Method and system for aggregating and combining manufacturing data for analysis

Abstract

A method and system for aggregating and combining manufacturing data for analysis for the purposes of increasing manufacturing efficiency and reducing manufacturing downtime due to abnormal conditions. An embodiment provides for a method of dividing an entire manufacturing process into parts and further into subparts for the purposes of tracking the path that a workpiece takes during the entire manufacturing process. Data is measured specific to the path and assigned to a data set stored on a data processing device for analysis of the conditions for the workpiece being examined. An embodiment provides for quicker data analysis which may result in less manufacturing product being discarded due to lengthy delays between abnormal conditions and the response to those conditions. An embodiment provides for users to be alerted when abnormal conditions are present. In one example, a data processing device non-manually halts production when abnormal conditions are present.

1 . A system for analyzing an electronics fabrication process, comprising: 
 a processor; and    a storage device coupled to the processor that is configured to store a set of instructions for performing a method that is executed by the processor, the method further comprising: 
 determining fabrication routes for workpieces subjected to the fabrication process;  
 acquiring production data for the fabrication process;  
 identifying a route for a selected workpiece;  
 identifying production data corresponding to the selected workpiece;  
 subjecting the identified production data to an analytical process;  
 determining if the identified production data conforms to an expected condition; and  
 if the identified production data does not conform to the expected condition, generating a warning condition.  
   
   
   
       2 . The system of  claim 1 , wherein determining fabrication routes for workpieces subjected to the fabrication process further comprises identifying one or more linked operations in the fabrication process.  
   
   
       3 . The system of  claim 2 , wherein identifying one or more linked operations in the fabrication process further comprises identifying a physical location of the linked operation in the fabrication process.  
   
   
       4 . The system of  claim 2 , wherein identifying one or more linked operations in the fabrication process further comprises identifying a machine performing the linked operation in the fabrication process.  
   
   
       5 . The system of  claim 2 , wherein identifying one or more linked operations in the fabrication process further comprises identifying a processing time associated with the linked operation in the fabrication process.  
   
   
       6 . The system of  claim 1 , wherein identifying a route for a selected workpiece further comprises identifying the route as a subset of operations in the fabrication process.  
   
   
       7 . The system of  claim 6 , wherein identifying the route as a subset of operations in the fabrication process further comprises identifying a subset of operations having a similar end product.  
   
   
       8 . The system of  claim 1 , wherein acquiring production data for the fabrication process further comprises measuring the production data using at least one sensor operably coupled to the processor and positioned in selected locations within the fabrication process.  
   
   
       9 . The system of  claim 1 , wherein subjecting the identified production data to an analytical process further comprises subjecting the identified production data to one of a statistical analysis, and a trend analysis.  
   
   
       10 . The system of  claim 1 , wherein generating a warning condition further comprises generating an audible alarm.  
   
   
       11 . The system of  claim 1 , wherein generating a warning condition further comprises triggering a shut down of the fabrication process.  
   
   
       12 . A system for analyzing an electronics fabrication process, comprising: 
 a processor; and    a storage device coupled to the processor that is configured to store a set of instructions for performing a method that is executed by the processor, the method further comprising: 
 determining fabrication routes for workpieces subjected to the fabrication process;  
 acquiring production data for the fabrication process;  
 for a selected workpiece, determining a fabrication route for the workpiece;  
 collecting production data corresponding to the selected workpiece;  
 processing the collected data in an analytical process to determine if the processed data conforms to an expected condition; and  
 if the identified production data does not conform to the expected condition, generating a warning condition.  
   
   
   
       13 . The system of  claim 12 , wherein acquiring production data for the fabrication process further comprises measuring the production data using at least one sensor that is positioned in selected locations within the fabrication process.  
   
   
       14 . The system of  claim 12 , wherein acquiring production data for the fabrication process further comprises collecting at least one of test probe data, parametric data, film thickness data and critical dimension data.  
   
   
       15 . The system of  claim 12 , wherein determining a fabrication route for the workpiece further comprises determining one or more linked operations in the fabrication route.  
   
   
       16 . The system of  claim 15 , wherein determining one or more linked operations in the fabrication route further comprises identifying at least one of a physical location of the operation, a machine performing the operation in the fabrication process, and a processing time associated with the operation in the fabrication process.  
   
   
       17 . The system of  claim 12 , wherein determining a fabrication route for the workpiece 
 further comprises identifying the route as a subset of operations in the fabrication process.    
   
   
       18 . The system of  claim 17 , wherein identifying the route as a subset of operations in the fabrication process further comprises identifying a subset of operations having a similar end product.  
   
   
       19 . The system of  claim 12 , wherein processing the collected data in an analytical process to determine if the processed data conforms to an expected condition further comprises performing one of a statistical analysis and a trend analysis on the collected data.  
   
   
       20 . The system of  claim 12 , wherein processing the collected data in an analytical process to determine if the processed data conforms to an expected condition further comprises forming a weighted mean value and comparing the weighted mean value to a selected key value.  
   
   
       21 . The system of  claim 12 , further comprising at least one output device coupled to the processor, and wherein generating a warning condition further comprises transferring the warning condition to the at least one output device.  
   
   
       22 . The system of  claim 21 , wherein the at least one output device comprises a loudspeaker, and wherein transferring the warning condition to the at least one output device further comprises transferring an audible alarm to the loudspeaker.  
   
   
       23 . The system of  claim 21 , wherein the at least one output device comprises a visual display, and wherein transferring the warning condition to the at least one output device further comprises displaying a text message corresponding to the warning condition on the visual display.  
   
   
       24 . A system for analyzing an electronics fabrication process, comprising: 
 a computer; and    a communications network coupled to the computer;    wherein the computer includes a processor that is configured to execute a set of instructions for performing a method, the method further comprising: 
 determining fabrication routes for workpieces subjected to the fabrication process;  
 acquiring production data for the fabrication process, and for a selected workpiece, determining a fabrication route for the workpiece;  
 collecting production data corresponding to the selected workpiece;  
 processing the collected data in an analytical process to determine if the processed data conforms to an expected condition; and  
 if the identified production data does not conform to the expected condition, generating a warning condition.  
   
   
   
       25 . The system of  claim 24 , wherein the computer further comprises a storage device, and wherein the method further comprises storing the set of instructions on the storage device.  
   
   
       26 . The system of  claim 25 , wherein the storage device further comprises at least one of a read only memory (ROM), a random access memory (RAM), a magnetic disk storage media, an optical storage media, and a flash memory device.  
   
   
       27 . The system of  claim 24 , wherein the method further comprises communicating at least a portion of the set of instructions to the computer using the communications network.  
   
   
       28 . The system of  claim 24 , wherein the method further comprises communicating at least a portion of the production data to the computer using the communications network.  
   
   
       29 . The system of  claim 24 , further comprising at least one server coupled to the communications network that is operable to communicate at least a portion of the set of instructions to the computer using the communications network.  
   
   
       30 . The system of  claim 24 , further comprising at least one server coupled to the communications network that is operable to communicate at least a portion of the production data to the computer using the communications network.  
   
   
       31 . The system of  claim 24 , wherein acquiring production data for the fabrication process further comprises measuring the production data using at least one sensor positioned in selected locations within the fabrication process.  
   
   
       32 . The system of  claim 24 , wherein acquiring production data for the fabrication process further comprises collecting at least one of test probe data, parametric data, film thickness data and critical dimension data.  
   
   
       33 . The system of  claim 24 , wherein processing the collected data in an analytical process further comprises performing one of a statistical analysis and a trend analysis on the collected data.  
   
   
       34 . The system of  claim 24 , wherein processing the collected data in an analytical process to determine if the processed data conforms to an expected condition further comprises forming a weighted mean value and comparing the weighted mean value to a selected key value.  
   
   
       35 . The system of  claim 24 , wherein determining a fabrication route for the workpiece further comprises determining one or more linked operations in the fabrication route.  
   
   
       36 . The system of  claim 35 , wherein identifying one or more linked operations in the fabrication route further comprises identifying at least one of a physical location of the operation, a machine performing the operation in the fabrication process, and a processing time associated with the operation in the fabrication process.  
   
   
       37 . The system of  claim 24 , wherein determining a fabrication route for the workpiece further comprises identifying the route as a subset of operations in the fabrication process.  
   
   
       38 . The system of  claim 37 , wherein identifying the route as a subset of operations in the fabrication process further comprises identifying a subset of operations having a similar end product.  
   
   
       39 . The system of  claim 24 , further comprising at least one output device coupled to the communications network, and wherein generating a warning condition further comprises communicating the warning condition to the at least one output device.  
   
   
       40 . The system of  claim 39 , wherein the at least one output device comprises a loudspeaker, and wherein communicating the warning condition to the at least one output device further comprises transferring an audible alarm to the loudspeaker.  
   
   
       41 . The system of  claim 39 , wherein the at least one output device comprises a visual display, and wherein communicating the warning condition to the at least one output device further comprises displaying a text message corresponding to the warning condition on the visual display.  
   
   
       42 . The system of  claim 24 , wherein generating a warning condition further comprises triggering a shut down of the fabrication process.