TWI802334B - Multiple-variable predictive maintenance method for component of production tool and computer program product thereof - Google Patents
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Abstract
Description
本發明是有關於一種生產機台組件的多變量預測保養方法與其電腦程式產品,且特別是有關於一種基於剩餘使用壽命(Remaining useful life;RUL)預測之生產機台組件的多變量預測保養方法與其電腦程式產品。 The present invention relates to a multivariable predictive maintenance method for production machine components and its computer program product, and in particular to a multivariable predictive maintenance method for production machine components based on remaining useful life (Remaining useful life; RUL) prediction and its computer program products.
生產機台是任何製造廠不可缺少的部分。生產機台中之組件、模組或裝置(例如:加熱器、壓力模組和節流閥(Throttle Valve)等)的失效會引起生產異常,導致不良的產品品質和/或降低產能,因而造成重大損失。 Production machines are an integral part of any manufacturing plant. The failure of components, modules or devices in the production machine (such as: heaters, pressure modules and throttle valves (Throttle Valve), etc.) will cause abnormal production, resulting in poor product quality and/or reduced production capacity, resulting in major loss.
一般,解決上述問題最常用的方法是定期的預防保養(Preventive Maintenance;PM)。即,在預設時間間隔下執行保養相關作業。此預設時間間隔基本上是根據標的裝置(TD)的平均故障時間間隔(Mean Time between Failure)來決定。因此,如何安排適當的PM計畫通常是工 廠的關鍵議題。一個不當的定期PM計畫會增加維修成本或降低產能。 Generally, the most common method to solve the above problems is regular preventive maintenance (PM). That is, maintenance-related work is performed at preset time intervals. The preset time interval is basically determined according to the mean time between failure (Mean Time between Failure) of the target device (TD). Therefore, how to arrange an appropriate PM plan is usually a task Key issues of the plant. An improperly scheduled PM program can increase maintenance costs or reduce productivity.
預測性維護目的在找出標的設備(即生產機台的組件)何時生病並在標的設備死亡發生之前以進行即時性維護,以避免意外的標的設備停機時間。通過這種方式,不僅提高了生產機台的稼動率和製造品質,而且還可以降低預防性保養中的過度維護的額外成本。 The purpose of predictive maintenance is to find out when the target equipment (ie, the components of the production machine) is sick and perform immediate maintenance before the death of the target equipment occurs, so as to avoid unexpected target equipment downtime. In this way, not only the utilization rate and manufacturing quality of the production machine are improved, but also the extra cost of excessive maintenance in preventive maintenance can be reduced.
為改善機台保養計畫以增加晶圓廠的績效,國際半導體技術製造協會(International Sematech Manufacturing Initiative;ISMI)提出一種預測性和預防性保養(Predictive and Preventive Maintenance;PPM)的指標。如ISMI所定義,PPM包含預防保養(PM)、基於條件的保養(Condition-based Maintenance;CbM)、預測保養(Predictive Maintenance;PdM)和故障後維修(Breakdown Maintenance;BDM)。其中,ISMI主張CbM和PdM的技術應被發展,並以單一模組或多個模組的型式被使用,使得終端使用者能有效率地使用這些技術。CbM的定義為:「在指出機台將要失效或機台的性能正在惡化的一或多個指標出現後進行保養」。錯誤偵測及分類(Fault Detection and Classification;FDC)是一種與CbM相關的方法,其定義為:「監控機台與工廠資料以評估機台的健康,並在偵測到錯誤時發出警報和/或關閉機台」。另一方面,PdM是一種應用預測模型的技術,找出設備狀態資訊與保養資訊間之關聯,來預測機台或標的裝置(TD)的剩餘 壽命(Remaining Useful Life;RUL),以達到減少非計畫性停機之保養事件的目標。 In order to improve the tool maintenance plan to increase the performance of the fab, the International Sematech Manufacturing Initiative (ISMI) proposes a predictive and preventive maintenance (PPM) index. As defined by ISMI, PPM includes preventive maintenance (PM), condition-based maintenance (Condition-based Maintenance; CbM), predictive maintenance (Predictive Maintenance; PdM) and post-breakdown maintenance (Breakdown Maintenance; BDM). Among them, ISMI advocates that CbM and PdM technologies should be developed and used in the form of a single module or multiple modules so that end users can use these technologies efficiently. CbM is defined as: "Maintenance performed after one or more indicators indicate that the machine is about to fail or that its performance is deteriorating". Fault Detection and Classification (FDC) is a method related to CbM, which is defined as: "monitoring machine and factory data to assess the health of the machine, and issuing an alarm and/or when an error is detected or turn off the machine". On the other hand, PdM is a technology that uses a predictive model to find out the relationship between equipment status information and maintenance information to predict the remaining of the machine or target device (TD) Life (Remaining Useful Life; RUL), in order to achieve the goal of reducing maintenance events of unplanned downtime.
在一些習知技術中,只用單一個特徵來預測設備的老化特徵,進而判斷設備的剩餘使用壽命,如何增加預測的準確度,為此領域技術人員所關心的議題。 In some conventional technologies, only a single feature is used to predict the aging characteristics of the equipment, and then determine the remaining service life of the equipment. How to increase the accuracy of prediction is a topic of concern to those skilled in the art.
由於習知演算法的限制,當標的設備即將死亡時,若標的設備的老化特徵突然上升或變得平滑,指數模型可能無法跟上即時預測甚至錯誤地預測標的設備的RUL。 Due to the limitations of conventional algorithms, when the target device is about to die, if the aging characteristics of the target device suddenly rise or become smooth, the exponential model may not be able to keep up with the real-time prediction or even wrongly predict the RUL of the target device.
本發明之一目的是在提供一種生產機台組件的多變量預測保養方法與其電腦程式產品,藉以即時並準確地預測生產機台組件的RUL,而可及時地進行生產機台組件的維修。 One object of the present invention is to provide a multi-variable predictive maintenance method for production machine components and its computer program product, so that the RUL of the production machine components can be predicted in real time and accurately, and the maintenance of the production machine components can be carried out in time.
本發明之另一目的是在提供一種生產機台組件的多變量預測保養方法與其電腦程式產品,藉由提出了預警機制和死亡相關指數(Death Correlation Index;DCI),以便在生產機台組件可能很快死亡狀態時立即進行維護,並以數據化的方式來呈現生產機台組件進入死亡狀態的可能性。 Another object of the present invention is to provide a multi-variable predictive maintenance method and its computer program product for production machine components, by proposing an early warning mechanism and a death correlation index (Death Correlation Index; DCI), so that the production machine components may Immediately perform maintenance in the dead state, and present the possibility of the production machine components entering the dead state in a digital way.
根據本發明之一態樣,提供一種生產機台組件的多變量預測保養方法。首先,獲得生產機台的組件依序處理複數個工件時所使用之複數組製程資料,其中每一個組製程資料包含複數個參數的數值。然後,獲得分別對應至此些 組製程資料的複數個事件指示值,其中此些事件指示值指出當此組件在處理每一個工件時該組件是否發生異常事件。接著,分別使用複數個演算法將每一組製程資料之此些參數的數值轉換成複數個參數指標的數值。然後,對此些組製程資料中的每一個參數指標與此些事件指示值進行一相關性分析,而獲得分別對應至此些參數指標的複數個相關係數。接著,選取對應至此些相關係數中一最大者的參數指標為一老化特徵,並設定一輔助老化特徵。接著,進行第一判斷步驟,以根據每一個工件對應之此老化特徵的數值,來判斷此組件在處理此些工件時是否處於一生病狀態,其中一旦此組件在處理該些工件之一者時是處於生病狀態時,則將此工件設定為一樣本選取點。然後,進行一多變量建模步驟,此多變量建模步驟包含:使用此樣本選取點前N個工件所對應之N組製程資料中對應至此老化特徵的N個數值以及對應輔助老化特徵的N個數值為一組建模樣本資料,其中N為正整數。接著,對老化特徵與輔助老化特徵執行一格蘭傑因果關係檢驗(Granger causality test)以判斷老化特徵與輔助老化特徵之間的相關性,若不相關則從組建模樣本資料中刪除輔助老化特徵。接著,以使用此組建模樣本資料並根據一多變量時間序列預測演算法來建立一老化特徵預測模型,而獲得依工件生產次序排列之此老化特徵的複數個預測數值。接著,使用每一個工件之一工件處理時間和此組件無法使用時之此老化特徵的一死亡規格值,來將此些預測數值轉換成的複數個剩餘使用壽命(Remaining useful life;RUL)預測值 (RULt),其中t代表第t個工件,t為整數。然後,進行第二判斷步驟,以根據此些剩餘使用壽命預測值(RULt)來判斷此組件是否需要更換或維修。 According to an aspect of the present invention, a multivariable predictive maintenance method for production machine components is provided. Firstly, multiple sets of process data used by the components of the production machine to sequentially process multiple workpieces are obtained, wherein each set of process data contains multiple values of parameters. Then, a plurality of event indication values respectively corresponding to the groups of process data are obtained, wherein the event indication values indicate whether the component has an abnormal event when the component is processing each workpiece. Then, the values of these parameters of each set of process data are converted into the values of a plurality of parameter indexes by using a plurality of algorithms respectively. Then, a correlation analysis is performed between each parameter index in the groups of process data and the event indicator values, so as to obtain a plurality of correlation coefficients respectively corresponding to the parameter indexes. Then, select the parameter index corresponding to the largest one of these correlation coefficients as an aging feature, and set an auxiliary aging feature. Next, a first judging step is performed to determine whether the component is in a sick state when processing the workpieces according to the value of the aging characteristic corresponding to each workpiece, wherein once the component is processing one of the workpieces is in the sick state, set this artifact as a sample selection point. Then, a multivariate modeling step is carried out, and the multivariate modeling step includes: N values corresponding to this aging feature and N values corresponding to the auxiliary aging feature in N sets of process data corresponding to the N workpieces before using this sample selection point The values are a set of modeling sample data, where N is a positive integer. Next, perform a Granger causality test on the aging features and the auxiliary aging features to determine the correlation between the aging features and the auxiliary aging features, and delete the auxiliary aging from the group modeling sample data if there is no correlation feature. Then, use the set of modeling sample data to establish an aging characteristic prediction model according to a multivariate time series prediction algorithm, and obtain a plurality of prediction values of the aging characteristics arranged according to the production sequence of the workpieces. These predicted values are then converted into a plurality of remaining useful life (RUL) predicted values using a workpiece processing time for each workpiece and a death specification value of the aging characteristic when the component becomes unusable (RUL t ), where t represents the tth workpiece, and t is an integer. Then, a second judging step is performed to judge whether the component needs to be replaced or repaired according to the remaining service life prediction values (RUL t ).
在一些實施例中,在前述之第一判斷步驟中,首先以一組轉換公式分別將每一組製程資料之上述老化特徵的數值轉換成分別對應至工件之複數個裝置健康指數(Device Health Index;DHI),此組轉換公式為: In some embodiments, in the aforementioned first judging step, firstly, a set of conversion formulas are used to convert the values of the aforementioned aging characteristics of each group of process data into a plurality of Device Health Indexes (Device Health Indexes) respectively corresponding to workpieces. ;DHI), the conversion formula of this group is:
當; when ;
當; when ;
當; when ;
當; when ;
當; when ;
當; when ;
其中為此些組製程資料之該老化特徵的數值的平均 值,其中為所對應之轉換值; in This is the average value of the values of the aging characteristics of these sets of process data, where for The corresponding conversion value;
Max yT為此些組製程資料之該老化特徵的最大數值,Max yT_mapping 為Max yT所對應之轉換值; Max y T is the maximum value of the aging characteristic of these groups of process data, and Max y T_ mapping is the conversion value corresponding to Max y T ;
Min yT為此些組製程資料之此老化特徵的最小數值,Min yT_mapping 為Min yT所對應之轉換值; Min y T is the minimum value of this aging characteristic of these groups of process data, and Min y T_ mapping is the conversion value corresponding to Min y T ;
LSL為規格下限;LCL為管制下限;UCL為管制上限;USL為規格上限;LSL_mapping 為LSL所對應之轉換值;LCL_mapping 為LCL所對應之轉換值;UCL_mapping 為UCL所對應之轉換值;USL_mapping 為USL所對應之轉換值。 LSL is the lower specification limit; LCL is the lower control limit; UCL is the upper control limit; USL is the upper specification limit; LSL_mapping is the conversion value corresponding to LSL; LCL_mapping is the conversion value corresponding to LCL; UCL_mapping is the conversion value corresponding to UCL Conversion value; USL_mapping is the conversion value corresponding to USL.
然後,依序判斷此些裝置健康指數是否大於或等於一門檻值,並將此些裝置健康指數中最先大於或等於一門檻值之一者所應的工件設定為前述之樣本選取點。 Then, determine whether the device health indices are greater than or equal to a threshold value in sequence, and set the artifact corresponding to the first one of the device health indices greater than or equal to a threshold value as the aforementioned sample selection point.
在一些實施例中,在前述之多變量建模步驟中,首先使用一向量自迴歸模型(Vector AutoRegression Model;VAR)為前述之多變量時間序列預測演算法,來建立前述之老化特徵預測模型。使用偏自相關函數(partial autocorrelation function;PACF)選出此向量自迴歸模型的最大落後期數。然後,對建模樣本資料中之數值進行一白噪音檢定,其中當此些數值是白噪音時,則加入前述之樣本選取點前N+1個工件所對應之又一組製程資料中對應至此老化特徵的數值至建模樣本資料。接著,使用此向量自迴歸模型的最大落後期數,來建立複數個向量自迴歸模型組合。然後,使用一訊息準則演算法,來計算出每一個向量自迴歸模型組合的訊息量。接著,選出此些向量自迴歸模型組合中具有最大訊息量之一者為一最佳模型。 In some embodiments, in the aforementioned multivariate modeling step, a vector autoregression model (Vector AutoRegression Model; VAR) is firstly used as the aforementioned multivariate time series forecasting algorithm to establish the aforementioned aging characteristic prediction model. Use the partial autocorrelation function (PACF) to select the maximum number of lagging periods for this vector autoregressive model. Then, a white noise test is performed on the values in the modeling sample data, and when these values are white noise, they are added to another set of process data corresponding to the N+1 workpieces before the sample selection point to correspond to this Numerical values for aging features to model sample data. Next, use the maximum number of backward periods of this VAR model to create a plurality of VAR model combinations. Then, an information criterion algorithm is used to calculate the information amount of each vector autoregressive model combination. Then, select one of the vector autoregressive model combinations with the largest amount of information as a best model.
在一些實施例中,前述之訊息準則演算法為貝氏訊息準則(Bayesian Information Criteria;BIC)。 In some embodiments, the aforementioned information criterion algorithm is Bayesian Information Criteria (BIC).
在一些實施例中,前述之多變量建模步驟更包含:判斷建模樣本中之數值的變異數是否會隨著時間而越來越大,其中當此些數值的變異數隨著時間而越來越大時,對建模樣本資料之每一個數值進行對數轉換;對此些數值進行一單根檢定(unit root test),以確認依序排列之此些數值是否為穩態狀態,其中當此些數值不是穩態狀態時,對建模樣本資料之每一個數值進行差分轉換。 In some embodiments, the aforementioned multivariate modeling step further includes: judging whether the variance of the values in the modeling samples will increase over time, wherein when the variance of these values increases over time When the value is larger, perform logarithmic transformation on each value of the modeling sample data; perform a unit root test on these values to confirm whether these values arranged in sequence are in a steady state, where When these values are not in a steady state, differential conversion is performed on each value of the modeling sample data.
在一些實施例中,前述之單根檢定為擴充迪基-福勒(Augmented Dickey-Fuller;ADF)檢驗或Kwiatkowski-Phillips-Schmidt-Shin(KPSS)檢定。 In some embodiments, the aforementioned single root test is Augmented Dickey-Fuller (ADF) test or Kwiatkowski-Phillips-Schmidt-Shin (KPSS) test.
在一些實施例中,前述之第二判斷步驟包含: In some embodiments, the aforementioned second determination step includes:
判斷(RUL t -RUL t-1 )/RUL t-1 是否大於或等於一門檻值,而獲得第一結果,其中t-1代表第t-1個工件;判斷RUL t 是否小於一維修緩衝時間,而獲得第二結果,其中前述之組件必須在此維修緩衝時間進行維修;當第一結果和第二結果均為否時,此組件處於生病狀態但未急速惡化,不需進行維修;當第一結果為否而第二結果為是時,此組件未急速惡化但其剩餘使用壽命不足,需進行維修;當第一結果為是而第二結果為否時,此件急速惡化,若處理連續第t+i個工件的每一者的第一結果為是而第二結果為否,則需檢查或維修此組件,其中i為正整數;以及當第一結果和第二結果均為是時,此組件需進行維修。 Judging whether ( RUL t - RUL t - 1 )/ RUL t - 1 is greater than or equal to a threshold value, and obtaining the first result, wherein t - 1 represents the t-1th workpiece; judging whether RUL t is less than a maintenance buffer time , and the second result is obtained, wherein the aforementioned components must be repaired during this repair buffer time; when both the first result and the second result are no, the component is in a sick state but not deteriorating rapidly, and maintenance is not required; when the second When the first result is no and the second result is yes, the component has not deteriorated rapidly but its remaining service life is insufficient, and maintenance is required; when the first result is yes and the second result is no, the component has deteriorated rapidly. If the treatment continues For each of the t+i-th workpieces, the first result is yes and the second result is no, the component needs to be inspected or repaired, where i is a positive integer; and when both the first result and the second result are yes , this component requires repair.
在一些實施例中,前述之第二判斷步驟包含: In some embodiments, the aforementioned second determination step includes:
以一組轉換公式分別將每一組製程資料之前述老化特徵的數值轉換成分別對應至工件之前述組件的複數個死亡相關指數(Death Correlation Index;DCI),此組轉換公式為: Using a set of conversion formulas to convert the values of the aforementioned aging characteristics of each set of process data into a plurality of death correlation indices (Death Correlation Index; DCI) respectively corresponding to the aforementioned components of the workpiece, the set of conversion formulas are:
其中y death 為此組件在死亡狀態時所對應之此老化特徵的數值,y t-1 為此組件在處理第t-1個工件時所對應之此老化特徵的數值,conv為共變異數計算,Var為變異數計算; Among them, y death is the value of the aging feature corresponding to the component in the dead state, y t - 1 is the value of the aging feature corresponding to the component when processing the t-1th workpiece, and conv is the covariance calculation , Var is the variation calculation;
當DCIt大於一門檻值時,代表此組件在處理第t個工件時接近死亡狀態,其中此門檻值的計算是根據DCIt的標準差。 When the DCI t is greater than a threshold value, it means that the component is close to a dead state when processing the t-th job, wherein the calculation of the threshold value is based on the standard deviation of the DCI t .
在一些實施例中,前述之組件為一加熱器、一壓力模組、一節流閥、一無油襯套或一軸承,該些參數包含:一軸偏度、一閥開度、一振動振幅、一驅動電壓、一驅動電流、一溫度和一壓力。 In some embodiments, the aforementioned component is a heater, a pressure module, a throttle valve, an oil-free bushing or a bearing, and these parameters include: a shaft deflection, a valve opening, a vibration amplitude, A driving voltage, a driving current, a temperature and a pressure.
在一些實施例中,前述之參數指標包含:一轉換至頻域後之k倍頻(其中k大於0)、一整體相似度指標(Global Similarity Index;GSI)、一統計資料分佈的峰度(kurtosis)、一統計資料分佈的偏度(skewness)、一標準差、一均方根(root mean square)、一平均值、一最大值和一最小值。 In some embodiments, the aforesaid parameter index includes: k multiplied frequency (wherein k is greater than 0) after converting to the frequency domain, an overall similarity index (Global Similarity Index; GSI), a kurtosis of a statistical data distribution ( kurtosis), a statistical distribution of skewness (skewness), a standard deviation, a root mean square (root mean square), a mean, a maximum and a minimum.
根據本發明之又一態樣,提供一種電腦程式產品,當電腦載入此電腦程式產品並執行後,可完成前述之標的裝置的基底多變量預測保養方法。 According to another aspect of the present invention, a computer program product is provided. After the computer program product is loaded and executed, the basic multivariable predictive maintenance method of the aforementioned target device can be completed.
因此,應用本發明實施例,可即時並準確地預測生產機台組件的RUL,而可及時地進行生產機台組件的維修;並可在生產機台組件可能很快死亡狀態時立即進行維護,且以數據化的方式來呈現生產機台組件進入死亡狀態的可能性。 Therefore, by applying the embodiment of the present invention, the RUL of the production machine assembly can be predicted in real time and accurately, and the maintenance of the production machine assembly can be performed in time; and the maintenance can be performed immediately when the production machine assembly may die soon, And the possibility of the production machine components entering the dead state is presented in a digital way.
200:製程資料 200: Process information
210:資料品質檢查 210: Data quality check
220:轉換成參數指標 220: Convert to parameter index
222,224,226,228:曲線 222,224,226,228: curves
230:演算法庫 230: Algorithm library
240:DHI模組 240: DHI module
250:第一判斷步驟(DHI<0.7) 250: The first judgment step (DHI<0.7)
260:應用多變量之RUL預測建模步驟 260: Applying multivariate RUL predictive modeling steps
270:預警模式 270: Early warning mode
280:DCI模式 280: DCI mode
300:選取建模樣本資料 300: Select modeling sample data
302:建模樣本中之數值的變異數隨時間而越來越大? 302: Does the variance of the values in the modeling sample increase over time?
304:對建模樣本資料之數值進行對數轉換 304: Perform logarithmic transformation on the numerical values of the modeling sample data
306:建模樣本資料之數值是否為穩態狀態 306: Whether the value of the modeling sample data is a steady state
308:對建模樣本資料之數值進行差分轉換 308: Perform differential conversion on the numerical value of the modeling sample data
309-1:執行格蘭傑因果關係檢驗 309-1: Perform Granger Causality Tests
309-2:從組建模樣本資料中刪除輔助老化特徵(zT) 309-2: Remove Auxiliary Aging Features from Group Modeling Sample Data (z T )
310:使用PACF選出VAR(p)模型的最大落後期數 310:Using PACF to select the maximum backward period of VAR( p ) model
312:對建模樣本資料之數值進行白噪音檢定 312: Perform white noise verification on the numerical values of the modeling sample data
314:加入又一老化特徵的數值至建模樣本資料 314: Add the value of another aging feature to the modeling sample data
316:建立VAR模型組合 316: Establish VAR model combination
318:計算出VAR模型組合的訊息量 318: Calculate the amount of information of the VAR model combination
320:選出最佳VAR模型 320: Select the best VAR model
324:去除最佳VAR模型中不顯著的預測成分 324:Removing insignificant predictive components in the best VAR model
326:對最佳VAR模型的殘差進行檢定 326: Test the residual of the best VAR model
328:確認最佳VAR模型 328:Confirm the best VAR model
400:RUL t 是否下降大於或等於門檻值 400: Whether the RUL t drop is greater than or equal to the threshold
410:RUL t 是否小於維修緩衝時間 410: Whether RUL t is less than the maintenance buffer time
420:RUL t 是否小於維修緩衝時間 420: Whether RUL t is less than the maintenance buffer time
510,520:預測值 510,520: predicted value
530:實際值 530: actual value
540:死亡規格值 540: death specification value
550:生病規格值 550: sick specification value
560,570:RUL 560,570:RUL
580:DCI門檻值 580:DCI Threshold
DCI:死亡相關指數 DCI: Death Correlation Index
RUL:剩餘使用壽命 RUL: remaining useful life
TSP:時間序列預測演算法 TSP: Time Series Forecasting Algorithm
TSPMVA:多變量時間序列預測演算法 TSP MVA : Multivariate Time Series Forecasting Algorithm
為了更完整了解實施例及其優點,現參照結合所附圖式所做之下列描述,其中 For a more complete understanding of the embodiments and advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings, in which
〔圖1A〕為繪示根據本發明一些實施例之用以說明生產機台組件的多變量預測保養方法的方塊示意圖; [FIG. 1A] is a schematic block diagram illustrating a multi-variable predictive maintenance method for production machine components according to some embodiments of the present invention;
〔圖1B〕為繪示根據本發明一些實施例之用以說明事件指示值與參數指標(平均開度)的關係; [FIG. 1B] is a diagram illustrating the relationship between event indication value and parameter index (average opening) according to some embodiments of the present invention;
〔圖1C〕為繪示根據本發明一些實施例之用以說明事件指示值與參數指標(1/4倍頻)的關係; [FIG. 1C] is a diagram illustrating the relationship between an event indication value and a parameter index (1/4 octave frequency) according to some embodiments of the present invention;
〔圖2A〕和〔圖2B〕為繪示根據本發明一些實施例之多變量建模步驟的流程示意圖; [FIG. 2A] and [FIG. 2B] are flow diagrams illustrating the steps of multivariate modeling according to some embodiments of the present invention;
〔圖3A〕為繪示本發明一實施例之老化特徵之偏自相關函數的示意圖; [FIG. 3A] is a schematic diagram showing the partial autocorrelation function of the aging characteristics of an embodiment of the present invention;
〔圖3B〕為繪示本發明一實施例之輔助老化特徵之偏自相關函數的示意圖; [FIG. 3B] is a schematic diagram showing the partial autocorrelation function of the assisted aging feature according to an embodiment of the present invention;
〔圖4〕為繪示根據本發明一些實施例之用以說明預警模式的方塊示意圖; [FIG. 4] is a schematic block diagram illustrating an early warning mode according to some embodiments of the present invention;
〔圖5〕為繪示組件之軸偏度的預測結果; [Figure 5] shows the prediction results of the axial deflection of the component;
〔圖6〕為繪示組件之RUL的預測結果; [Figure 6] shows the prediction results of the RUL of the components;
〔圖7〕為繪示組件之一DCI(TSP)的預測結果;以及 [Figure 7] shows the prediction result of DCI(TSP), one of the components; and
〔圖8〕為繪示組件之另一DCI(TSPMVA)的預測結果。 [Fig. 8] shows the prediction result of another DCI (TSP MVA ) of the module.
以下仔細討論本發明的實施例。然而,可以理解的是,實施例提供許多可應用的發明概念,其可實施於各 式各樣的特定內容中。所討論之特定實施例僅供說明,並非用以限定本發明之範圍。 Embodiments of the invention are discussed in detail below. It should be appreciated, however, that the embodiments provide many applicable inventive concepts that can be implemented in various in a wide variety of specific content. The specific embodiments discussed are illustrative only and do not limit the scope of the invention.
因單變數無法表徵機台老化的訊息全貌,故為了解決單變量失準的問題,本發明實施例提出了多變量時間序列預測演算法(TSPMVA),並使用應用訊息準則演算法來建立最佳的向量自迴歸模型(Vector AutoRegression Model;VAR),以預測生產機台組件意外停機之複雜的未來趨勢。另外,習知的時間序列預測(Time Series Prediction;TSP)技術只採用一個變數來做預測,則預測準確度有限,而本發明之多變量的時間序列預測擴充了只能使用一個變數的限制,所預測的老化特徵不僅取決於過去的老化特徵,也依賴其他特徵(輔助老化特徵),因此採用多變數可以提升預測準確度。此外,本發明實施例還提出了預警機制,以便在生產機台組件可能很快死亡時立即進行維護,並提供死亡相關指數(DCI),以數據化來呈現生產機台組件進入死亡的可能性。 Because a single variable cannot represent the full picture of machine aging information, in order to solve the problem of single variable inaccuracy, the embodiment of the present invention proposes a multivariate time series prediction algorithm (TSP MVA ), and uses the application information criterion algorithm to establish the most The best vector autoregression model (Vector AutoRegression Model; VAR) to predict the complex future trend of unexpected downtime of production machine components. In addition, the known time series prediction (Time Series Prediction; TSP) technology only uses one variable to make predictions, and the prediction accuracy is limited, while the multivariate time series prediction of the present invention expands the limitation that only one variable can be used, The predicted aging characteristics depend not only on past aging characteristics, but also on other characteristics (auxiliary aging characteristics), so the use of multiple variables can improve the prediction accuracy. In addition, the embodiment of the present invention also proposes an early warning mechanism, so that maintenance can be performed immediately when the production machine components may die soon, and a death correlation index (DCI) is provided to present the possibility of the production machine components entering death with data .
請參照圖1A,圖1A為繪示根據本發明一些實施例之用以說明生產機台組件的多變量預測保養方法的方塊示意圖。首先,獲得生產機台的組件依序處理複數個工件時所使用之複數組製程資料200,其中每一組製程資料200包含複數個參數的數值。生產機台為在一生產線上處理工件的機台。生產線可為例如:半導體生產線、TFT-LCD生產線、工具機加工生產線等;工件可為例如:晶圓、玻璃基板、輪框、螺絲等;機台可為例如:薄膜沉積機台、正光阻塗佈機台、曝光機台、顯影機台、蝕刻機台、光阻去除機台、工
具機等;組件可為例如:加熱器、壓力模組、節流閥、無油襯套或軸承;參數可為例如:閥開度、振動振幅、驅動電壓、驅動電流、溫度和/或壓力等。以上所述僅係舉例說明,故本發明實施例並不在此限。值得一提的是,每一組製程資料200之每一個參數的數值為一段工件處理時間中的時序資料值,即參數數值對時間的曲線。
Please refer to FIG. 1A . FIG. 1A is a schematic block diagram illustrating a multi-variable predictive maintenance method for production machine components according to some embodiments of the present invention. Firstly, multiple groups of
接著,對製程資料200進行資料品質檢查(步驟210),以確認製程資料200的品質是否優良。若製程資料200的品質不佳,則須獲得生產機台的組件依序處理其他工件時所使用之製程資料。步驟210可採用類似於美國專利前案第8095484B2號所使用的製程資料品質評估方法。本發明之實施例引用此美國專利前案第8095484B2號之相關規定(Incorporated by reference)。
Next, a data quality check is performed on the process data 200 (step 210 ) to confirm whether the quality of the
然後,分別使用一演算法庫230中之複數個演算法將每一組製程資料之每一個參數的數值轉換成複數個參數指標的數值(步驟220)。此些參數指標包含:轉換至頻域後之k倍頻(其中k大於0)、整體相似度指標(Global Similarity Index;GSI)、統計資料分佈的峰度(kurtosis)、統計資料分佈的偏度(skewness)、標準差(STD)、均方根(root mean square;RMS)、平均值(Average)、最大值(Max)和最小值(Min),而此些參數指標的轉換方式可採用一移動視窗視窗法(Moving Window;MW)來決定樣本的數目。
Then, use a plurality of algorithms in an
例如:每一組製程資料200具有一組閥開度的時序資料、一組振動振幅的時序資料。演算法庫230中的統計製程控制(Statistical Process Control;SPC)可將此
組閥開度的時序資料轉換成一峰度、一偏度和一標準差;演算法庫230中的整體相似度指標(Global Similarity Index;GSI)演算法可將此組閥開度的時序資料轉換成一GSI值;演算法庫230中的時頻轉換演算法可將此組振動振幅的時序資料轉換成一1/4倍頻、一1/2倍頻、一2倍頻、一4倍頻等參數指標的數值。GSI演算法可參照美國專利前案第8095484B2號。以上所述之演算法庫230中的演算法僅係舉例說明,故本發明實施例並不在此限。
For example: each set of
另一方面,本方法獲得分別對應至此些組製程資料的複數個事件指示值,其中這些事件指示值指出當生產機台組件在處理每一個工件時生產機台組件是否發生異常事件。請參照圖1B,圖1B為繪示根據本發明一些實施例之用以說明事件指示值與參數指標(平均開度)的關係,其中曲線222指出生產機台組件在處理各工件時之平均開度;曲線224指出生產機台組件在處理各工件時是否有異常事件發生。如圖1B所示,生產機台組件在處理第289個工件之前,均無異常事件發生,其事件指示值可為例如“0”;生產機台組件在處理第289個工件之後,有異常事件發生,其事件指示值可為例如“1”。請參照圖1C,圖1C為繪示根據本發明一些實施例之用以說明事件指示值與參數指標(1/4倍頻)的關係,其中曲線226指出生產機台組件在處理各工件時在1/4倍頻的振動幅度值;曲線228指出生產機台組件在處理各工件時是否有異常事件發生。如圖1C所示,生產機台組件在處理第287個工件之前,均無異常事件發生,其事件指
示值可為例如“0”;生產機台組件在處理第287個工件之後,有異常事件發生,其事件指示值可為例如“1”。
On the other hand, the method obtains a plurality of event indication values respectively corresponding to the sets of process data, wherein the event indication values indicate whether an abnormal event occurs in the production machine assembly when the production machine assembly is processing each workpiece. Please refer to FIG. 1B. FIG. 1B is a diagram illustrating the relationship between an event indication value and a parameter index (average opening) according to some embodiments of the present invention, wherein the
然後,對此些組製程資料中的每一個參數指標與事件指示值進行一相關性分析,而獲得分別對應至此些參數指標的複數個相關係數,如表一所示。接著,選取對應至此些相關係數中一最大者的參數指標為一老化特徵(yT),如表一所示之開度。此外,也可以挑選一輔助老化特徵,此輔助老化特徵可以與上述的老化特徵(yT)結合,一起用來預測下個時間點的老化特徵。由於老化特徵(yT)與輔助老化特徵合併成為一個向量,在此提出的方法也可稱為向量自迴歸模型(Vector AutoRegression Model;VAR)。輔助老化特徵可以是表一除了開度以外的任意其他特徵(如軸偏度),在一些實施例中可以人為的挑選輔助老化特徵,例如挑選溫度做為輔助老化特徵。在一些實施例中也可以用任意的特徵選擇方法,例如自適應增強(Adaptive Boosting),但本揭露並不在此限。 Then, a correlation analysis is performed between each parameter index and event indication value in these sets of process data, and a plurality of correlation coefficients respectively corresponding to these parameter indexes are obtained, as shown in Table 1. Next, select the parameter index corresponding to the largest of these correlation coefficients as an aging characteristic (y T ), as shown in Table 1. In addition, an auxiliary aging feature can also be selected, and this auxiliary aging feature can be combined with the aforementioned aging feature (y T ) to predict the aging feature at the next time point. Since the aging feature (y T ) and the auxiliary aging feature are merged into a vector, the method proposed here can also be called a vector autoregression model (Vector AutoRegression Model; VAR). The auxiliary aging feature can be any other feature (such as axis deflection) in Table 1 except the opening degree. In some embodiments, the auxiliary aging feature can be selected artificially, for example, temperature can be selected as the auxiliary aging feature. In some embodiments, any feature selection method, such as Adaptive Boosting, can also be used, but the present disclosure is not limited thereto.
接著,進行第一判斷步驟250,以根據每一個工件對應之此老化特徵的數值,來判斷生產機台組件在處理此些工件時是否處於一生病狀態,其中一旦生產機台組件在處一個工件時是處於生病狀態時,則將此工件設定為一樣本選取點(t)。以下舉例說明第一判斷步驟的一種實施方式,然本發明實施例並不在此限。如圖1A所示,第一判斷步驟中,首先,將此些組製程資料之老化特徵(yT)的數值輸入至裝置健康指數(Device Health Index;DHI)模組240,DHI模組240以一組轉換公式分別將每一組製程資料之此老化特徵(yT)的數值轉換成分別對應至工件之複數個裝置健康指數(DHI)。然後,依序判斷此些裝置健康指數是否大於或等於一門檻值(例如:0.7),並將此些裝置健康指數中最先大於或等於一門檻值之一者所應的工件設定為樣本選取點。此組轉換公式為:
Next, the
當; when ;
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其中為此些組製程資料之此老化特徵的數值的平均值, 其中為所對應之轉換值; in is the average value of the values of this aging characteristic for these sets of process data, where for The corresponding conversion value;
Max yT為此些組製程資料之此老化特徵的最大數值,Max yT_mapping 為Max yT所對應之轉換值; Max y T is the maximum value of this aging characteristic of these groups of process data, and Max y T_ mapping is the conversion value corresponding to Max y T ;
Min yT為此些組製程資料之此老化特徵的最小數值,Min yT_mapping 為Min yT所對應之轉換值; Min y T is the minimum value of this aging characteristic of these groups of process data, and Min y T_ mapping is the conversion value corresponding to Min y T ;
LSL為規格下限;LCL為管制下限;UCL為管制上限;USL為規格上限;LSL_mapping 為LSL所對應之轉換值;LCL_mapping 為LCL所對應之轉換值;UCL_mapping 為UCL所對應之轉換值;USL_mapping 為USL所對應之轉換值。DHI演算法參照類似於美國專利前案第10,242,319B2號。本發明之實施例引用此美國專利前案第10,242,319B2號之相關規定(Incorporated by reference)。 LSL is the lower specification limit; LCL is the lower control limit; UCL is the upper control limit; USL is the upper specification limit; LSL_mapping is the conversion value corresponding to LSL; LCL_mapping is the conversion value corresponding to LCL; UCL_mapping is the conversion value corresponding to UCL Conversion value; USL_mapping is the conversion value corresponding to USL. The DHI algorithm is similar to US Patent No. 10,242,319B2. The embodiments of the present invention refer to relevant provisions of the US Patent No. 10,242,319B2 (Incorporated by reference).
接著,進行一多變量建模步驟260。首先,使用樣本選取點(t)前N個工件所對應之N組製程資料中對應至此老化特徵(yT)的N個數值以及對應輔助老化特徵的N個數值做為一組建模樣本資料,其中N為正整數。然後,對老化特徵(yT)與輔助老化特徵執行一格蘭傑因果關係檢驗(Granger causality test)以判斷老化特徵(yT)與輔助老化特徵之間的相關性,若不相關則從此組建模樣本資料中刪除輔助老化特徵。例如:假設老化特徵有一個(如SX1),而後
選的輔助老化特徵有兩個(如SY1、SZ1),其中輔助老化特徵SY1與老化特徵(yT)有相關,則保留;輔助老化特徵SZ1與老化特徵(yT)不相關,則刪除,進而使此組建模樣本資料對應老化特徵SX1與輔助老化特徵SY1(如圖3A、3B所示)。在一實施例中,老化特徵SX1與輔助老化特徵SY1、SZ1可為軸偏度,軸偏度為工件(如軸承)的軸所偏離的角度。老化特徵SX1為工件的軸於X平面所偏離的角度,輔助老化特徵SY1為工件的軸於Y平面所偏離的角度,輔助老化特徵SZ1為工件的軸於Z平面所偏離的角度,但本發明不以此為限;接著,以使用此組建模樣本資料並根據一多變量時間序列預測演算法來建立一老化特徵預測模型,而獲得依工件生產次序排列之此老化特徵(yT)的複數個預測數值。接著,使用每一個工件之一工件處理時間和生產機台組件無法使用時之此老化特徵(yT)的一死亡規格值,來將此些預測數值轉換成的複數個剩餘使用壽命(Remaining useful life;RUL)預測值(RULt),其中t代表第t個工件,t為整數。值得一提的是,本發明使用多變量時間序列預測演算法及多變量建模步驟260之緣由係因習知技術只採用一個變數來做預測,其預測準確度有限。而本發明之多變量的時間序列預測擴充了只能使用一個變數的限制,所預測的老化特徵不僅取決於過去的老化特徵,也依賴其他特徵(即輔助老化特徵),因此採用多變數以提升預測準確度。至於多變量時間序列預測演算法和詳細的多變量建模步驟260將於後說明。
Next, a
然後進行一第二判斷步驟,以根據此些剩餘使用壽命預測值(RULt)來判斷生產機台組件是否需要更換或維修。在一些實施例中,第二判斷步驟包含有預警模式270和DCI模式280。至於預警模式270和DCI模式280將於後說明。
Then a second judging step is performed to judge whether the components of the production machine need to be replaced or repaired according to the remaining service life prediction values (RUL t ). In some embodiments, the second determination step includes an
請參照圖2A和圖2B,圖2A和圖2B為繪示根據本發明一些實施例之多變量建模步驟260的流程示意圖。首先,進行步驟300,以選取使用前述之樣本選取點(t)(即DHI>0.7之工件)前N個工件所對應之N組製程資料中對應至此老化特徵(yT)的N個數值(老化特徵實際值)以及對應至輔助老化特徵的N個數值做為一組建模樣本資料(Y M ),其中N為正整數,例如30,即DHI>0.7之工件前30個工件,建模樣本資料中的老化特徵表示為Y M ={y t-30,y t-29,...,y t-2,y t-1},而輔助老化特徵表示為Z M ={z t-30,z t-29,...,z t-2,z t-1}。
Please refer to FIG. 2A and FIG. 2B . FIG. 2A and FIG. 2B are schematic flowcharts illustrating the
接著,進行步驟302,以判斷此組建模樣本中老化特徵之數值的變異數是否會隨著時間而越來越大。換言之,若y t =(1+α)×y t-1 ,其中α大於0,代表y t 隨時間增加,Var(y t )隨α成長,則進行步驟304,否則進行步驟306。在步驟304中,對此組建模樣本資料之每一個數值進行對數轉換,以強迫資料的增加率分布具有某種程度的規則性,然後進行步驟306。
Next,
在步驟306中,對此組建模樣本中之數值進行一單根檢定(unit root test),以確認此組建模樣本中依序
排列之數值是否為穩態狀態,其中當此些數值不是穩態狀態時,對此組建模樣本資料之每一個數值進行差分轉換(步驟308)。確認時序是否為穩態狀態的演算法有擴充迪基-福勒檢驗(Augmented Dickey-Fuller test;ADF)檢驗或Kwiatkowski-Phillips-Schmidt-Shin(KPSS)檢定等。ADF檢驗和KPSS檢定的公式與應用方法是習於此技藝之人士所知,故不在此贅述。
In
當依序排列之數值不為穩態狀態(步驟306的結果為否)時,進行步驟308,以對此組建模樣本資料之每一個數值進行差分轉換,以使在依序排列之數值(時序)達到穩態。差分轉換的公式為:▽ d y t-i =y t-i -y t-i-1,▽ d z t-i =z t-i -z t-i-1。當依序排列之數值為穩態狀態(步驟306的結果為是)時,進行步驟309-1,對老化特徵(yT)與輔助老化特徵(zT)執行格蘭傑因果關係檢驗(Granger causality test)以判斷老化特徵(yT)與輔助老化特徵(zT)之間的相關性,若不相關則在步驟309-2從組建模樣本資料中刪除輔助老化特徵(zT),若相關則保留輔助老化特徵(zT)。本領域具有通常知識者當可理解格蘭傑因果關係檢驗,在此並不詳細贅述。
When the values arranged in sequence are not in a steady state (the result of
接下來進行步驟310,以使用偏自相關函數(partial autocorrelation function;PACF)選出向量自迴歸(VAR(p))模型的最大落後期數p。其公式為:
Next,
B=arg max(ρρ k ). (1); B = arg max ( ρρ k ). (1);
γ k =cov(y t ,y t-k )=E(y t -μ)(y t-k -μ) (3-1); γ k = cov ( y t , y t - k ) = E ( y t - μ )( y t - k - μ ) (3-1);
ρρ k =Corr(y t ,y t-k |y t-1,y t-2,...,y t-k+1) (3-2); ρρ k = Corr ( y t , y t - k | y t -1 , y t -2 ,..., y t - k +1 ) (3-2);
其中B為與y t-1 相關之最大PACF的時間(工件號碼);Var(y t )=Var(y t+k )=E(y t -μ)2=γ 0.;E[.]為期望值函數;μ為y t 的平均值(mean)。舉例來說,參閱圖3A與圖3B,其中圖3A為繪示本發明一實施例之老化特徵SX1之偏自相關函數的示意圖;圖3B為繪示本發明一實施例之輔助老化特徵SY1之偏自相關函數的示意圖。老化特徵SX1與輔助老化特徵SY1為軸偏度。由圖3A與圖3B可知,老化特徵SX1經PACF選出之向量自迴歸(VAR(p))模型的最大落後期數p為3,而輔助老化特徵SY1經PACF選出之向量自迴歸(VAR(p))模型的最大落後期數p為3。藉此,本發明透過PACF可決定VAR(p)模型的最大落後期數p。 Where B is the time of the maximum PACF (workpiece number) related to y t - 1 ; Var ( y t ) = Var ( y t + k ) = E( y t - μ ) 2 = γ 0 .; E [. ] is the expected value function; μ is the mean value (mean) of y t . For example, refer to FIG. 3A and FIG. 3B , wherein FIG. 3A is a schematic diagram illustrating the partial autocorrelation function of the aging feature SX1 of an embodiment of the present invention; FIG. 3B is a schematic diagram of the auxiliary aging feature SY1 of an embodiment of the present invention. Schematic representation of the partial autocorrelation function. The aging feature SX1 and the auxiliary aging feature SY1 are axis skewness. It can be seen from Figure 3A and Figure 3B that the maximum backward period p of the vector autoregressive (VAR( p )) model selected by the aging feature SX1 through PACF is 3, and the vector autoregressive (VAR( p ) model selected by the auxiliary aging feature SY1 by PACF )) The maximum number of backward periods p for the model is 3. Thus, the present invention can determine the maximum backward period p of the VAR( p ) model through PACF.
接著,進行步驟312,以對此組建模樣本資料中之各數值(老化特徵的數值及輔助老化特徵的數值)進行白噪音檢定,白噪音檢定的演算法有Ljung-Box檢定等。步驟312的主要目的在確認時序是否為白噪音(即狀態與狀態之間彼此不相關)。當此些數值是白噪音時,此組建模樣本資料需要多一點資料,故加入樣本選取點前N+1個工件所對應之又一組製程資料中對應至老化特徵的數值(老化特徵實際值,即y t-(N+1) 或y t-31 )與輔助老化特徵的數值(輔助老化特徵實際值,即z t-(N+1) 或z t-31 )至此組建模樣本資料(步驟314)。
Next, proceed to step 312 to perform a white noise test on each value (the value of the aging feature and the value of the auxiliary aging feature) in the set of modeling sample data. The algorithm of the white noise test includes Ljung-Box test and the like. The main purpose of
然後,進行步驟316,建立複數個VAR(p)模型組合,並透過VAR(p)模型的最大落後期數p決定VAR(p) 模型組合之數量。例如:當前述VAR(p)模型的最大落後期數p為3時,建立3種模型組合:VAR(1)、VAR(2)、VAR(3)。VAR(1)、VAR(2)、VAR(3)分別為VAR(p)之p等於1、2、3。以下說明VAR(p)模型。 Then, go to step 316, establish a plurality of VAR( p ) model combinations, and determine the number of VAR( p ) model combinations according to the maximum backward period p of the VAR( p ) model. For example: when the maximum backward period p of the aforementioned VAR( p ) model is 3, three model combinations are established: VAR(1), VAR(2), and VAR(3). VAR(1), VAR(2), and VAR(3) are VAR( p ) where p is equal to 1, 2, and 3, respectively. The VAR( p ) model will be described below.
VAR(p)模型的定義為: The VAR( p ) model is defined as:
其中為在時間點t(第t個工件)的老化特徵預測值;b為常數向量;φ i 為在時間點(第t個工件)之VAR(p)模型的最小平方預估係數,i=1,2,...,p;y t-i 為在時間點t-i(第t-i個工件)的老化特徵實際值(對應圖3A之老化特徵SX1);z t-i 為在時間點t-i(第t-i個工件)的輔助老化特徵實際值(對應圖3B之輔助老化特徵SY1);β i 為所要訓練(尋找)的係數;ε t 為在時間點t(第t個工件)的白噪音項,亦即誤差向量。如果在步驟309-2中刪除了輔助老化特徵,則在式子(4)中的係數β i 都設為0。 in is the predicted value of aging characteristics at time point t (the t- th workpiece); b is a constant vector; φ i is the least square prediction coefficient of the VAR( p ) model at the time point ( t- th workpiece), i =1 ,2,..., p ; y t - i is the actual value of aging characteristics at time point t - i (the t - ith workpiece) (corresponding to the aging characteristics SX1 in Figure 3A); z t - i is the aging characteristic at time The actual value of the auxiliary aging feature at point t - i (the t - ith workpiece ) ( corresponding to the auxiliary aging feature SY1 in Figure 3B); β i is the coefficient to be trained (searched); artifacts), that is, the error vector. If the auxiliary aging feature is deleted in step 309-2, the coefficients β i in the formula (4) are all set to 0.
然後,進行步驟318,以使用一訊息準則演算法,來計算出每一個VAR(p)模型組合的訊息量,其中訊息準則演算法為貝氏訊息準則(Bayesian Information Criteria;BIC)。BIC演算法的公式如下: Then, proceed to step 318 to use an information criterion algorithm to calculate the information amount of each VAR( p ) model combination, wherein the information criterion algorithm is Bayesian Information Criteria (BIC). The formula of the BIC algorithm is as follows:
其中SSE為誤差平方的和;M為建模樣本資料的大小。 Where SSE is the sum of squared errors; M is the size of the modeling sample data.
表二為以BIC演算法來計算出每一個VAR(p)模型組合VAR(1)、VAR(2)、VAR(3)的訊息量的舉例說明。 Table 2 is an example for calculating the information volume of each VAR( p ) model combination VAR(1), VAR(2), and VAR(3) using the BIC algorithm.
接著,進行步驟320,以選出此些VAR(p)模型組合VAR(1)、VAR(2)、VAR(3)中具有最大訊息量(即最小BIC)之一者為一最佳模型,例如:VAR(1)。 Next, proceed to step 320 to select one of the VAR( p ) model combinations VAR(1), VAR(2), and VAR(3) with the largest amount of information (i.e. the smallest BIC) as an optimal model, for example : var(1).
然後,進行步驟322,以去除最佳模型中不顯著預測子(參數)。當預測子的預估係數大於95%的信心區間時,此預測子不顯著,應予以去除。在正常分佈的假設下,95%的信心區間等於1.96,最佳模型中不顯著預測子(參數)的判斷公式如下: Then, step 322 is performed to remove insignificant predictors (parameters) in the best model. When the prediction coefficient of the predictor is greater than the 95% confidence interval, the predictor is not significant and should be removed. Under the assumption of normal distribution, the 95% confidence interval is equal to 1.96, and the judgment formula of the insignificant predictor (parameter) in the best model is as follows:
|φ i |>1.96×s.e.(φ i ) (7); | φ i |>1.96× s . e .( φ i ) (7);
|β i |>1.96×s.e.(β i ) (8); | β i |>1.96× s . e .( β i ) (8);
其中i=1,2,...,p;s.e.(.)為係數的標準差。 Where i =1,2,..., p ; s . e .(.) is the standard deviation of the coefficient.
接著,進行步驟324,以在除不顯著預測子(參數)後針對VAR(p)模型重行估計權重。
Next,
然後,進行步驟326,以對重新估計之模型的殘差進行檢定,此檢定的演算法有Ljung-Box檢定等。重新估計之模型的殘差均已被解釋時,確認重新估計之模型為最佳模型(步驟328),並以此獲得依工件生產次序排列之老化特徵(yT)的複數個預測數值。接著,進行步驟330,以使用生產機台組件處理每一個工件的工件處理時間(dt)和生產機台組件無法使用時之老化特徵(yT)的死亡規格值,來將 該些預測數值轉換成的複數個剩餘使用壽命(Remaining useful life;RUL)預測值(RUL t ),其公式為RUL t =k D -k t .,其中t代表第t個工件;k t 代表第t個工件所對應的時間點(即第7×dt),t為整數k D 代表老化特徵(yT)的死亡規格值所對應的時間點。 Then, go to step 326 to test the residual error of the re-estimated model. The algorithm for this test includes Ljung-Box test and the like. When the residuals of the re-estimated model have been explained, it is confirmed that the re-estimated model is the best model (step 328 ), and a plurality of predicted values of the aging characteristics (y T ) arranged according to the production order of the workpieces are obtained accordingly. Next, step 330 is performed to convert these predicted values by using the workpiece processing time ( dt ) for processing each workpiece of the production tool assembly and the death specification value of the aging characteristic (y T ) of the production tool assembly when it cannot be used. The complex remaining useful life (Remaining useful life; RUL) prediction value ( RUL t ), the formula is RUL t = k D - k t ., where t represents the t -th workpiece; k t represents the t -th workpiece The corresponding time point (ie the 7th × dt ), where t is an integer k D represents the time point corresponding to the death standard value of the aging characteristic (y T ).
在獲得RUL預測值(RUL t )後,進行第二判斷步驟,以根據RUL t 來判斷生產機台組件是否需要更換或維修。如圖1A所示,在一些實施例中,第二判斷步驟包含有預警模式270和DCI模式280。
After the RUL predicted value ( RUL t ) is obtained, a second judgment step is performed to judge whether the components of the production machine need to be replaced or repaired according to the RUL t . As shown in FIG. 1A , in some embodiments, the second determination step includes an
當RUL預測值(RUL t )有大幅度的下降或在靠近死亡狀態震盪時,使用者難以判斷生產機台組件是否需要更換或維修。因此,本發明實施例提出預警模式來解決此問題。請參照圖4,圖4為繪示根據本發明一些實施例之用以說明預警模式的方塊示意圖。首先,在第一階中進行步驟400,以判斷目前的RUL t 相較於前一個RUL t-1 是否下降大於或等於一門檻值(例如30%),即(RUL t-1-RUL t )/RUL t-1 0.3是否成立?當步驟400的結果為是時,在第一階中進行步驟410或420,以判斷RUL t 是否小於一維修緩衝時間(Buffer Time;BT),而獲得一第二結果,其中BT係由生產機台組件的原廠提供,當生產機台組件異常時,必須在此維修緩衝時間(BT)對生產機台組件進行維修或更換。當第一結果和第二結果均為否時,生產機台組件處於生病狀態但未急速惡化,不需進行維修,而顯示例如綠燈。當第一結果為否而第二結果為是時,生產機台組件未急速惡化但其剩餘使用壽命
不足,需進行維修,而顯示例如藍燈。當第一結果為是而第二結果為否時,生產機台組件急速惡化,而顯示例如褐燈。若生產機台組件處理連續第t+i個工件之每一者均顯示例如褐燈時,則需檢查或維修生產機台組件,其中i為正整數。當第一結果和第二結果均為是時,生產機台組件需進行維修,而顯示例如紅燈。
When the predicted value of RUL ( RUL t ) drops sharply or oscillates close to the state of death, it is difficult for the user to judge whether the components of the production machine need to be replaced or repaired. Therefore, the embodiment of the present invention proposes an early warning mode to solve this problem. Please refer to FIG. 4 , which is a schematic block diagram illustrating an early warning mode according to some embodiments of the present invention. First,
以下以組件的軸偏度(老化特徵SX1與輔助老化特徵SY1)、RUL預測結果以及DCI預測結果來說明本發明實施例。軸偏度代表組件之軸所偏離的角度,老化特徵SX1代表組件之軸於X平面所偏離的角度,輔助老化特徵SY1代表組件之軸於Y平面所偏離的角度,其中輔助老化特徵SY1依據前述多變量建模步驟260之格蘭傑因果關係檢驗所檢定出來的結果。請參照圖5、6、7、8,其中圖5為繪示組件之軸偏度的預測結果;圖6為繪示組件之RUL的預測結果;圖7為繪示組件之一DCI(TSP)的預測結果;圖8為繪示組件之另一DCI(TSPMVA)的預測結果。其中TSP代表習知之單變量時間序列預測演算法(僅考量單個老化特徵);TSPMVA代表本發明之多變量時間序列預測演算法(考量多個老化特徵)。在圖5中,橫軸為時間,縱軸為軸偏度,曲線510為使用本發明TSPMVA所獲得之組件之軸偏度的預測值;曲線520為使用習知TSP所獲得之組件之軸偏度的預測值;點群530(由“*”所組成)為實際值;直線540為組件之軸偏度的死亡規格值;直線550為組件之軸偏度的生病規格值。在圖6中,橫軸為工件號碼,縱軸為RUL(天數),曲線
560與曲線570分別為使用習知TSP與本發明TSPMVA算出的RUL。曲線560於工件號碼中第106個工件出現預警,曲線570於工件號碼中第119個工件出現預警。在圖7與圖8中,直線580為DCI門檻值(DCIT)。當DCI小於DCI門檻值時,不需進行維修;當DCI大於DCI門檻值時,代表組件在處理工件時接近死亡狀態,需要維修。圖7是用習知TSP算出的DCI,圖8是用本發明TSPMVA算出的DCI。習知TSP在距離死亡時間為24天前發出預警,而本發明TSPMVA在距離死亡時間為11天前才發出預警。兩者相較之下可知,習知TSP過早發出預警,因此本發明TSPMVA評估的RUL比較準確。
The embodiment of the present invention will be described below by using the axial skewness of the component (the aging characteristic SX1 and the auxiliary aging characteristic SY1 ), the RUL prediction result and the DCI prediction result. Axis skewness represents the angle of deviation of the axis of the component, aging feature SX1 represents the angle of deviation of the axis of the component on the X plane, and auxiliary aging feature SY1 represents the angle of deviation of the axis of the component on the Y plane, wherein the auxiliary aging feature SY1 is based on the aforementioned The result of the Granger causality test in the
可理解的是,本發明之生產機台組件的多變量預測保養方法為以上所述之實施步驟,本發明之內儲用於量測抽樣之電腦程式產品,係用以完成如上述之量測抽樣的方法。上述實施例所說明的各實施步驟的次序可依實際需要而調動、結合或省略。上述實施例可利用電腦程式產品來實現,其可包含儲存有多個指令之機器可讀取媒體,這些指令可程式化(programming)電腦來進行上述實施例中的步驟。機器可讀取媒體可為但不限定於軟碟、光碟、唯讀光碟、磁光碟、唯讀記憶體、隨機存取記憶體、可抹除可程式唯讀記憶體(EPROM)、電子可抹除可程式唯讀記憶體(EEPROM)、光卡(optical card)或磁卡、快閃記憶體、或任何適於儲存電子指令的機器可讀取媒體。再者,本發明之實施例也可做為電腦程式產品來下載,其可藉由使用通訊連 接(例如網路連線之類的連接)之資料訊號來從遠端電腦轉移本發明之電腦程式產品至請求電腦。 It can be understood that the multi-variable predictive maintenance method of the production machine components of the present invention is the above-mentioned implementation steps, and the computer program product stored in the present invention for measurement and sampling is used to complete the above-mentioned measurement Sampling method. The order of the implementation steps described in the above embodiments can be adjusted, combined or omitted according to actual needs. The above-mentioned embodiments can be realized by using a computer program product, which can include a machine-readable medium storing a plurality of instructions, and these instructions can program a computer to perform the steps in the above-mentioned embodiments. A machine-readable medium may be, but is not limited to, floppy disk, compact disk, compact disk, magneto-optical disk, read-only memory, random access memory, erasable programmable read-only memory (EPROM), electronically erasable Excluding programmable read-only memory (EEPROM), optical or magnetic cards, flash memory, or any machine-readable medium suitable for storing electronic instructions. Moreover, the embodiment of the present invention can also be downloaded as a computer program product, which can be downloaded by using a communication link The computer program product of the present invention is transferred from the remote computer to the requesting computer by means of a data signal connected (such as a connection such as a network connection).
亦可注意的是,本發明亦可描述於一製造系統的語境中。雖然本發明可建置在半導體製作中,但本發明並不限於半導體製作,亦可應用至其他製造工業。製造系統係配置以製造工件或產品,工件或產品包含但不受限於微處理器、記憶體裝置、數位訊號處理器、專門應用的電路(ASICs)或其他類似裝置。本發明亦可應用至除半導體裝置外之其他工件或產品,如車輛輪框、螺絲。製造系統包含一或多個處理工具,其可用以形成一或多個產品或產品的一部分,在工件(例如:晶圓、玻璃基板)上或中。發明本領域具有通常技藝者應可知,處理工具可為任何數目和任何型式,包含有微影機台、沉積機台、蝕刻機台、研磨機台、退火機台、工具機和類似工具。在實施例中,製造系統亦包含散射儀、橢圓偏光儀、掃描式電子顯微鏡和類似儀器。 It should also be noted that the invention may also be described in the context of a manufacturing system. Although the present invention can be implemented in semiconductor fabrication, the present invention is not limited to semiconductor fabrication, but can be applied to other manufacturing industries as well. A manufacturing system is configured to manufacture workpieces or products including but not limited to microprocessors, memory devices, digital signal processors, application specific circuits (ASICs) or other similar devices. The present invention can also be applied to other workpieces or products other than semiconductor devices, such as vehicle wheel frames and screws. A manufacturing system includes one or more processing tools that can be used to form one or more products, or a portion of a product, on or in a workpiece (eg, wafer, glass substrate). Those skilled in the art will appreciate that the processing tools can be any number and any type, including lithography tools, deposition tools, etching tools, grinding tools, annealing tools, tool tools and the like. In an embodiment, the fabrication system also includes a scatterometer, an ellipsometer, a scanning electron microscope, and the like.
綜上所述,本發明實施例可利用老化特徵與輔助老化特徵來預測老化特徵,這意味著用多個變數來預測一個變數。習知技術只採用一個變數來做預測,則預測準確度有限,而本發明之多變量的時間序列預測擴充了只能使用一個變數的限制,所預測的老化特徵不僅取決於過去的老化特徵,也依賴其他特徵(輔助老化特徵),因此採用多變數可以提升預測準確度。本發明實施例也可以即時並準確地預測生產機台組件的RUL,而可及時地進行生產機台組件的維修;並可在生產機台組件可能很快死亡狀態時立即進行維 護,且以數據化的方式來呈現生產機台組件進入死亡狀態的可能性。 To sum up, the embodiment of the present invention can use the aging feature and the auxiliary aging feature to predict the aging feature, which means using multiple variables to predict one variable. Conventional technology only uses one variable to make predictions, and the prediction accuracy is limited. However, the multivariate time series prediction of the present invention expands the limitation of using only one variable. The predicted aging characteristics not only depend on the past aging characteristics, Also depends on other features (auxiliary aging features), so using multivariate can improve prediction accuracy. The embodiment of the present invention can also immediately and accurately predict the RUL of the production machine components, so that the maintenance of the production machine components can be carried out in time; and the maintenance can be performed immediately when the production machine components may die soon. protection, and present the possibility of production machine components entering a dead state in a digital way.
雖然本發明已以實施方式揭露如上,然其並非用以限定本發明,任何熟習此技藝者,在不脫離本發明之精神和範圍內,當可作各種之更動與潤飾,因此本發明之保護範圍當視後附之申請專利範圍所界定者為準。 Although the present invention has been disclosed above in terms of implementation, it is not intended to limit the present invention. Anyone skilled in this art can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection of the present invention The scope shall be defined by the appended patent application scope.
200:製程資料 200: Process information
210:資料品質檢查 210: Data quality check
220:轉換成參數指標 220: Convert to parameter index
230:演算法庫 230: Algorithm library
240:DHI模組 240: DHI module
250:第一判斷步驟(DHI<0.7) 250: The first judgment step (DHI<0.7)
260:應用多變量之RUL預測建模步驟 260: Applying multivariate RUL predictive modeling steps
270:預警模式 270: Early warning mode
280:DCI模式 280: DCI mode
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