Training Rprt(Modified Until 13 June)1

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:

1

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.

15

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.

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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

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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.

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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 [email protected]. 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

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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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