Resource efficiency within an integrated 200-mm fabricator

Survival in the semiconductor business of the 1990's and beyond will be driven primarily by low cost, high quality producers. Key to accomplishing this will be the efficient use of resources-both human and material. IBM's 200-mm semiconductor fabricator in Essex Junction, Vermont, the Apply/Align department has pursued cost reduction by more efficiently using all of its members, from production technicians to entry-level operators. This paper describes the efficiencies derived from the use of Market-Driven Quality (MDQ) teams within the department and across all four Alternate Work Schedule (AWS) shifts. MDQ teams are involved with a wide variety of activities such as cross training, rework and scrap reduction, cost reduction of spare parts, as well as improved tool availability and utilization. The efforts of each team have enabled this department to realize a 13 percent reduction in staffing while increasing output by five percent. The majority of this improvement resulted from cross-training, where individuals within the department were separated into two areas; align and apply, where no one was receiving cross-training. Because of the MDQ team approach the department has been able to implement a cross-training program on all align and apply tools. This has given the team the flexibility it needs to adequately cover vacations, lunch breaks, work breaks and illnesses, as well as realize a significant reduction in staffing. Continuing its efforts to become even more efficient, the department has set an additional seven percent increase in output as its target for year-end 1994.