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What are the best ways to increase yield during fabrication process scaling?

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If you are an electrical engineer involved in fabrication process integration and scaling, you know that increasing yield is one of the most important and challenging goals. Yield is the percentage of functional devices produced from a given wafer, and it depends on many factors, such as defect density, process variability, design complexity, and test strategy. In this article, you will learn some of the best ways to increase yield during fabrication process scaling, which is the reduction of feature sizes and dimensions to improve performance, power, and cost.

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Shadi Abdelkareem aleryani

+26Million Impressions | +45kFollower |Professional Electrical Engineering at OMV
Ehsan Mokhtari

Electrical Engineer ? | Oil & Gas Expert ? | Green Hydrogen Advocate ?? | Passionate About Sustainable Energy Solutions…
Lee Barrett

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1 Design for manufacturability

One of the best ways to increase yield during fabrication process scaling is to design for manufacturability (DFM), which is the practice of optimizing the design to make it more compatible with the process capabilities and limitations. DFM can help reduce defect sensitivity, improve tolerance to variability, and enhance robustness and reliability. Some of the DFM techniques include layout regularity, critical area analysis, redundant via insertion, dummy fill, and lithography-aware design.

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Shadi Abdelkareem aleryani

+26Million Impressions | +45kFollower |Professional Electrical Engineering at OMV
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Actually, the goal of DFM is to design products that are as easy to manufacture as possible. Simplifying the manufacturing process, cutting production costs, raising product quality & accelerating time-to-market are the objectives of DFM. Some essential DFM concepts & strategies are: -Simplify Design: Maintain a minimal amount of complexity in the design while yet adhering to functional specifications. Complex designs frequently result in more complicated & expensive manufacturing processes. -Standardization: To expedite production & lower variability, standardize parts, supplies & procedures wherever feasible. -Minimize Part Count: To make assembly easier & manufacturing less complex, minimize the number of distinct parts in the design

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Ehsan Mokhtari

Electrical Engineer ? | Oil & Gas Expert ? | Green Hydrogen Advocate ?? | Passionate About Sustainable Energy Solutions ??
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capabilities and limitations. DFM can help reduce defect sensitivity, improve tolerance to variability, and enhance robustness and reliability. Some of the DFM techniques include

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Lee Barrett

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What really helps is to go down and do the manufacturing yourself. Do a run-through to see where the boundaries are with the people who have to do them. Get their input and listen. Then make the design so that each stage of the build can be defined as a specific process with beginning with a "supplier" who hands off each element to the "customer" - the person who must do the current process (also well defined). Then the current person becomes the "supplier" to the next stage "customer". It's all about process controls. If well defined and followed, you get predictable results no matter how you scale the output quantity. These are basics of Total Quality Management - Shewhart, Deming, etc. They work!

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2 Process control and optimization

Another way to increase yield during fabrication process scaling is to control and optimize the process parameters and conditions to minimize variations and defects. Process control and optimization can involve monitoring and adjusting the equipment settings, the wafer temperature, the gas flow, the pressure, the deposition rate, the etch rate, the doping concentration, and other factors that affect the quality and uniformity of the layers and features. Process control and optimization can also involve using advanced metrology and inspection tools, such as scanning electron microscopy, atomic force microscopy, optical critical dimension, and defect review.

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ígor Botelho

Perícias e Avalia??es | Engenheiro Eletricista, Civil e de Seguran?a do Trabalho | Seguran?a Eletr?nica | SDAI | Instala??es Prediais | HVAC | Estágios no IPT (Geotecnia) e Polícia Federal (Perícias)
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Para aumentar o rendimento durante o dimensionamento do processo de fabrica??o, é essencial implementar controle e otimiza??o de processos. Isso pode ser alcan?ado através da utiliza??o de tecnologias avan?adas de monitoramento em tempo real, como IoT e sensores inteligentes, para identificar e corrigir falhas rapidamente. Além disso, a análise de dados e a aplica??o de técnicas estatísticas, como Six Sigma, permitem identificar áreas de melhoria e reduzir varia??es no processo, aumentando assim a eficiência e o rendimento da produ??o.

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3 Yield learning and analysis

A third way to increase yield during fabrication process scaling is to learn from the data and feedback obtained from the testing and characterization of the devices and wafers. Yield learning and analysis can help identify and diagnose the root causes of yield loss, such as systematic defects, random defects, parametric failures, or functional failures. Yield learning and analysis can also help evaluate and improve the design rules, the process recipes, the test plans, and the yield models. Some of the yield learning and analysis methods include statistical process control, design of experiments, failure analysis, and yield ramp.

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ígor Botelho

Perícias e Avalia??es | Engenheiro Eletricista, Civil e de Seguran?a do Trabalho | Seguran?a Eletr?nica | SDAI | Instala??es Prediais | HVAC | Estágios no IPT (Geotecnia) e Polícia Federal (Perícias)
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Para melhorar o rendimento, é fundamental investir em aprendizado contínuo e análise de dados. Capacite a equipe com treinamentos relevantes, promova uma cultura de melhoria contínua e incentive a colabora??o para identificar oportunidades de otimiza??o. Utilize análise de dados para identificar padr?es, gargalos e oportunidades de melhoria, permitindo ajustes precisos para maximizar o rendimento e a eficiência do processo de fabrica??o.

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4 Fault tolerance and redundancy

A fourth way to increase yield during fabrication process scaling is to incorporate fault tolerance and redundancy mechanisms in the design and architecture of the devices and circuits. Fault tolerance and redundancy can help increase the functionality and performance of the devices and circuits in the presence of defects, variations, or errors. Fault tolerance and redundancy can also help reduce the test cost and time by allowing some defects or failures to be tolerated or repaired. Some of the fault tolerance and redundancy techniques include error correction codes, built-in self-test, built-in self-repair, spare rows and columns, and reconfigurable logic.

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Shadi Abdelkareem aleryani

+26Million Impressions | +45kFollower |Professional Electrical Engineering at OMV
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Actually, redundancy and fault tolerance are essential concepts in systems design, especially when it comes to guaranteeing the reliability and availability of critical systems. Below is a summary of each: -Fault tolerance refers to a system's ability to continue functioning properly in the event of the failure of one or more components. Fault tolerance can be achieved through various methods, including redundancy, error detection & correction, fault Isolation, hot/cold standby & graceful degradation. - Redundancy involves duplicating critical components or systems to provide backup in case of failure. Redundancy are hardware & software types. It increases system reliability & availability by reducing the risk of single points of failure.

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ígor Botelho

Perícias e Avalia??es | Engenheiro Eletricista, Civil e de Seguran?a do Trabalho | Seguran?a Eletr?nica | SDAI | Instala??es Prediais | HVAC | Estágios no IPT (Geotecnia) e Polícia Federal (Perícias)
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A tolerancia a falhas e redundancia s?o essenciais para garantir a continuidade operacional e a confiabilidade de sistemas críticos. Implemente redundancia de componentes-chave e sistemas de backup para mitigar falhas. Adote estratégias como RAID em sistemas de armazenamento e sistemas de energia alternativos para garantir opera??o contínua em caso de falhas. Além disso, estabele?a procedimentos de monitoramento e manuten??o preventiva para detectar e corrigir problemas antes que afetem a produ??o.

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5 Test optimization and compression

A fifth way to increase yield during fabrication process scaling is to optimize and compress the test procedures and data to reduce the test cost and time, while maintaining the test quality and coverage. Test optimization and compression can involve selecting the optimal test parameters, such as voltage, frequency, temperature, and duration, to maximize the defect detection and minimize the test escapes. Test optimization and compression can also involve using advanced test methods, such as scan-based testing, logic built-in self-test, memory built-in self-test, and test data compression.

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6 Yield enhancement and recovery

A sixth way to increase yield during fabrication process scaling is to enhance and recover the yield of the devices and wafers that have failed or performed below the specifications. Yield enhancement and recovery can involve applying post-processing techniques, such as laser repair, chemical-mechanical polishing, or annealing, to remove or reduce the defects or variations that cause the failures or performance degradation. Yield enhancement and recovery can also involve using adaptive techniques, such as voltage scaling, frequency scaling, or power gating, to adjust the operating conditions and modes of the devices and circuits to meet the specifications.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Lee Barrett

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If your processes are under control and you make incremental improvements to the processes based on the feedback of those who have to perform them, you quality is "built in" at each stage and you get predictable success in the market and in use. Very low return rates and a love for the product develops.

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What are the best ways to increase yield during fabrication process scaling?

1

2

3

4

5

6

7

1 Design for manufacturability

2 Process control and optimization

3 Yield learning and analysis

4 Fault tolerance and redundancy

5 Test optimization and compression

6 Yield enhancement and recovery

7 Here’s what else to consider

Electrical Engineering

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What are the best ways to increase yield during fabrication process scaling?

1

2

3

4

5

6

7

1 Design for manufacturability

2 Process control and optimization

3 Yield learning and analysis

4 Fault tolerance and redundancy

5 Test optimization and compression

6 Yield enhancement and recovery

7 Here’s what else to consider

Electrical Engineering

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