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varying degrees of conditional automation to change to something better than the nor does anyone start at the top of the
and higher (Figure 2). These factories status quo. mountain. Our experience is that achieving
have become equipped to take the next zero defects really does start with the
step towards AI. Most chips for automotive CSR: How would you characterize the technology visionary who understands
applications are being manufactured in way advanced excursion control, along with the manufacturing business impact that
less sophisticated factories. These factories metrology capacity and dynamic metrology, technology can deliver. Selecting the right
lack data systems and enough of the right achieve a holistic approach to a customer’s partners and suppliers is critical. This
resources (money and people) to master quality strategy? process often results in replacing legacy
AI. For the industry to move forward, DH: We define a holistic quality systems (homegrown or under-capable)
increased levels of commitment are approach as one that can learn and utilize that will leverage industry learning, as
required. Furthermore, an understanding three fundamental types of definitions of opposed to single fab learning. This effort
of the applications that leverage Industry intelligence. We talk about these in terms of often requires a shift in culture and change
4.0 concepts and technologies are required levels of intelligence (Figure 3). At the first in processes and skill profiles. Finally,
to move towards AI. Companies we have level – sensory intelligence – quality systems it is important to not underestimate the
seen succeed typically begin when they can make decisions within the scope of their challenge of change. But for those willing,
have a “technology visionary” followed by data. This is a passive automation system the reward of increased quality can
executive sponsorship and a willingness (Figure 2). When two or more systems be realized.
share data to increase the effectiveness of a
decision, we call this peripheral intelligence. Biography
Next, interdependent intelligence occurs David F. Hanny is Director of Marketing
when systems work together to achieve at Applied Materials, Automation Products
common objectives. At this level, machine Group, Salt Lake City, UT. He has been
learning begins and is supported by data working in the nano-manufacturing
analytics. In our view, this level provides a industries for the past 25 years as a supplier
holistic approach to customer quality and of automation software, bringing multiple
maps to the predictive automation state. innovative software products to market that
For factories, these are stepping stones of are being used in semiconductor, display, and
continuous improvement to increase quality. pharma industries. He has done extensive
work in the areas of material handling
Figure 3: Quality intelligence levels: A holistic CSR: Are there any other significant controls, RFID, and advanced short-
quality approach can be addressed in terms of levels aspects to achieving a zero defects quality interval scheduling. He has a BS degree
of intelligence, starting with sensory intelligence, in control strategy for automotive applications? in Computer Science from Weber State U.
which quality systems can make decisions within the DH: There are no silver bullets,
scope of their data. Email David_Hanny@amat.com

Moving automotive quality to zero defects

By Selim Nahas [Applied Materials, Automation Products Group] Manan Dedhia [Analog Devices]
T he last 10 years have experienced automated to manual and have been in

an explosive demand for
that drive the decision to use 150mm and
automotive electronic parts production for 15 to 30 years. The economics
(Figure 1). In 2016, for example, a top-of-the- 200mm facilities is also changing—although
line Bentley required 110 pounds of wiring not for the foreseeable next five years. Within
with 90 computers to connect. In 2020, the Automotive Electronics Council (AEC)
similar wiring and connectivity requirements and International Standards Organization
are prevalent in most cars that people buy. (ISO), recent announcements on increased
The automotive industry is among the least safety, design for test (DFT), and design
dependent on leading-edge supply chain for manufacturability (DFM) reflect the Figure 1: The automotive electronic revolution.
technologies, instead choosing to use parts inevitable rise of Level 4 and Level 5 Tier 1s. These announcements have rightfully
made on legacy nodes with proven reliability. autonomous vehicles and automotive original doubled down on a zero-defect mindset to
Most of these legacy node fabs are semi- equipment manufacturers (OEMs) and reduce the cost of non-quality.

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