Efficient lot movement within semiconductor manufacturing facilities is essential for maintaining productivity and adapting to dynamic production environments. Traditional approaches reliant on manual labor are becoming increasingly inefficient and are unable to keep pace with the demands of modern manufacturing. In response to this challenge, our abstract presents an innovative solution for automating lot movement and machine loading, drawing upon insights gained from deployments across multiple continents.
Horizontal movement predominates across the factory floor, with lots transitioning between storage locations and machines. To facilitate these movements efficiently, a range of automation solutions exist, encompassing conveyors, Automated Guided Vehicles (AGVs), Autonomous Mobile Robots (AMRs), and Overhead Transportation (OHT) systems. These solutions not only cater to vertical transport but also enable horizontal movements within the facility. However, to truly replicate the dexterity and adaptability of human operators, particularly in loading machines, a more sophisticated approach is required. Enter Mobile Cobots, a novel type of robot specifically designed to perform intricate motions and manipulations. By incorporating Mobile Cobots alongside existing automation technologies, manufacturers can elevate their capabilities for advanced motion and manipulation, thereby reducing reliance on manual operators while optimizing machinery utilization.
Based on observations from deployments in eight different factories, we have identified six key activities essential for automation success:
- Simulation: Efficient workflow allocation and seamless handover between automation solutions are crucial for realizing an effective automation system. - Standardization: Standardizing processes and equipment specifications minimizes development overhead and enhances deployment speed, reliability, and flexibility. - Digitalization: Transitioning from physical to digital workflows improves efficiency and reduces failure rates, particularly in legacy manufacturing environments. - Integration: Seamlessly integrating automation systems with existing MES and shopfloor machinery enhances throughput and overall equipment effectiveness (OEE). - Monitoring: Continuous performance monitoring and analysis are essential for driving improvements and avoiding sub-optimization in automated systems. - Change Management: Effective collaboration between human operators and automated systems is vital for successful implementation and acceptance of new technologies.
In summary, our proposed solution offers a transformative pathway to automate lot movement in semiconductor manufacturing, addressing key industry objectives such as operational efficiency, flexibility, and cost-effectiveness. By embracing automation, semiconductor manufacturers can not only optimize their current processes but also pave the way for future advancements in production methodologies.
