Direct labor headcount model study for semiconductor fab operation-modulator design concept approach

To fully utilize the expensive tools used in the semiconductor manufacturing industry, without loss or waste caused by inappropriate direct labor (DL) arrangements, it is critical to setup a good headcount (H/C) model for both competitive fab operation and effective DL assignment. In the past, heuristic rules have often been applied in shop floor DL arrangements, but in this changing business environment, robust indicators with theoretical support are needed. Therefore, a DL H/C model based on the (M/M/C/K) type queuing model was developed to estimate the required H/C under a given loading status. Benchmarking among fabs was also performed while collecting basic data via time and motion studies. In this project, we successfully developed a model for major process tools and established a mechanism for similar applications in the future.