Dynamic routing control methods and systems for a cluster tool

1. A method of operating a cluster tool comprising:

receiving recipe time data;

receiving transfer time data;

receiving process programs and associated substrate lots wherein the process programs include a plurality of sequences;

determining cluster tool chambers associated with sequences that are bottleneck sequences;

setting equipment constant values for components of the cluster tool to implement transfer priorities wherein the chambers associated with bottleneck sequences are given highest priority;

executing a next sequence based on the transfer priorities; and

repeating determining, setting and executing for each remaining sequence.

2. The method of claim 1 wherein receiving recipe time data and receiving transfer time data includes accessing a recipe time database and a transfer time database respectively.

3. The method of claim 1 wherein receiving process programs and associated substrate lots includes continuously receiving different process programs and associated substrate lots.

4. The method of claim 1 wherein determining cluster tool chambers associated with sequences that are bottleneck sequences includes calculating a total time employed for each sequence and identifying a sequence that employs more time than all others as a bottleneck sequence.

5. The method of claim 4 wherein determining cluster tool chambers associated with sequences that are bottleneck sequences further includes identifying chambers used in bottleneck sequences.

6. The method of claim 1 wherein setting equipment constant values for components of the cluster tool to implement transfer priorities includes setting equipment constants that include at least one of routing priority of a chamber, transfer out priority of a chamber, and transfer order data of the cluster tool.

7. The method of claim 1 wherein repeating determining, setting and executing further includes repeating receiving process programs and associated substrate lots.

8. A cluster tool comprising:

a transfer chamber including a transfer robot;

a plurality of chambers serviced by the transfer robot; and

a controller including a memory and adapted to store instructions adapted to:

receive recipe time data;

receive transfer time data;

receive process programs associated with substrate lots wherein the process programs include a plurality of sequences;

determine cluster tool chambers associated with sequences that are bottleneck sequences;

set equipment constant values for components of the cluster tool to implement transfer priorities wherein the chambers associated with bottleneck sequences are given highest priority;

execute a next sequence based on the transfer priorities; and

repeat the determine, set and execute instructions for each remaining sequence.

9. The cluster tool of claim 8 wherein the controller further includes a recipe time database and a transfer time database respectively.

10. The cluster tool of claim 8 wherein the instructions adapted to receive process programs and associated substrate lots includes instructions adapted to continuously receive different process programs and associated substrate lots.

11. The cluster tool of claim 8 wherein instructions adapted to determine cluster tool chambers associated with sequences that are bottleneck sequences includes instructions adapted to calculate a total time employed for each sequence and to identify a sequence that employs more time than all others as a bottleneck sequence.

12. The cluster tool of claim 11 wherein instructions adapted to determine cluster tool chambers associated with sequences that are bottleneck sequences further includes instructions adapted to identify chambers used in bottleneck sequences.

13. The cluster tool of claim 8 wherein instructions adapted to set equipment constant values for components of the cluster tool to implement transfer priorities include instructions adapted to set equipment constants that include at least one of routing priority of a chamber, transfer out priority of a chamber, and transfer order data of the cluster tool.

14. The cluster tool of claim 8 wherein instructions adapted to repeat the determine, set and execute instructions further include instructions adapted to repeat the instruction adapted to receive process programs and associated substrate lots.

15. A controller for a cluster tool comprising:

a processor;

memory coupled to the processor;

a recipe time database accessible by the processor;

a transfer time database accessible by the processor;

a user interface for controlling the cluster tool; and

a plurality of instructions stored in the memory and operative to:

access recipe time data in the recipe time database;

access transfer time data in the transfer time database;

receive process programs associated with substrate lots received by the cluster tool wherein the process programs include a plurality of sequences;

determine cluster tool chambers associated with sequences that are bottleneck sequences;

set equipment constant values for components of the cluster tool to implement transfer priorities wherein the chambers associated with bottleneck sequences are given highest priority;

cause the cluster tool to execute a next sequence based on the transfer priorities; and

repeat the determine, set and execute instructions for each remaining sequence.

16. The controller of claim 15 wherein the instructions operative to receive process programs associated with substrate lots received by the cluster tool includes instructions operative to continuously receive different process programs associated with substrate lots continuously received by the cluster tool.

17. The controller of claim 15 wherein instructions operative to determine cluster tool chambers associated with sequences that are bottleneck sequences includes instructions operative to calculate a total time employed for each sequence and to identify a sequence that employs more time than all others as a bottleneck sequence.

18. The controller of claim 17 wherein instructions operative to determine cluster tool chambers associated with sequences that are bottleneck sequences further includes instructions operative to identify chambers used in bottleneck sequences.

19. The controller of claim 15 wherein instructions operative to set equipment constant values for components of the cluster tool to implement transfer priorities include instructions operative to set equipment constants that include at least one of routing priority of a chamber, transfer out priority of a chamber, and transfer order data of the cluster tool.

20. The controller of claim 15 wherein instructions operative to repeat the determine, set and execute instructions further include instructions operative to repeat the instruction operative to receive process programs associated with substrate lots received by the cluster tool.