Recognizing yield patterns through hybrid applications of machine learning techniques
Introduction
In the manufacturing of semiconductors, final products are fabricated through several hundred processes which are highly automated and dramatically interdependent. Most manufacturing processes in use today are complexly intertwined and become infinitesimal when using nanometer-scale technology.
For those manufacturers or engineers, the yield is considered a very important factor that has to be monitored and controlled. Yield is defined as the ratio of normal products to finished products. Yield management in the semiconductor industry is understood as a comprehensive analytical system which has the characteristics of a complex system. A complex system has many independent component variables that interact with each other in many complicated ways. Therefore, it is considered difficult to predict and control.
Yield in semiconductor fabrication is strongly affected by several factors, including particles or contaminants on the wafer, substances in the manufacturing instruments, manufacturing process parameters, process engineers’ attitudes, and the design of semiconductors.
Semiconductor companies can achieve a certain degree of yield by applying statistical process controls and 6-sigma to a semiconductor. Yield enhancement employing statistical measurements, however, has difficulty in preventing low-yield lots effectively in advance. This is because manufacturing process variables which affect changes in the yield have a non-linear complex relationship with the yield. Due to this interactive effect among several variables, manufacturers find it difficult to pinpoint problems in time, when small changes in a relationship between process parameters can cause changes in the yield.
Thus, other intelligent techniques are needed in order to detect the main process variables which seriously affect changes in the yield. This study has developed a hybrid yield prediction system in the semiconductor industry, called HYPSSI, as a complement to the existing statistical approach. This system is based on a hybrid application of machine learning techniques to depict multiple process variables concerned with effectively predicting the production yield in semiconductor manufacturing.
HYPSSI adopts neural networks (NNs) and case-based reasoning (CBR) which can be directly applied to prediction purposes. However, CBR suffers from feature weighting; when it measures the distance between cases, some features should be weighted differently. Many feature-weighted variants of the k-Nearest Neighbor (k-NN) have been proposed to assign higher weights to more relevant features for case retrieval purposes [2], [37]. Though those variants have been reported as improving their retrieval accuracy regarding some tasks, few have been used in conjunction with neural networks to predict yield performance in semiconductor manufacturing.
In order to weigh features and guide CBR, HYPSSI adopts four feature-weighting methods: sensitivity, activity, saliency, and relevance. Each method calculates the degree of each feature’s importance by using the connection weights and activation patterns of the nodes in the trained neural network.
In order to validate this hybrid approach within the semiconductor industry, HYPSSI was applied to the International Semiconductor Company, which has been ranked one of the top manufacturers in the world. After comparing this hybrid method with other methods that have been used, this paper shows the hybrid method provides a more accurate yield prediction.
This paper is organized as follows: Section 2 reviews various approaches used in providing yield management applied to semiconductor manufacturing. This section focuses on hybrid applications combining machine learning techniques. Section 3 describes the methodology of the hybrid yield prediction system in the semiconductor industry, called HYPSSI. Experimental results are presented in Section 4 to validate the system. Finally, this paper is concluded by briefly summarizing the study and the direction of future research.
Section snippets
Research methods applied to semiconductor manufacturing
In a high-tech industry such as semiconductor manufacturing, yield improvement is increasingly important as advanced fabrication technologies are complicated and many interrelated factors affect the yield of fabricated wafers. A few studies have aimed to improve yield performance and to reduce operating and capital investment cost in the semiconductor industry.
There are several statistical approaches applied to semiconductor manufacturing. Wang [36] used the lower confidence bound and
Hybrid yield prediction system in semiconductor industry (HYPSSI)
In order to improve the ability of predicting yield accurately, a hybrid yield prediction system was developed in the semiconductor industry (HYPSSI). It is the following hybrid method, combining machine learning techniques, such as back-propagation network (BPN), CBR, and k-NN (see Fig. 1).
HYPSSI consists of four phases: Learning about the relationship between case variables and yield, feature weighting, extracting k similar cases, and weighted averaging of extracted yields. The first phase
Application and evaluation
In order to verify the effectiveness of the hybrid method devised in this paper, it was applied to the production data collected from the manufacturing lots of a Korean semiconductor company: 230 high-yield lots, 230 low-yield lots, and 16 process variables. By definition, a high-yield lot delivers more than 90% yield from a lot and a low-yield lot conveys less than 60% yield from a lot. This definition is still in use by the engineers of the company. Sixteen process variables, including film
Conclusion
Yield management in the semiconductor industry is a very important management practice that has to be monitored and completely controlled. Because manufacturing process variables have a non-linear complex relationship with the yield, manufacturers need an intelligent approach to pinpoint the relationship between process parameters in time.
In this paper, the authors devised and applied HYPSSI, a hybrid method combining BPN and CBR, to predict the yield of the target semiconductor manufacturing
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