Methods and apparatus for white space reduction in a production facility
View Patent ↗Efficient manufacturing automation system and methods are described. The automation system controls movement of materials for processing by tools in a manufacturing facility. The system and methods include pre-emptive dispatching for transferring of materials. With the pre-emptive dispatching, the next destination and next lot to be processed is determined prior to a first lot being converted to a ready to unload state. This reduces wait time or idle time to improve tool utilization.
1. An automated method for movement of material in a production facility comprising:
detecting an anticipated conversion in status of a first lot processing in a first equipment to a ready to unload state, wherein the ready to unload state indicates that the first lot has completed processing and is ready to be unloaded from the first equipment;
issuing a next destination command to determine a next processing tool for the first lot before the first lot is converted to the ready to unload state, wherein determining the next processing tool for the first lot comprises
performing a next destination analysis to select the next processing tool that is available for processing the first lot for subsequent processing, and
performing a priority analysis of the first lot to be processed at the next processing tool; and
dispatching a pickup transport to pick up the first lot from the first equipment before the first lot is converted to the ready to unload state.
2. The method of claim 1 , further comprising selecting the next processing tool for the first lot before the first lot is converted to the ready to unload state.
3. The method of claim 2 , wherein the pickup transport is parked within a proximate domain of the first equipment before the first lot is converted to the ready to unload state.
4. The method of claim 1 , wherein determining a next processing tool for the first lot comprises checking at least one of a next equipment availability and priority of the first lot with respect to the next equipment.
5. The method of claim 1 , further comprising issuing a next lot command to determine a second subsequent lot to be processed in the first equipment before the first lot is unloaded from the first equipment.
6. The method of claim 5 , wherein the next lot command is issued before the first lot is converted to the ready to unload state.
7. The method of claim 6 , further comprising selecting the second lot to be processed on the first equipment before the first lot is converted to the ready to unload state.
8. The method of claim 7 , further comprising issuing a delivery transport request to dispatch a delivery transport for retrieving the second lot from an original location and transporting the second lot to the first equipment, wherein the delivery transport request issued before the first lot is converted to the ready to unload state.
9. The method of claim 8 , further comprising dispatching a delivery transport to pick up the second lot from the original location for transportation to the first equipment before the first lot is unloaded from the first equipment.
10. The method of claim 9 , wherein the delivery transport has picked up the second lot from the original location before the first lot is unloaded from the first equipment.
11. The method of claim 10 , wherein the delivery transport is parked within the proximate domain of the first equipment before the first lot is unloaded from the first equipment.
12. The method of claim 9 , further comprising reserving the second lot after the second lot has been picked up by the delivery transport from the original location.
13. The method according to claim 5 wherein the next destination and next lot commands are issued simultaneously.
14. The method of claim 13 , further comprising executing the next destination and next lot commands in parallel.
15. An automated method for movement of material in a production facility comprising:
detecting an anticipated conversion in status of a first lot processing in a first equipment to a ready to unload state, wherein the ready to unload state indicates that the first lot has completed processing and is ready to be unloaded from the first equipment; and
performing the following actions before the first lot is converted to the ready to unload state:
issuing a next destination command to determine a next processing tool for the first lot, wherein determining the next processing tool for the first lot comprises
performing a next destination analysis to select the next processing tool that is available for processing the first lot for subsequent processing, and
performing a priority analysis of the first lot to be processed at the next processing tool;
selecting the next processing tool for the first lot and dispatching a pickup transport to pick up the first lot from the first equipment,
issuing a next lot command to determine a second subsequent lot to be processed in the first equipment, and
selecting the second lot to be processed in the first equipment and dispatching a delivery transport for retrieving the second lot from an original location and transporting the second lot to the first equipment.
16. The method of claim 15 , wherein
the pickup transport is parked within a proximate domain of the first equipment before the first lot is converted to the ready to unload state; and
the delivery transport is parked within a proximate domain of the first equipment before the first lot is unloaded from the first equipment.
17. A computer medium for storing a computer program for manufacturing automation comprising:
detecting an anticipated conversion in status of a first lot processing in a first equipment to a ready to unload state, wherein the ready to unload state indicates that the first lot has completed processing and is ready to be unloaded from the first equipment; and
issuing a next destination command to determine a next processing tool for the first lot before the first lot is converted to the ready to unload state, wherein determining the next processing tool for the first lot comprises
performing a next destination analysis to select the next processing tool that is available for processing the first lot for subsequent processing, and
performing a priority analysis of the first lot to be processed at the next processing tool; and
dispatching a pickup transport to pick up the first lot from the first equipment before the first lot is converted to the ready to unload state.
18. A method of manufacturing articles comprising:
processing a first article in a first tool;
detecting an anticipated conversion in status of the first article to a ready to unload state; and
issuing a next destination command to determine the next processing tool for the first article before the first article is converted to the ready to unload state, wherein determining the next processing tool for the first lot comprises
performing a next destination analysis to select the next processing tool that is available for processing the first lot for subsequent processing, and
performing a priority analysis of the first lot to be processed at the next processing tool; and
dispatching a pickup transport to pick up the first lot from the first tool before the first lot is converted to the ready to unload state.
19. The method in claim 18 wherein the first article comprises a first lot of semiconductor wafers on which integrated circuits are formed.
20. The method in claim 18 comprising selecting the next processing tool for the first article before the first article is converted to the ready to unload state.
21. The method in claim 20 wherein the pickup transport is parked within a proximate domain of the first tool before the first article is converted to the ready to unload state.
22. The method in claim 18 wherein determining a next processing tool for the first article comprises checking at least one of a next equipment availability and priority of the first article with respect to the next equipment.
23. The method in claim 18 comprising issuing a next article command to determine a second subsequent article to be processed in the first tool before the first article is unloaded from the first tool.
24. The method in claim 23 wherein the next article command is issued before the first article is converted to the ready to unload state.
25. The method in claim 24 comprising selecting the second article to be processed on the first tool before the first article is converted to the ready to unload state.
26. The method in claim 25 comprising issuing a delivery transport request to dispatch a delivery transport for retrieving the second article from an original location and transporting the second article to the first tool, wherein the delivery transport request issued before the first article is converted to the ready to unload state.
27. The method in claim 26 comprising dispatching a delivery transport to pick up the second article from the original location for transportation to the first tool before the first article is unloaded form the first tool.
28. The method in claim 27 wherein the delivery transport has picked up the second article from the original location before the first article is unloaded from the first tool.
29. The method in claim 28 wherein the delivery transport is parked within the proximate domain of the first tool before the first article is unloaded from the first tool.
30. The method in claim 27 comprising reserving the second article after the second article has been picked up by the delivery transport from the original location.
31. The method in claim 23 wherein the next destination and next article commands are issued simultaneously.
32. The method in claim 31 comprising executing the next destination and next article commands in parallel.