Lean implementation in a GaAs semiconductor factory

Lean Manufacturing principles were introduced in an existing Gallium Arsenide IC factory which manufactures state-of-the-art RF products. While the products produced in this factory were of cutting-edge performance and design, much of the equipment and factory procedures were vintage and in some cases outdated. This situation had worked well at modest production volumes; however, ramping to high-volume production has proven difficult. After introducing a new production framework based on Lean Manufacturing principles, dramatic improvements have been achieved in all aspects of factory performance. We will describe the implementation strategy, discuss some of the roadblocks that had to be eliminated, and give a summary of the improvements which were achieved.