Process development execution system: Difference between revisions

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In the high-tech industries, '''Process Developmentdevelopment Executionexecution Systemssystems''' ('''PDES''') are [[software systemssystem]]s used to guide the development of high-tech manufacturing technologies like [[semiconductor]] manufacturing, [[MEMS]] manufacturing, [[photovoltaics]] manufacturing, [[bio-medicalbiomedical]] devices or [[nano-particlenanoparticle]] manufacturing. Software systems of this kind have similarities to [[Productproduct Lifecyclelifecycle Managementmanagement]] (PLM) systems. in that theyThey guide the development of new or improved technologies from its conception, through development and into manufacturemanufacturing. Furthermore, they borrow on concepts of [[Manufacturingmanufacturing Executionexecution Systemssystems]] (MES) systems but tailor them for R&D rather than for production. PDES integrate people (with different backgrounds from potentially different legal entities), data (from diverse sources), information and, knowledge and business processes.

== Benefits ==

[[File:PDESvsMESbyPR.jpg|thumb|right|PDES vs [[manufacturing execution systems|MES]] in the technology development cycle]]

Documented benefits of Processprocess Developmentdevelopment Executionexecution Systemssystems include:

* Reduced [[time to market]]

* Reduced amounts of experimentation

* Improved quality / more robust manufacturing process

* Reduced [[prototyping]] costs

* Savings through the re-use of original data, information and knowledge

* A [[framework]] for product optimization

* Reduced waste

* Savings through the complete integration of engineering workflows

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== Relationships with other level 3 / level 4 systems ==

A '''Processprocess Developmentdevelopment Executionexecution Systemsystem (PDES)''' is a [[system]] which is used by companies to perform development activities for [[high-tech]] [[manufacturing]] processes.

Software systems of this kind leverage diverse concepts from other software categories like [[Productproduct Lifecyclelifecycle Managementmanagement|PLM]], [[Manufacturingmanufacturing Executionexecution Systemssystems|Manufacturingmanufacturing Executionexecution Systemsystem (MES)]], [[Enterprise content management|ECM]] but focus on tools speedingto speed up the technology development rather than the production.

A PDES is similar to a [[Manufacturingmanufacturing Executionexecution Systemssystems]] (MES) in several ways. The key distinguishing factor of a PDES is that it is tailored for steering the development of a manufacturing process, while MES is tailored for executing the volume production using the developed process. Therefore, the toolset and focus of a PDES is on lower volume but higher flexibility and experimentation freedom. The tools of an MES are more focused on less variance, higher volumes, tighter control and logistics. Both types of [[application software]] increase [[traceability]], [[productivity]], and [[Quality (business)|quality]] of the delivered result. For PDESs quality refers to the capability of the process to perform without failure under a wide range of conditions, i.e. the robustness of the developed manufacturing process. For MESs quality refers to the quality of the manufactured [[good (economics and accounting)]]/commodity. Additionally both software types share functions including equipment tracking, [[Product (business)|product]] genealogy, labour and item tracking, costing, [[electronic signature]] capture, [[Product defect|defect]] and resolution monitoring, [[Executiveexecutive Dashboarddashboard]]s, and other various reporting solutions.

In contrast to [[Product Lifecycle Management|PLM]] systems, PDES typically address the collaboration and innovation challenges with a bottom-up approach. They start-out with the details of manufacturing technologies (like [[Product lifecycle management#Product and Processprocess lifecycle Lifecyclemanagement Management.28PPLM.29|PPLM]]), a single manufacturing step with all its physical aware parameterization and integrating steps into sequences, into devices, into systems, etc.

Other rather similar software categories are [[LIMS|Laboratorylaboratory Informationinformation Managementmanagement Systemssystem]]s (LIMS) and [[Laboratorylaboratory Informationinformation Systemsystem]] (LIS). PDESs’PDESs offer a wider set of functionalities e.g. virtual manufacturing techniques, while they are typically not integrated with the equipment in the laboratory.

PDESs have many parts and can be deployed on various scales -– from simple [[Work in Progress]] tracking, to a complex solution integrated throughout an enterprise development infrastructure. The latter conncetsconnects with other enterprise systems like [[Enterprise resource planning|Enterpriseenterprise Resourceresource and Planningplanning Systemsystem]]s (ERPs), Manufacturingmanufacturing Executionexecution Systemssystems (MESs), [[Productproduct Lifecyclelifecycle Managementmanagement]] (PLM), [[SCADA|Supervisorysupervisory, Controlcontrol and Datadata Acquisitionacquisition]] (SCADA) solutions and [[Automated planning and scheduling|Schedulingscheduling and Planningplanning Systemsystem]]s (both long-term and short-term tactical).

== Example: PDES usage during semiconductor device development ==

New ideas for manufacturing processes (for new goods/commodities or improved manufacturing) are often based on, or can at least benefit from, previous developments and recipes already in use. The same is true when developing new devices, for example, a [[Microelectromechanical systems|MEMS]] [[sensor]] or actuator. A PDES offers an easy way to access these previous developments in a structured manner. Information can be retrieved faster, and previous results can be taken into account more efficiently. A PDES typically offers means to display and search for result data from different viewpoints, and to categorise the data according to the different aspects. These functionalities are applied to all result [[data]], such as materials, process steps, machines, experiments, documents and pictures. The PDES also provides a way to relate entities belonging to the same or similar context and to explore the resulting information.

In the assembly phase from process steps to process flows, a PDES can helphelps to easily build, store, print, and transfer new process flows. By providing access to previously assembled process flows the designer is able to use those as building blocks or modules in the newly developed flow. The usage of standard building blocks can dramatically reduce the design time and the probability of errors.

A PDES demonstrates its real benefits in the verification phase. [[Knowledge]] (for example in the [[semiconductor device fabrication]] -– clean before deposition; After polymer spin-on no temperature higher than 100 °C until resist is removed) takesis onprovided in a formformat that can be interpreted by a computer; they can be expressed inas rules. If a ___domain expert enters the rules for his/her process steps, all engineers can later referuse tothese themrules to check newly developed process flows, even if the ___domain expert is not available. For a PDES, this means it has to be able to

# manage rules

# connect rules with Boolean terms (and, or, not) and

# to check process flows using these rules. This rule check verifies the principle manufacturability of a newly designed manufacturing flow.

The processing rule check gives no indication about the functionality or even the structure of the produced good or device. In the area of [[semiconductor device fabrication]], the techniques of [[semiconductor process simulation]] / [[Technology CAD|TCAD]] can provide an idea about the produced structures. To support this ’virtual'virtual fabrication’fabrication', a PDES is able to manage simulation models for process steps. Usually the simulation results are seen as standalone data,. toTo rectify this situation PDESs' are also able to manage the resulting files in combination with the process flow. This enables the engineer to easily compare the expected results with the simulated outcome. The knowledge gained from the comparison can again be used to improve the simulation model.

After virtual verification the device is produced in an experimental fabrication environment. A PDES allows a transfer of the process flow to the fabrication environment (for example in semiconductor: [[Fab (semiconductors)|FAB]]). This can be done by simply printing out a runcard for the operator or by interfacing to the [[Manufacturing Execution Systems]] (MES) of the facility. On the other hand, a PDES is able to manage and document last minute changes to the flow like parameter adjustments during the fabrication.

During and after processing a lot of measurements are taken. The results of these measurements are often produced in the form of files such as images or simple text files containing rows and columns of data. The PDES is able to manage these files, to link related results together, and to manage different versions of certain files, for example reports. Paired with flexible text, and graphical retrieval and search methods, a PDES provides the mechanism to view and assess the accumulated data, information and knowledge from different perspectives. It provides insight into both the information aspects as well as the time aspects of previous developments.

Increasingly developmentDevelopment activities within industryhigh tech industries are aan increasingly collaborative effort. This leads to the need to exchange the information between the partners or to transfer process [[intellectual property]] from a vendor to a customer. PDESs' support this transfer while being selective to protect the IPR of the company.

== See also ==

* [[Microfabrication]]

* [[Manufacturing Process Management]]

* [[Manufacturing Execution Systems|Manufacturing Execution System (MES)]]

* [[Semiconductor device fabrication]]

* [[LIMS|Laboratory Information Management System (LIMS)]]

* [[Laboratory information system|Laboratory information system (LIS)]]

* [[Microelectromechanical systems]]

* [[Product information management]] system (PIMS)

* [[Production Information Management System|Production Information Management System (PIMS)]]

== References ==

*D. Ortloff, J. Popp, T. Schmidt, and R. Brück. Process Development Support Environment: A tool SUITE TO ENGINEER MANUFACTURING SEQUENCES Inin International Journal of Nanomanufacturing, “Recent"Recent Developments and Innovations in NEMS/MEMS devices”devices", 2007

*T. Schmidt, K. Hahn, T. Binder, J. Popp, A. Wagener, and R. Brück. OPTIMIZATION OF MEMS FABRICATION PROCESS DESIGN BY VIRTUAL EXPERIMENTS. In Proceedings of SPIE: Micro- and Nanotechnology: Materials, Processes, Packaging, and Systems III, Adelaide, volume 6415, 2006. Smart Materials, Nano and Micro-Smart Systems 2006.

*NEXUS news. [http://www.mstnews.de/downloads/pdf/news-0208.pdf "Successful Outcome from the PROMENADE Project..."], ''mst|news'', April, 2008.

*ICT Results. [http://cordis.europa.eu/ictresults/pdf/factsheet/INF%207%200100%20IST%20Results%20fact%20sheets_%20promenade.pdf "A virtual factory for micromachines"], ''ICT Results'', June, 2007.

*Electronics World – High-Tech R&D − Drowning in Data but Starving for Information [http://www.electronicsworld.co.uk/index.php/white-papers/4185-high-tech-rad-drowning-in-data-but-starving-for-information].

*NEXUS news. [http://www.mstnews.de/downloads/pdf/news-0208.pdf "Successful Outcome from the PROMENADE Project..."], ''mst|news'', April, 2008.

*ICT Results. [http://cordis.europa.eu/ictresults/pdf/factsheet/INF%207%200100%20IST%20Results%20fact%20sheets_%20promenade.pdf "A virtual factory for micromachines"], ''ICT Results'', June, 2007.

== External links ==

* [http://www.siliconfareast.com/manufacturing.HTM Semiconductor Manufacturing]

* [httphttps://wwwweb.archive.org/web/20060201232428/http://semiconductorglossary.com/ Semiconductor Glossary]

[[Category:Knowledge management]]

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[[Category:Information systems]]

[[Category:Technical communication]]

[[Category:Semantic Web]]