Block cross processing: an innovative approach to constraint management

Abstract

Block cross processing (BXP) is an innovative system developed to provide manufacturing operations with a means for managing constrained areas of a process line using intra-site or inter-site material movement. This system is a proactive process that improves flexibility and increases capacity. The BXP system can be applied to any factories running a common process; it segments the fab process into several "blocks" that are identified as "technically safe" with respect to queue times, integrated yield issues, equipment and/or recipe matching, and capacity concerns. Blocks are a group of operation steps that range in size from 1 to about 10 operation steps depending on the technology and capacity issues within the block. Lots exercising BXP are processed through an entire block on a single manufacturing floor. BXP significantly reduced the amount of transferring between the two New Mexico 6" fab floors. In addition BXP data was used as a diagnostic tool for improving yield by identifying and closing unmatched "gaps" between different factories at a block level. This paper depicts the process used to develop and qualify BXP. It records key learning within the process and notes suggestions for possible improvements.