A TRIZ approach to reduce unscheduled downtime in semiconductor industry

Ng, Yean Kit (2016) A TRIZ approach to reduce unscheduled downtime in semiconductor industry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Most organizations are facing similar challenges which involve decreasing profit and throughput. This project was conducted in a multinational semiconductor industry to improve its throughput and profit. Based on the data collected, low Overall Equipment Effectiveness (OEE) due to low machine availability affects the throughput of the company. Low machine availability happens because the machine unscheduled downtime is high. Therefore, the purpose of this study is to propose solutions to reduce machine unscheduled downtime of the case company. The objectives of this project are to identify different types of machine unscheduled downtime, to identify root causes of machine unscheduled downtime and to collect and analyse data to propose solutions to increase machine availability. TRIZ method was used for this project. First, real time data for taping machines in Discrete Department was collected via TFM system and analysed by using Pareto Chart to determine the most critical problems. Then, Cause and Effect Analysis was done to determine its potential root causes. After that, Trimming was done to eliminate all the not significant root causes and identify the most critical root cause. Lastly, Contradiction Matrix was applied on the most critical root cause that was determined to propose solutions by implementing the 40 Inventive Principle concepts. A total of 4 solutions were proposed but only 2 solutions were implemented and tested by pilot run on 1 machine. The pilot run results showed that the 2 implemented solutions had reduced 1.55% of taping machines unscheduled downtime and hence increases machine availability by 1.55%. By that, OEE was estimated to have an increment of 1.3% by using the OEE calculation formula. According to the case company's cost estimation, by increasing 1.3% in OEE enables the company to profit extra RM500, 000 in a year. Besides, it can also reduce maintenance and components replacement cost. Hence, the significance of this study is to enhance the profit of the case company and reduce waste of cost.

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