External Use

Streamlining Product Development at Applied Materials With Siemens PLM and Microsoft

External Use

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Author’s InformationHerman Harwell, Senior Member in Design For Excellence (DFx) Group of Applied Materials Global Operations Manufacturing Engineering Organization (GOME)

200mm – 300mm Wafer Semiconductor Processing Systems

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3

Applied Materials OverviewApplied Materials is the global leader in Nanomanufacturing Technology™

solutions with a broad portfolio of innovative equipment, service and software products for the fabrication of semiconductor chips, flat panels, solar photovoltaic cells, flexible electronics and energy efficient glass.

Results for Third Quarter of Fiscal 2007

· Net Sales: $2.56 billion

· Net Income: $474 million

· EPS: $0.34

· New Orders: $2.28 billion

Flat Panel Display Processing Systems 200mm – 300mm Wafer Inspection Systems

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Product Development RoadmapPeople Driven Framework

Research

and Plan

ConceptDesign/Develop

Validate/Source

Market/ Promote

Produce/Sell

Support/Retire

Management

Idea management

Project and portfolio management

Regulatory compliance

Configuration management

Sales and marketing Customer needs Product marketing and publishing

R&D and Engineering

Requirements management

Design data creation

Visualization and digital mockup

Product structure record

Engineering change management

Sourcing Direct material sourcing

Mfg Manufacturing process management

Customer Service

Aftermarket support

EOL

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New Product Development Challenges

Common Issues In New Product Development– Design Issue capture mostly done with Excel spreadsheets– Issue closure difficult to track at all project levels (many ad hoc)– No consistent process for design issue identification in WIP– Design project management varies by business group & size– Lotus Notes databases most often utilized tool for design task

tracking (EWR/PRIME/HSR/SPS)– Lack of consistent approach with PLC phase task deliverables– Few people proficient in use of all the new tools TcE/TcVis/NX– E-mail most often used tool to notify team members of project

issues or changes– Supplier collaboration is needed earlier in design process– Cross-Functional team members aren’t involved early enough to

identify design changes needed

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Product Planning Process PPP Mature ProductsVolume Manufacturing VM Product Development Process PDP

Alpha

Stage

BetaStage

Gamma Stage 81 2 4 6 753SM

RPRS

PDSS

Vol Mfg

Mature Product

Validation (Gamma) Build• Strategy Validation• BOM(97% Accurate)• Tooling/Fixture Validation• Engineering Issues Closed• Work Center Train Plan Complete• Field NC Goals Met

Pre-Build Requirements• Strategies

• Manufacturing• Test• Sourcing

Managed (1st Beta) Build• OMS/SOE Verification• Train the “Trainer” Started• Engineering Issues Verification• Digital Validation - DV

PLC Product Development Roadmap

TcCommunity-Based Activities:

Use Case Roadmap for TcCommunity supporting PLC Deliverables & Tasks

Controlled (2nd Beta) Build• Strategy Verification

• Cost Goals Achieved• MIT Goals Achieved

• BOM (EVAL Status)• Material Status @ EVAL• Critical Parts FAI’d

• OMS/SOE Released @ EVAL• Tool/Fixture Implementation• Engineering Issue List Addressed• Train the “Trainer” Completed• Field NC Input

Engineering (Alpha) Build• Strategy Trial• BOM (Draft)• OMS/SOE Draft• Tool/Fixture Trial• Initial Engineering Issue List• Virtual Build - VB

Detail Product Design• BOM (Preliminary)• Preliminary OMS/SOE• Preliminary Tool/Fixture• Critical Parts List• PLC Task Assignments• Digital Mockup -

DMU

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Utilize Teamcenter Community in Design ReviewsConduct DMU activities on WIP design data in TcEngineering

regardless of geographic location (PLC deliverables in Phase 4)Capture design issues and disposition them before design freeze and

procurement of physical materialsProvide extended design team with non-CAD tools to enable design

reviews using most current TcEngineering data

Utilize Teamcenter Community in global design environmentEngage a product development team during PLC Phase 4 to conduct

DMU tasks using TcCommunity, TcEngineering & TcVisualization toolsHave the team execute the Visualization process workflow and it’s

discrete tasks utilizing the capabilities of TcC, TcE & TcVisEvaluate TcCommunity performance when combined with TcE & TcVis

against existing processes with only TcE and TcVis tools.

Collaboration Objectives

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Applied’s New Product Development Tools

PLM System – All Tools are Integrated via TeamCenter

VisMockup§ 3D Clearance Analysis

(Static & Dynamic)§ Animation/Motion Authoring§ 3D Model Filters & Groups§ VisVSA Analysis

(PMI Verify – Tolerance Simulations & Stack Up)

§ VisJack – Classic Jack Analysis (Serviceability – Ergo – Safety – Access Evaluation & Viewing)

§ Path Planning Authoring (Component & Assembly Extraction – Installation Analysis)

VisViewPro§ JT 3D Model/Structure Viewing§ Alt Hierarchy Authoring

(Mfg Build Sequence – Reports)§ 3D Model Section Viewing§ 3D Model Measurement§ 3D Model Markup

(JT models w/TcE Identification)§ VisPublish Authoring

(OMS - Assembly Documents)§ Visual Issue Authoring

(Linked to TcE Models)§ 2D Drawing Overlay & Compare§ 2D Drawing Redlining & Markup

Web§ Design Issues Management.

(Closed Loop Corrective Action)§ PLC Tasks Management

(External Linked Spreadsheet)§ Tools For Internal Multi-Site TcE

Dynamic Design Collaboration§ Tools For External Supplier

Static TcE Design Collaboration (i-Series Embedded Viewer)

§ PLC Deliverables Library (Linked PLC Documentation)

§ Conferencing Server Options (AppShare Or VisConference)

Portal - Web§ Design Data Management

(WIP & Release Designs)§ 3D Solid Models Revisions§ 2D Drawings Revisions§ Manufacturing Documents Library§ Commercial Part Library§ Product Structure BoMs

(Product Core & Options Config)§ Multi-Site Design Data Sources§ Release Data Management§ Part Number Issuance Workflow§ Part Status Workflows§ Document Status Workflows

Portal§ 3D Model Authoring

(NX parts & assemblies)§ Model As Master Authoring

(GD&T – PMI data content)§ JT 3D Model Creation

(Attributes - PMI data content)§ 2D Drawing Authoring

(NX dwg - .cgm)§ Assembly Structure Authoring

(Multiple Product Configurations)§ Large Model Management

(Load Options & View Options)§ CAD Data Import & Export

TcVisualization TcCommunity TcEngineering UG - NXDirect

Integration

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New Product Development Process Deliverables

Governance By The Applied Materials PLC Phase Gated Development Model

Identified Use Cases** For TcCommunity Applications– Phase 3: Product Definition (Program Charter)

3 Deliverables [4 Tasks with 6** Sub-Tasks]– Phase 4: Alpha Development

9 Deliverables [18 Tasks with 56** Sub-Tasks]– Phase 5: Beta Development

7 Deliverables [19 Tasks with 59** Sub-Tasks]

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Applied Materials Visualization Process: DMU

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TcCommunity Deployment Configuration

3

1

2

4

5

6

78

AMAT Community Home Login Page

External Use

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3

1 2

TcCommunity Deployment Configuration

AMAT Community Home Login Page (cont.)

4

5

External Use

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6

1

2

3

4

5

7

8

PLC Program’s Design Review Workspace (Home Tab)

TcCommunity Deployment Configuration

External Use

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6

1

2

3

4

5

PLC Program’s Design Review Workspace (My Workspace Tab)

TcCommunity Deployment Configuration

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MARKUP CONTENT CONSISTS OF 3-ELEMENTS:OBSERVATION [O]; RECOMMENDATION [R]; FEEDBACK [F]

2D DRAWING VISUAL ISSUE2D DRAWING & MARKUP ARE STORED IN TCE:VISUAL ISSUES ARE CREATED AND STORED IN TCCOMMUNITY DATABASE

2D MARKUPS ARE POSITIONED OUTSIDE THE DRAWING:ALL MARKUPS ARE MERGED & POSITIONED OUTSIDE THE DRAWING BORDER TO ALLOW READABILITY

2D Drawing Issues Tracking Prior To Product MRP Release

Applied DMU 2D Drawing Review Example

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Closed Loop Corrective Action Process

4

VisualIssue 1

23

Team Conference For Review Date

Visual Issue Dispositioned(Facilitator)

Resolution Due Date Assigned

[Due Date]

Reason for Issue

[Observation]

Proposed solution

[Recommendation]

Assign To A Team Conference

[Review Date]

T1

End

Create Routing Slip Link ToVisual Issue

(1- Res Owner)(2- VI Owner)(3-Facilitator)

Visual Issue ResolutionCompletedApproved

[Res Owner]

Resolution Of Visual Issue

VerifiedApproved(VI Owner)

Resolution Determined

[Feedback]

Resolution Owner Identified

[Assigned To]

T2

Visual Issue Resolution Verified& Status Changed

Closed[VI Owner]

Task Assignment Scope From

Facilitator UsingReview Module

(Reviewer)

Visual Issue Form With

Audit History& Routing Slip Dispositions

PLC Deliverable From Task Assignment(Reviewer)

Lotus Notes

Disposition Of Visual Issue

CompleteApproved(Facilitator)

Visual Issue Actions Complete& Content Frozen

Locked[Facilitator]

Visual Issue Resolution

ImplementedCAD a/o TcE[Res Owner]

Dispositioned Visual Issue

Status ChangedResolved[VI Owner]

Reviewer Finds Problem; Creates

Visual IssueActive

(VI Owner)

Email Notification Approval Status

(Res Owner)(VI Owner)(Facilitator)

Start

Product Design Issues Tracking Prior To MRP Release

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Closed Loop Corrective Action Process

ROUTING SLIP APPROVAL:STATUS OF EACH REVIEWER IN THE ORDER OF REVIEW

LINK TO VISUAL ISSUE CONTENT

CLCA HISTORY STORED IN VISUAL ISSUE

CLCA HISTORY FOR ROUTING SLIP:

VISUAL ISSUE PROVIDES EVIDENCE OF ALL ACTIONS:FROM DISCOVERY OF ISSUE, THROUGH RESOLUTION OR FINAL DISPOSITION, TO VERIFICATION AND CLOSING OF ISSUE.

Product Design Issues Tracking Prior To MRP Release

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TcC Resource Usage Efficiencies– Lowest Administration Burden

Design Review Sites & Workspaces DMU Roles Established Within TcC Managed Review Tasks Assignments Managed Review Scope & Agendas TcC Event Links in Lotus Notes eMail

– Lowest Data Management Burden DMU Data Linked To TcE, Not Copied DMU BOM Synced To TcE Eng_BOM All TcE Sites Accessible Within TcC

– Lowest PLC Deliverables Burden PLC Deliverables Doc Libraries in TcC TcE Item Issues Linked To PLC Docs

– Lowest Issues Management Burden Visual Issue Data Capture & Tracking Visual Issues Link To TcE Design Data Issue Routing Via Lotus Notes email Issue Reporting, Rollups & Dashboards

– Highest Reviewer Time Availability 83% Increase Over Vis-Based Reviews 175% Increase Over CAD-Based

Basis: Equal Resource Allocation / Method / Assembly Reviewed (Avg.)

0

10

20

30

40

50

60

% of Total; C

umulative A

ll Categories = 100%

Administration Data Management PLC Tasks Issue Management Review Effort

Resource Burden In Each DMU Method Evaluated

TcCommunity's ApplicationAdvantages In Each Virtual

Design Review Category

TcC-Based

TcVis-Based

CAD-Based

New Product Development IntegrationTcCommunity Return On Investment

External Use

Future Direction

Applied Materials Roadmap– Deploy Teamcenter

Engineering 2007 during FY 2008

– Deploy Microsoft Office SharePoint Server (MOSS) during FY 2009

– Deploy Teamcenter Community 2007 on MOSS during FY2009

19

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Thank You,Herman Harwell

Applied Materials

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