Published on 27 Apr 2012
Macronix International Co., Ltd.
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.
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.
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.
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
IBM products and services that were used in this case study.
Netcool/OMNIbus Virtual Operator, Rational ClearCase, Rational PurifyPlus Enterprise Edition, Tivoli Storage Manager, WebSphere Application Server
Power Systems, System x
Application Design-Build-Manage, Automation, Industry Framework, Smarter Planet, Systems & Network Management
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