Risk management exercise in a wafer fab utilizing dynamic simulation

In the semiconductor industry, companies must be prepared to effectively respond to emergency situations that threaten employee safety and their manufacturing sites. Most emergencies are small incidents with minor impact; however, the potential human and financial loss resulting from a large scale emergency can be very great. Prior experience had shown that although the Motorola and City of Austin emergency response groups operate effectively on an independent basis, cross-group communication and coordination needed improvement. To assist with this, a large-scale, multiple emergency drill involving all groups was conducted. A forty-two member simulation team was organized to design and implement a scenario using dynamic simulation in order to make the drill as realistic as possible. A five hour drill was successfully completed without interruption to manufacturing with approximately eighty responders at eight different, simultaneous activity areas across a 245 acre campus containing five manufacturing facilities. Several opportunities to improve and refine the processes of preplanning, response, follow-up and drill implementation were identified. Annual drills of this magnitude and style will be institutionalized as part of how each group manages risk and protects their employees and other assets