ramp-up to automation at 86 percent within one year—the fastest in the semiconductor industry—and will virtually remove the human error factor from production in areas where full automation is achieved Estimated that equipment investment can be reduced by 10 percent when equipment is shared at two fabrication plants

Case Study

Established in 1989 at the Science Park in Hsinchu, Taiwan, Macronix International Co., Ltd. (Macronix) is one of the largest suppliers of read-only memory (ROM) products worldwide. Macronix has 4,400 employees and operations in Asia, Europe and the Americas. The company’s top customers include Nintendo, LG Electronics and Hewlett-Packard.

The Opportunity
Macronix used its acquisition of a local company in the 300 mm (approximately 12-inch) wafer market segment as an opportunity to rethink its IT infrastructure strategy. Extending its existing manufacturing execution system was an option but would not adequately address a growing concern: losses caused by equipment contamination, many of which were due to human error in loading the “recipe” for any process. With cost and quality concerns vying for the top spot on the company’s priority list, the manufacturer needed a solution that would satisfy both areas while delivering a flexible framework for future growth.

What Makes It Smarter
In the semiconductor industry, absolute precision and a pristine manufacturing environment are paramount. In order to effectively compete on cost while meeting the highest levels of quality control, Macronix implemented a new-generation manufacturing execution system that uses sensors to proactively prevent process errors and—when errors are unavoidable—intervene early to help mitigate any ill effects. To reduce the possibility of equipment contamination and help keep production on schedule and within budget, an alert system was established that, based on the severity of the error, will automatically respond with: an alarm and alert message; the suspension of a process and unloading of wafers from a piece of equipment; or suspension of an entire operation.

Real Business Results
· Increased process capability to 40 percent using Six Sigma system metrics
· Expected ramp-up to automation at 86 percent within one year—the fastest in the semiconductor industry—and will virtually remove the human error factor from production in areas where full automation is achieved
· Estimated that equipment investment can be reduced by 10 percent when equipment is shared at two fabrication plants

Products and services used

Legal Information

© Copyright IBM Corporation 2012 IBM Corporation Software Group Route 100 Somers, NY 10589 Produced in the United States April 2012 IBM, the IBM logo, ibm.com, ClearCase, DB2, Global Technology Services, Netcool, Power Systems, PurifyPlus, Rational, System Storage, System x, Tivoli and WebSphere and are trademarks of International Business Machines Corp., registered in many jurisdictions worldwide. Other product and service names might be trademarks of IBM or other companies. A current list of IBM trademarks is available on the Web at “Copyright and trademark information” at ibm.com/legal/copytrade.shtml This document is current as of the initial date of publication and may be changed by IBM at any time. Not all offerings are available in every country in which IBM operates. The performance data and client examples cited are presented for illustrative purposes only. Actual performance results may vary depending on specific configurations and operating conditions. THE INFORMATION IN THIS DOCUMENT IS PROVIDED “AS IS” WITHOUT ANY WARRANTY, EXPRESS OR IMPLIED, INCLUDING WITHOUT ANY WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND ANY WARRANTY OR CONDITION OF NON-INFRINGEMENT. IBM products are warranted according to the terms and conditions of the agreements under which they are provided.