5th ISMI Symposium on Manufacturing Effectiveness

Short Course: "Art and Science of Maintenance"

Tuesday, October 21
1PM-5PM
Instructor: Dr. James P. Ignizio, Consultant

Factory maintenance, sometimes known as the “Thankless Science” plays a crucial but often unappreciated role in production line performance. The impact of machine and workstation maintenance in the semiconductor industry (e.g., fabs and assembly/test) is even more pronounced. Factory cycle time, a fundamental measure of manufacturing performance, may often be reduced by half or more by simply changing maintenance protocols. This improvement is possible by extending factory decision making into the overlooked Third Dimension of Manufacturing; i.e., changes in factory protocols as opposed to more time consuming and costly changes in the factory’s physical features (e.g., machines, workforce, and layout). By means of the Third Dimension of Manufacturing we are able to overcome the Three Enemies of Factory Performance (i.e., Complexity, Variability, and Poor Business Practices).

In this course the attendee will be able to actively engage in making decisions in the operation of a simulated factory. The (generally hidden) impact of maintenance protocols on factory performance will be made evident in this exercise. It will also be shown how some well-known BKMs (“best known methods”) and recent manufacturing fashions can actually degrade, rather than improve performance). Following the factory simulations the scientific basis for an understanding of why and how changes in maintenance protocols impact cycle time, capacity, and lead time performance will be presented. This will be followed by an introduction to the guidelines and metrics necessary to optimize factory performance via changes in maintenance protocols. Included among these topics is an overview of:

Waddington Analysis; a method for achieving C4U compliant (i.e., clear, concise, complete, correct and unambiguous) PM specifications – as well as a means to optimally allocate maintenance personnel
Waddington Effect, Availability Profile Plot, and the M-Ratio – three fundamental metrics that provide useful and effective means for the identification and rectification of improper maintenance protocols

About the Instructors

Dr. Ignizio is Principal and Founder of the Institute for Resource Management in Manufacturing, an organization dedicated to the implementation of the art and science of manufacturing. He is a Fellow of the Institute of Industrial Engineering; a Fellow of the British Operational Research Society; a Fellow of the World Academy of Productivity Science; and a Distinguished Alumni of Virginia Tech. Dr. Ignizio is the author of 8 books and more than 300 refereed publications. His latest book, The Politics, Art, and Science of Manufacturing, will be released in 2009. Dr. Ignizio has served as both an external and internal consultant to more than 100 manufacturing firms and his short courses in Industrial Engineering, Manufacturing Science, and Military Operations Research have been attended by several thousand individuals over the past two decades. Prior to his present position he was Professor and Chair of Systems Engineering at the University of Virginia, Professor and Chair of Industrial Engineering at the University of Houston, and Professor of Industrial Engineering at Penn State. In addition he has held industrial positions in the U.S. Aerospace industry and at Intel.

Who should Attend

The course is designed for semiconductor fab and assembly/test engineers and managers as well as for tool vendors who want to become more involved in all aspects of the maintenance of process tools within the environment of the factory, and for partnerships in improved fab performance.