4P Approach for Equipment Maintenance

In manufacturing context, proper equipment maintenance is always necessary. However, it comes at a cost, creating a dilemma between cost saving and quality, among other factors. Inadequately maintained equipment leads to poorer performance and quality issues, while overly maintained equipment incurs high costs. The challenge for equipment and process owners is to determine the right maintenance cycle that strikes a balance between cost and quality.

In the AI industry, we have heard of predictive maintenance, which is a condition-based approach. However, in this article, we want to revisit the fundamental question: "Which parts or components of equipment require maintenance?" For some, it may seem like a simple question, as certain equipment parts are easily identified as requiring maintenance. This article aims to share a 4P assessment approach that provides a simple, easy-to-follow guideline as a starting point for equipment and process owners.

Place:

This "P" considers the condition of the locations where specific components are operating. Factors such as temperature, pressure, and impurity buildup often influence the integrity of the component. For example, a heater chuck operating at 1000°C will degrade faster compared to one operating at 500°C assuming other factors remain the similar.?Engineers need to evaluate whether the conditions where the components operate are harsh and have the potential to impact the components in the long run.

Leading questions:

• What are the conditions under which the component is operating?
• How do these conditions affect the component's performance?
• Will these conditions deteriorate over time and negatively affect the component's integrity?

Purpose:

This "P" focuses on the function of the component. While every function of each component is important, some may pose a critical concern to the process and product when their integrity is compromised.?For instance, in a TSV etch equipment, how would one assess the criticality of the robot arm that transfers the product versus that of RF power generator unit?

Leading questions:

• What would happen to the process if the component malfunctions?
• How would the effect manifest?
• What would be the likely impact of the effect when detected at the earliest point?

Process:

As the name suggests, this "P" assesses the criticality of the component in relation to the process. For example, in a CVD deposition process, temperature is a primary process parameter delivered through the heater chuck. The heater chuck is undoubtedly a crucial component because it directly delivers the process parameter of temperature.

Leading questions:

• What are the process parameters required for this process to function well?
• Which components deliver these parameters?

Product:

This "P" involves a simple yet essential evaluation of component criticality. It looks at the physical contact between the product and the components or parts. Are they in direct contact with the product during the process? Examples of direct contact include the probe head of a tester or the capillary in wire bonding. One should also consider the proximity of the parts to the process environment. Potential effects could include vibration, residue or by-product buildup, or signal interference.

Leading questions:

• How does the interaction between the product and the part occur?
• How does the interaction between the product and the component/part change over time?

Undoubtedly, achieving excellence in equipment maintenance requires a thorough analysis and evaluation with a greater depth and scope.?Nevertheless, I trust that this 4P approach to Equipment PPM will provide you with a starting point and ignite ideas for approaching equipment maintenance excellence.