NEW PHOTO B-SHIFT

CONTINUOUS IMPROVEMENT

POD Inspection Project

January 2017

• New POD audit ongoing • Durables system set up in test environment • FAST technologies tasked with designing pm kit

PROJECT DESCRIPTION

PROBLEM STATEMENT OBJECTIVE

There is currently no system in

place for regular POD quality

inspection. Cost due to

repairs/replacements are

continually at an unacceptable

level

CURRENT STATUS

To implement a sufficient

system for a regular POD

quality inspection

• Regular update meetings across the shifts

• Liaise with TSR team in NRM

• Provide an efficient, progressive, deliverable system which will have

a positive impact on reducing cost related to PODs

• Implement the POD pm kit

• Roll out training across shifts

• Maintaining the standard attained

James Doherty/Gavin Porter/ Dympna Bonner/Floyd Gilmour/Fergal

Canning/John Plower/Stephen McEvoy

TEAM MEMBERS

NEXT STEPS PROJECT METRIC

J.Doherty

J.Doherty

ANALAYSIS

• Pods are currently inspected RANDOMLY or AFTER an event

• We need to be more PROACTIVE rather than REACTIVE

• Too many PODs in circulation at TSR

• Set up a system where an email/notification is sent to relevant personnel when POD needs inspected

• Agree on timeframe for POD inspection

• Design a sign off system where whoever inspects the POD signs it off and resets the counter to zero

J.Doherty

INSPECTING A POD

• Remove POD/s from fab by using trolley provided

• Take to Reticle Inspection Room

• Use manual POD remover to take off outer casing

• Check Shock Watch

• Check inner cassette for missing screws and damaged slots

• Check interlocks on outer casing

• Check H-Bar on outer casing

• Check outer casing for missing screws

• Check back-plate on inner cassette is tight

• Check outer casing for any other damage

• Any damaged PODs to be taken out of circulation and Dympna notified

J.Doherty

Check no screws missing

and slots in good condition Check interlocks move freely Check H-Bar moves freely

Ensure Shock watch

has not been activated Make sure flange is fitted securely

And RFID tag in place securely

Ensure screws are intact on base

and that base is in good condition

STEP BY STEP INSPECTION GUIDE(current)

Check Back Plate is tight

And all screws in place

J.Doherty

FEEDBACK FROM MEETING

• Notifications to be sent to Dympna, New Photo trainers & unit managers

• Inspect PODs once a month or after 200 movements (whichever is sooner)

• Include an ad hoc inspection option

• Movement of POD should be measured in 1 full cycle (from when a POD is built until

it is placed on a tool) will be counted as 1 movement

J.Doherty

ACTIONS

• Need storage space for spare PODs in fab or sub fab - I.E Space identified

• Define number of PODs needed in use - Dympna/James 16 in circulation

• Change out defective PODs with new/re-certified pods - Dympna/James In progress

• Can we source a tool to check tolerance of H-Bar and Interlocks? - FAST In progress

• Need system set up on Durables to flag PODs that need inspected - Fergal C In progress

• Need system set up to send notifications when durables flags a POD for inspect – Kevin

• Need TSR instruction PC to prompt operator if ‘overdue inspect’ POD is loaded – Tina

• Can we carry out our own repairs on site? – John Plower/FAST

J. Doherty

Fergal

• Setting up durables for POD Inspect

• Will have soft limit & hard limit

• Soft limit after 180 movements or 1 month (earliest)

• Hard Limit after 200 movements

• If POD not inspected by hard limit POD will deactivate

J. Doherty

POD INSPECTION FLOW CHART

T.Alford

ACTIONS FOR DEFECTIVE PODS (current)

• POOR QUALITY – TAKEN OUT OF USE IMMEDIATELY AND SENT TO MT FOR REPAIR

• MODERATE QUALITY – PLACED IN POD RACK AS RESERVE POD. WILL BE REVIEWED REGULARY

J. Doherty

CURRENT POD EXPENDITURE

• FULL BRAND NEW POD - $2,500

• NEW INNER - $1,600

• NEW OUTER - $900

• REPAIR - $250 - $1700 (based on last years costs)

J. Doherty

PODs 11,24,28 & 29

taken out of use to

go out for repair

13 4

4

POD QUALITY

GOOD

POOR

MODERATE

POD Quality audit January 2017 MT PODS for TSR only

J. Doherty

UPDATE FROM FAST 10/01/2017

• Dismantled POD 29

• Found that spring on H-Bar was very weak

• Found a lot of wear on tear in pin holes

• Ordered heavier springs

• Requested a brand new POD to compare with POD 29

• Going to rebuild POD 29 after some maintenance and

with new heavier spring in place and put into production

• Meeting with FAST on Friday

J. Doherty

NOTES

• PODs In storage, when does PODs counter start?

• If TSR is down hard what state do we put PODs into?

• Will ESG be trained on pm system?

• Only 2 states PODs can be in after inspect – pass/fail

• Can we delay green light on tool from activating for few seconds?