RFID application case of NEC Chongyue Quartz Semiconductor Wafer Factory
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Case summary
Chongyue Quartz introduced RFID solutions to the quartz (high-purity glass) manufacturing plant required for semiconductor wafers. In a quartz manufacturing factory that relies heavily on the experience of operators, as long as the RFID (UHF standard specification) label is attached to the work order, the work flow can be mastered for production management. In addition, it can clearly grasp the time required before delivery and the production operations to deal with urgent orders, thereby reducing working hours and improving production efficiency.
Import background
Chongyue Quartz’s core competitiveness is: quality, delivery time, technology, in order to expand its business in the future.
When it is difficult to grasp the progress status of each operation process and the required time, it is impossible to respond to the customer’s delivery date, and it is impossible to clearly formulate a production plan.
Since it is impossible to grasp the unfinished products and their remaining status, it is impossible to make the most appropriate deployment of the operators or improve the process to shorten the delivery time.
Quartz manufacturing is different from general process manufacturing, and it is more difficult to manage and increase production efficiency. Therefore, how to manage the process history and how to achieve visualization has become a major issue.
Import results
Adding RFID to the work order can grasp the progress of each work process without affecting the original work.
When there is a process that takes too much work time, because it can be locked which process is, so it can clearly improve the process to improve production efficiency.
Through real-time and detailed grasp of production information, production efficiency and customer service quality can be improved.
NEC’s proposal
In order to cooperate with the establishment of the new factory and construct the system in a short period of time, NEC proposes an RFID solution with proven performance.
RFID tags and RFID card readers (readers) cooperate with NEC partner companies such as Alien Technology and Impinj in the United States to provide a more global overall solution.
Import background
Construct a system belonging to the new factory to accurately master the manufacturing process
Chongyue Quartz is a quartz manufacturing enterprise that manufactures semiconductor wafer storage. It has a 50% market share in Taiwan and has a place in the industry. Quality, delivery time, and technology are the core competitiveness of Chongyue Quartz to expand its commercial territory. And to further improve product quality, we are more committed to obtaining international quality certifications such as ISO9002 and ISO14001.
Mr. An Yong, deputy general manager of Chongyue Quartz, said: Because quartz manufacturing is a variety of small-scale production and the operation process is complicated, it cannot be like the production line of the general manufacturing industry. It is very difficult to manage the process or improve the efficiency. At the same time, the manufacturing site belongs to the world of the quartz master, and the process management or operation time will vary according to people’s feelings and ideas, so it is very difficult to grasp. In this context, the current top priority is to improve productivity and quality while also taking into account the past operating methods and not placing excessive burdens on the operators.
Therefore, by attaching RFID tags to the work order, the RFID tag can be attached to the work order without affecting the original operation process, and the location of the operator and the product can be grasped without affecting the original operation process. Stay time to establish a process management system.
Import process
Full use of performance and international support system is the charm
Chongyue Quartz is a multinational joint venture between Taiwan and Japan. When planning to open a new factory in Chiayi in November 2007, it was planned to introduce the factory’s process visualization system.
Shin-Etsu Quartz, the Japanese parent company that also manufactures quartz, is more concerned about the application of RFID in the new factory in Chiayi. At that time, when Mr. Ernst & Young and others investigated the exhibition and RFID introduction cases held in Japan, they learned about NEC’s RFID solution demo at the “Automatic Identification Exhibition” and considered them.
Finally, Chongyue Quartz decided to adopt NEC’s RFID SOLUTION based on the following reasons: using WebOTX RFID Manager (hereinafter referred to as RFID Manager) with considerable import performance, RFID readers and handheld readers that comply with the international standard EPCglobal Class1 Gen2, etc. Not only is it easy to import, but the application demand in the manufacturing industry is also increasing.
System summary
Use middleware to construct an optimized system in a short time
In order to cooperate with the operation of the new factory, Chongyue Quartz built a set of process management system in a short time, and used NEC’s middleware-RFID Manager. RFID Manager will process the information read by the RFID reader into appropriate content according to the business or user, and then combine it with the application system. Able to construct an optimized system in the shortest time.
RFID tags and RFID card readers (read writers) are highly reliable products launched by American Alien Technology, which uses UHF standard specifications, and the multinational cooperation between Impinj and NEC.
The actual operation process is: After receiving the order, a work order must be made according to the content of the order. RFID tags are attached to the work order, so the operator can follow the work order to pick materials and perform operations. When the operator brings the materials and instructions into the studio, the RFID reader installed at the door will automatically read the operator’s entry and exit data. Finally, after entering the final stage of inspection, the handheld reader is used for reading. The data read by the card reader will be collected on the server of the management class to keep abreast of the production situation.
Introduction results and future prospects
Find the problem as early as possible, so that we can try our best to improve and increase productivity and customer satisfaction
The introduction of this system belongs to the first stage. Collect the information of each process with the work order attached with the RFID tag, and use the real-time collection and visualization of this information to realize the process management. The goal in the future is to actively analyze and make good use of the collected information to calculate the standard time of each product and process, or to quickly take countermeasures when abnormal phenomena occur.
However, the problem encountered at present is that the information collected can only be analyzed and mastered by experts familiar with the operation site. Therefore, in the future, I hope that we can try to make the data and display interface easier to understand, so that we can more easily grasp and analyze the data.
A more profound point in application: the introduction of this system is not the end, but the beginning. For example, the amount of information collected by RFID is huge, and it also contains some unnecessary data. For this reason, it is hoped that NEC will be able to select useful information for analysis with its rich experience, knowledge and skills in the future.
“If we can analyze the data more accurately, we can find out the problems in the manufacturing as soon as possible, so as to find out and improve early, so as to further improve production efficiency and customer satisfaction.”
Message from the person in charge of NEC
Cooperate with the establishment of the new factory and grasp the overall operation situation
Compared with the circulation industry, the use of RFID in the manufacturing industry is still quite rare. Chongyue Quartz’s application of RFID in job management has set a precedent in the industry and has attracted attention. Therefore, in addition to the use of UHF standard specifications of RFID tags and other NEC cross-border cooperation products, the goal is to build a system with high technology and reliability.
The manufacturing of quartz products is an extremely personal operation process, so we hope to use this system smoothly without affecting on-site operations. In this way, the introduction of the new system will not impose too much burden on the field operators. And this has also been highly affirmed by Chongyue Quartz, which makes the relevant employees of our company feel proud.
In addition, Chongyue Quartz chose NEC’s RFID Manager and other effective RFIDs to complete the system construction in just half a year when introducing the new system, thus smoothly cooperating with the customer to transfer the old factory in November 2007 The demand to start a new factory.
In the future, the second stage of the proposal will be used as the goal, and the collected information will be used for analysis, so that customers can find process bottlenecks and problems early and improve them in real time, so as to contribute to the improvement of Chongyue Quartz’s customer satisfaction. At the same time, I hope to use this performance to make further proposals for other manufacturing industries.
Contact number: (02)2515-0000
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