Instructor Guide process control by 095rp4


									          Process Control

             Instructor Guide

Rev 2.0

    K-Tech Process Control Training

         Instructional Designer:
              Kathy Cairns

            Content Expert:

               Tamer Rip
              Izaak Spain

                          Table of Contents

    Table of Contents...................................................................... 3

    Course Description ................................................................... 4

    Instructor Notes ........................................................................ 4

    Class Materials ......................................................................... 5

    Course Agenda .......................................................................... 6
    Take Notes ................................................................................ 8

    Process Control Activity Directions are in a separate document.

Course Description

Course Overview
                         This QuickStart module: "Process Control" provides an introduction to the process
                         control systems used at K-Tech. This module will be instructor led with activities.

Course Goal
& Objectives
                         The goal of this module is present the Process control systems used in manufacturing
                         microchips, and manufacturing technicians will learn their role in preventing excursions.

                         Upon completion, students will be able to:
                            • Summarize why quality is important and how process control systems help to
                               prevent and minimize quality events.
                            • Describe Quality events that can jeopardize the quality of our products.
                            • Identify the key Process Control Systems and functions.
                            • Explain the importance of defect analysis.
                            • Describe monitors, key data points and how to respond to OOC situations.
                            • Explain the importance of excursion prevention.
                            • Interpret and create control charts and apply general SPC rules.
                            • Complete a QEF offline.

                         This course has been developed for the K-TECH Quick Start NEO ramp training, blue
                         badge employees.

                         The K-TECH audience is a group of newly hired blue badge employees who will be
                         working in the manufacturing FAB and SORT areas in Dalian, China. The challenge
                         with the audience is that there may be a wide range of employees who may not speak
                         English. The instructor needs to pulse the audience at the beginning and continue to be
                         aware of the language skills of the students. The pace of the class may need to be

Instructor Facilitator
                         This training requires:
                         1. A bilingual instructor who speaks both Chinese and English.
                         2. An engineer who has 3-5 years experience in the Semiconductor industry.
                         3. A person who has effective training skills--who understands the level of knowledge
                            the students have about the subject and their language skills.

Instructor Notes
                         To successfully facilitate this class:
                            Know the Material – Read the presentation, activities, and handouts used in this
                             class. Practice completing the activities.
                            Plan for Questions - Identify content that may need further clarification for Chinese
                             new hires to comprehend. Predict questions from students and prepare answers.
                        Brush up on your Training Skills - Complete the "Training Skills Workshop" WBT
                         (00029721) or "Effective Training in China" WBT (10001147) or attend the
                         "Training in China" course (10001735) to brush up on your training skills and to
                         prepare yourself for cultural differences that may impact successful training delivery.

Note taking   
                     To improve retention, instruct students to take notes during the instructor led presentation
                     or while completing the WBT. Give them the handout "Take Notes" prior to beginning
                     the class. The Take Notes handout is a list of questions that they can answer and have to
                     refer back to at a later date.

Important Reminder
                     Remember to keep the information generic. Do not give examples from your area unless
                     it applies to the whole fab. Remember, these are new employees to K-Tech and have no
                     prior point of reference. Keep everything at a basic level and do not overwhelm them
                     with area specific or detailed information.

Instructor Notes
                     Refer to the instructor notes within the “notes pages” feature of the PowerPoint foils
                     for specific dialog and tips that are given to support the materials.

Materials and Equipment

Required Equipment
                     The following is the list of hardware/software requirements needed to conduct this class:
                         PCs: Both for students and for the instructor to be able to launch PowerPoint,
                            Internet Explorer, Windows Media Player, MyLearning and K-Tech Circuit
                         Overhead projection system for instructors PC

Class Materials

                            PowerPoint Presentation: Process_Control.ppt
                                o This presentation has 86 slides. This course will take approximately 4
                                  hours with activities.
                            Handouts: Must be copied, preferably in color, for this class.
                                o Take Notes – Handout blank Take notes page at the beginning of the
                                  class. The Take Notes handout is a list of questions that the students
                                  should answer to help reinforce learning the most important points of this
                                  module. The students can return to their notes later and put this knowledge
                                  to immediate use. At the end of the class, hand out the Take Notes with
                                  the answers, which can be found at the end of this document.

                                    o Control Charts and Dispositioning – a Lesson and Activity #1.
                                    o Completing a QEF – a Lesson and Activity #2.
                               Other: Name table tents, flip chart and markers

Course Agenda

Quick Start Instructor Led Delivery (in computer lab)

Lesson           Description                                  Time      Delivery           Links
Module             Module activities are as follows           5 hours Instructor Led
Overview            (details for each item are listed later in
                    this document):
                    First, the instructor will launch the powerpoint presentation, which walks the instructor
                     and class through the module agenda items and subsequent material.
                    Second, After section 3: Response Systems, there is an activity called "Control Charts
                     and Dispositioning." The activity includes both a lesson and exercises where the students
                     will answer questions and complete control charts.
                    Third, After section 4: Excursion Prevention, there is another activity called
                     "Completing a QEF." This activity includes a lesson and an exercise where students will
                     complete a QEF form (offline, on paper).
                    Lastly, the module lessons will be summarized and pluses and minuses will be captured
                     to determine whether or not the students liked the class.
Introduction     Instructor introduces him/herself and         10         Instructor          Take Notes with
                 hands out materials.                          minutes                         answers
                 Instructor should:
                  Welcome students to the "Process Control" QuickStart module.
                  Introduce yourself:
                     Write your name on the board and phone number where you can be reached.
                     Provide students with a little background on your years and experience with K-Tech.
                  Distribute handouts:
                     Vocabulary List
                     Take Notes handout
                     Control Charts and Dispositioning
                     Completing a QEF

Presentation     This presentation should be available to   3 hours Instructor Led         PowerPoint
                 both instructors and students.                                             Presentation
                 Instructor Should:
                  Launch the PowerPoint presentation
                  Review the Agenda
                  Review subsequent slides for the lessons and activities described below

Activity #1 –    Students will learn how control charts are   1 hour    Instructor Led        Handout
Control Charts   important tools used to monitor processes
and Material     and disposition material.
Dispositioning   Activity #1 – Learning Objectives

                 Students will be able to:

                        Define control charts and material dispositioning
                        Detect out-of-control processes
                        Recognize statistical process control trend rules
                        Explain the purpose of disposition and control limits
                        Interpret control charts
                        Learn to respond to unstable processes

                Directions - Each student should receive a copy of the Control Chart and
                Dispositioning handout. The instructor should review the lesson section of the
                handout with the students. This material has already been covered in the
                presentation. Remind the students that they can use the lesson as a job aid for
                future reference. After the lesson has been covered, handout the exercise. The
                exercise has the exact same charts as the lesson. This exercise is just to
                reinforce what they learned. Students should work in teams of 3 to read the
                complete the exercises. Ask them to try to work without referring back to their
                lesson materials, if possible depending on the audience. After teams have
                completed the exercise, the instructor will provide the correct answers and allow
                discussion. Remind students that on the job they should ask for help from their
                manager when they see a process trending abnormally. Excursion response and
                containment are our FIRST priority after safety. PMs and running WIP are
                second—SAFETY, quality, output!

Activity #2 –     Students will learn the importance of  30          Instructor Led   • Handout
Completing a       the online QEF tool that they will use minutes
QEF                in manufacturing to record data on
                   quality events that happen in the FAB.
                Activity #2 – Learning Objectives

                Students will be able to: Complete a QEF form offline (on paper).

                Directions - Each student should receive a copy of the QEF handout. The instructor
                should review the entire handout with the students. Students should work in teams of
                3 to read the lesson and complete the QEF. After teams have completed the exercise,
                the instructor will provide the correct answers and allow discussion.

Wrap-Up         The purpose of this exercise is to         15         Instructor       Flip Chart
Questions &     summarize/reiterate what the students      minutes
Answers         learned and to evaluate whether or not
                the students liked the module.

                Instructor will capture on flip chart:
               1. What did we learn from this module?
               2. On a second flip chart, capture:What did students like about the module
         Total •                                        5 hrs

                 Process Control

Take Notes:

1. What is Process Control?

    Process Control is used to maintain processes at a desired operating condition to meet product
    quality standards. To prevent or minimize Quality issues/ events and equipment problems before
    material is affected.

2. Why is Process Control important?

    Process Control provides methods, tools and systems that ensure that the factory is able to:
                – Run its process on target with minimum variation
                – Rapidly detect problems
                – Respond to shifts, trends, off-target

3. What are Control Charts and how are they used?

    Control charts are used to display data collected for the process and to monitor how the
    processes are performing.

4. What is a monitor and why are they used?

    A monitor is a test or an action to check the process to determine if it is performing as designed.
    Monitors are used to catch quality issues.

5. What is a good product called? What about bad products-what are the imperfections called?

    A good product is a Quality product. An imperfection is a defect, anything not wanted by our

6. What are quality events? And what is the biggest Quality event?

    Quality events are when issues occur where the quality of the wafer is jeopardized. The biggest
    Quality event at K-Tech is called an Excursion. Excursions are when a lot of material is impacted
    by a quality event.

7. What is the first line of defense to detect excursions?

       Each of us. When a quality event does occur, it is very important to respond in a timely
       manner to contain the wafer to prevent poor quality material from leaving your area and the

8. What system is used to identify and respond to process and/or equipment problems?

    The Response Flow Checklist (RFC) is a list of specific, ordered tasks used by the technician to
    take known corrective actions following an excursion or equipment problem.

9. What is the form called that you fill out when a quality event occurs?

       A Quality Event Form (QEF)

10. What is the process called for making a decision (based on data and process knowledge) on
whether a product is healthy or not and what steps should happen next.


11. When referring to Quality, what does it mean by "Do the right things right?"

    Preventing excursions: Follow Specs, Early Detection, Pay attention, Don’t assume, ask questions

12. What do you do when you believe a problem exists that could jeopardize quality?

       Contact Engineering and your manager


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