DEEP LEARNING COMES FROM EXPERIENCE
Manufacturing facilities for microelectronics and photovoltaic products are among the most specialized on earth. As technology continues to advance, manufacturing conditions must be on the cutting edge to meet tight requirements, robust device reliability, and growing product volumes. Proper facility management goes well beyond general operations maintenance and simple safety protocols. These innovative industries need facility managers who have a keen attention to detail and understand the need for process efficiencies.
Everything from site design and procuring, installing and operating state-of-the art process equipment, to managing the storage and delivery of specialty chemistries and volatile gasses, is part of the equation. Facility management for these high-tech industries requires a combination of smart automation and deep learning that only comes from decades of experience.
Particularly for semiconductor and microelectronics facility management, maintaining a pure environment — where the concentration of airborne particles, temperature, humidity, and pressure are carefully controlled — can be the difference between success and failure. Above all, environmental health and safety (EHS) support is paramount. As such, EHS planning must be designed in from the start, and include hazard analysis, work instructions and safety guidelines, as well as worker training.
At Kinetics, smart manufacturing refers to more than just artificial intelligence (AI) and Big Data. Our teams put a lifetime of deep learning to work for you, offering the technical and operational experience required to manage a wide variety of chemical, specialty, and bulk gas supply systems in microelectronic and photovoltaic facilities worldwide. EHS plans are built into every facility design, based on the most up-to-date data.
Our facility management teams understand the processes and can tailor a variety of total chemical management (TCM) and total chemical and gas management (TCGM) services to meet specific cost and operational requirements.
MAKING SOLID FACILITY MANAGEMENT CHOICES: PART 2
Getting past options to tangible plans takes pushing through piles of variables including potential facility management partners. As Kinetics has learned in supporting upgraded, expanded, and new facilities around the world, the fastest way to putting production online is by employing key questions. While Part 1 provided significant starting points, these final five Big Questions in Part 2 complete the package of inescapable questions.
Big Question #6: Is there attention to correcting problems and optimizing system performance?
First comes baseline production, what could be called the “survive” stage, where specs are met consistently over time. But the next stage, “thrive,” applies a troubleshooting mindset both to minor and major variables. This is only possible when measurement and analysis occur to support quality monitoring and documentation: “Set and forget” are for home crockpot cookers, not large-scale commercial facilities.
Big Question #7: Where are consumption forecasts translated into logistics and warehouse management?
The resources in play are extremely valuable. Plant uptime is essential. The convergence of these two factors requires that accurate forecasts are built. In the case of Kinetics, client forecast assistance is offered along with leading the team in the purchasing of chemicals and gases. Stock receipt is managed well beyond the loading dock to product and document quality control. In compliance with relevant laws, labeling, storage and booking are managed intelligently with a high level of management transparency.
Big Question #8: Will the contractor take downstream responsibility for materials?
An organized, well-stocked warehouse is a beautiful thing if it supports the facility’s goals. Material release needs to be metered and managed (based upon FIFO) while deviation is managed. Empty containers must be tracked and safely handled as the entire system flows from documentation against each client’s specific logistical software platform. Clearly, this about site-specific planning rather than generalized plans and protocols.
Big Question #9: Does efficiency get lost in the push for safety and control?
Thoughtful, experienced facility management partners factor in equipment and service maintenance requirements to support optimal operational levels across all chemical and gas systems, CDA compressors and dryers. Five of the items attached to a comprehensive view include these; preventive maintenance, system and unit inspection, filter change-out, pump repair and replacement as well as maintenance and calibration of the gas detection system.
Big Question #10: Is there anything we’re missing?
Effective monitoring and maintenance go beyond the five categories outlined in the answer to question #9. These inclusions bookend the entire facility maintenance flow to defy expectations about what should be delivered by a competent, global partner. Four stand out in this category; inspection of electrical distribution panels and control modules, maintenance of monitoring systems, measurement and analysis along with documentation process that impact QA and QC.
Do these 10 questions qualify as “Big?” From the perspective of Kinetics, they set the direction for an effective facility management relationship, even before one is formalized. Addressing them head-on is the recommended approach, a perspective that legitimate partners will welcome with enthusiasm rooted in documented experience. Click HERE to read Part 1.