Manufacturing Processing Technology
Exponent consultants have experience with process design, foundry selection and management for prototype to volume manufacturing. This includes implementation of Design-for-Manufacturability (DfM) yield enhancement methodologies, yield analysis and root cause identification, materials science-based characterization, test structures for process enhancement, equipment data analysis for failure mode fingerprinting, wafer mapping, defect density determination, process development support, and R&D to volume production support.
Exponent consultants perform design and implementation of reliability testing programs and qualification strategies. The FMEA (Failure Modes and Effects Analysis) technique is a very good method to summarize all processing and design information in a matrix format. Reliability impacts will be included in this effort. Reducing wafer fab defect densities, optimizing wafer processing, and using design-for-manufacturability and reliability methodologies can quickly result in yield improvements. Reducing time from concept to product introduction is key to a successful product. Early introduction to the marketplace can be precarious if the reliability issues are not well understood. The product must be ready and have demonstrated reliability prior to customer acceptance. We can provide expertise in:
- Accelerated life testing under controlled environments and temperatures
- Acceleration factor model development
- Mechanical shock and vibration response analysis
- Fatigue testing
- Stiction testing, wear testing, tribology