Fast Scheduling of Semiconductor Manufacturing Facilities Using Case-Based Reasoning

This paper presents a scheduling method for semiconductor manufacturing systems through utilizing a case-based reasoning approach that consists of modeling, casebase building, and reasoning steps. Petri nets are employed as a model for representing the behavior of a system and accommodating various types of constraints. Casebase contains the cases, composed of pairs of a state and the decision made at the state, and it is built from the solutions of previously solved problems. Subsequently, a schedule for a new problem with different production requirements, initial setup status, and number of setup change operators is obtained by sequentially retrieving and reusing the cases that are most similar to the states encountered during schedule generation in the reasoning step. Extensive experiments demonstrate the performances of the proposed approach, compared to those of dispatching rule and meta-heuristic methods, and also show the robustness against possible perturbations in terms of production requirements and initial setup status based on real world scale datasets. The proposed method significantly outperformed a meta-heuristic algorithm in terms of computation time while requiring much less sacrifice in a performance metric than the competitive dispatching rules.

[1]  MengChu Zhou,et al.  Real-Time Scheduling of Single-Arm Cluster Tools Subject to Residency Time Constraints and Bounded Activity Time Variation , 2012, IEEE Transactions on Automation Science and Engineering.

[2]  Tae-Eog Lee,et al.  An extended event graph with negative places and tokens for time window constraints , 2005, IEEE Transactions on Automation Science and Engineering.

[3]  El-Ghazali Talbi,et al.  Metaheuristics - From Design to Implementation , 2009 .

[4]  Zhibin Jiang,et al.  Simulation-based optimization of dispatching rules for semiconductor wafer fabrication system scheduling by the response surface methodology , 2009 .

[5]  Tae-Eog Lee,et al.  Scheduling single-armed cluster tools with reentrant wafer flows , 2006, IEEE Transactions on Semiconductor Manufacturing.

[6]  Sanja Petrovic,et al.  Case-based heuristic selection for timetabling problems , 2006, J. Sched..

[7]  Sanja Petrovic,et al.  A hybrid metaheuristic case-based reasoning system for nurse rostering , 2009, J. Sched..

[8]  MengChu Zhou,et al.  Optimal One-Wafer Cyclic Scheduling of Single-Arm Multicluster Tools With Two-Space Buffering Modules , 2014, IEEE Transactions on Systems, Man, and Cybernetics: Systems.

[9]  Jonathan F. Bard,et al.  AN OPTIMIZATION APPROACH TO CAPACITY EXPANSION IN SEMICONDUCTOR MANUFACTURING FACILITIES , 1999 .

[10]  Jun-Ho Lee,et al.  Non-Cyclic Scheduling of a Wet Station , 2014, IEEE Transactions on Automation Science and Engineering.

[11]  Weian Guo,et al.  A scheduling method in semiconductor manufacturing lines based on ant colony optimization , 2012, 2012 IEEE 11th International Conference on Cognitive Informatics and Cognitive Computing.

[12]  Guo-Jun Su,et al.  Semiconductor manufacture system dynamic scheduling based on HCTPN and GA , 2010, 2010 2nd International Conference on Future Computer and Communication.

[13]  Li-Chen Fu,et al.  Modelling, control and simulation of an IC wafer fabrication system: A generalized stochastic coloured timed Petri Net approach , 2000 .

[14]  Kenneth R. Baker,et al.  Principles of Sequencing and Scheduling , 2018 .

[15]  MengChu Zhou,et al.  Petri Net-Based Polynomially Complex Approach to Optimal One-Wafer Cyclic Scheduling of Hybrid Multi-Cluster Tools in Semiconductor Manufacturing , 2014, IEEE Transactions on Systems, Man, and Cybernetics: Systems.

[16]  Hyun-Jung Kim,et al.  A Branch and Bound Algorithm for Cyclic Scheduling of Timed Petri Nets , 2015, IEEE Transactions on Automation Science and Engineering.

[17]  Simon C. K. Shiu,et al.  Foundations of Soft Case-Based Reasoning: Pal/Soft Case-Based Reasoning , 2004 .

[18]  Katsumi Morikawa,et al.  Neural network approach for minimizing the makespan of the general job-shop , 1994 .

[19]  MengChu Zhou,et al.  A Petri Net-Based Novel Scheduling Approach and Its Cycle Time Analysis for Dual-Arm Cluster Tools With Wafer Revisiting , 2013, IEEE Transactions on Semiconductor Manufacturing.

[20]  Günter Schmidt,et al.  Case-based reasoning for production scheduling , 1998 .

[21]  Fei Qiao,et al.  Scheduling of Semiconductor Manufacturing Systems Using Petri Nets , 2014 .

[22]  Mingyuan Chen,et al.  A parallel genetic algorithm for a flexible job-shop scheduling problem with sequence dependent setups , 2010 .

[23]  David B. Leake Case-based reasoning , 1994, The Knowledge Engineering Review.

[24]  MengChu Zhou,et al.  How to Respond to Process Module Failure in Residency Time-Constrained Single-Arm Cluster Tools , 2014, IEEE Transactions on Semiconductor Manufacturing.

[25]  Dorit S. Hochbaum,et al.  Scheduling Semiconductor Burn-In Operations to Minimize Total Flowtime , 1997, Oper. Res..

[26]  Yang Song,et al.  Bottleneck Station Scheduling in Semiconductor Assembly and Test Manufacturing Using Ant Colony Optimization , 2007, IEEE Transactions on Automation Science and Engineering.

[27]  Yuehwern Yih,et al.  Selection of dispatching rules on multiple dispatching decision points in real-time scheduling of a semiconductor wafer fabrication system , 2003 .

[28]  R. Haupt,et al.  A survey of priority rule-based scheduling , 1989 .

[29]  MengChu Zhou,et al.  Scheduling of semiconductor test facility via Petri nets and hybrid heuristic search , 1998 .

[30]  L. Li,et al.  Adaptive Dispatching Rule for Semiconductor Wafer Fabrication Facility , 2013, IEEE Transactions on Automation Science and Engineering.

[31]  Qinghua Zhu,et al.  Cycle time analysis of dual-arm cluster tools for wafer fabrication processes with multiple wafer revisiting times , 2015, Comput. Oper. Res..

[32]  Reha Uzsoy,et al.  A REVIEW OF PRODUCTION PLANNING AND SCHEDULING MODELS IN THE SEMICONDUCTOR INDUSTRY PART I: SYSTEM CHARACTERISTICS, PERFORMANCE EVALUATION AND PRODUCTION PLANNING , 1992 .

[33]  S.J. Mason,et al.  Metaheuristic scheduling of 300-mm lots containing multiple orders , 2005, IEEE Transactions on Semiconductor Manufacturing.

[34]  Kazuo Miyashita,et al.  Case-based knowledge acquisition for schedule optimization , 1995, Artif. Intell. Eng..

[35]  Barry Smyth,et al.  Case-Based Reasoning in Scheduling: Reusing Solution Components. , 1996 .

[36]  Feng Chu,et al.  A Petri Net Method for Schedulability and Scheduling Problems in Single-Arm Cluster Tools With Wafer Residency Time Constraints , 2008, IEEE Transactions on Semiconductor Manufacturing.

[37]  Ramón López de Mántaras,et al.  Case-Based Reasoning , 2001, Machine Learning and Its Applications.

[38]  MengChu Zhou,et al.  A Petri-Net-Based Scheduling Strategy for Dual-Arm Cluster Tools With Wafer Revisiting , 2013, IEEE Transactions on Systems, Man, and Cybernetics: Systems.

[39]  MengChu Zhou,et al.  Petri Net-Based Optimal One-Wafer Scheduling of Single-Arm Multi-Cluster Tools in Semiconductor Manufacturing , 2013, IEEE Transactions on Semiconductor Manufacturing.

[40]  MengChu Zhou,et al.  A Closed-Form Solution for Schedulability and Optimal Scheduling of Dual-Arm Cluster Tools With Wafer Residency Time Constraint Based on Steady Schedule Analysis , 2010, IEEE Transactions on Automation Science and Engineering.

[41]  Peter Ross,et al.  Evolutionary Scheduling: A Review , 2005, Genetic Programming and Evolvable Machines.

[42]  J. Zhang,et al.  Multiagent-based modeling for re-entrant manufacturing system , 2007 .

[43]  Ivo Pereira,et al.  Meta-heuristics tunning using CBR for dynamic scheduling , 2010, 2010 IEEE 9th International Conference on Cyberntic Intelligent Systems.

[44]  Bernd Scholz-Reiter,et al.  Generating dispatching rules for semiconductor manufacturing to minimize weighted tardiness , 2010, Proceedings of the 2010 Winter Simulation Conference.

[45]  Han-Pang Huang,et al.  Specification, modelling and control of a flexible manufacturing cell , 1992 .

[46]  Fei Qiao,et al.  A Petri Net and Extended Genetic Algorithm Combined Scheduling Method for Wafer Fabrication , 2013, IEEE Transactions on Automation Science and Engineering.

[47]  Ivo Pereira,et al.  Self-Optimization module for Scheduling using Case-based Reasoning , 2013, Appl. Soft Comput..

[48]  MengChu Zhou,et al.  Petri Net-Based Scheduling of Single-Arm Cluster Tools With Reentrant Atomic Layer Deposition Processes , 2011, IEEE Transactions on Automation Science and Engineering.

[49]  Tae-Eog Lee,et al.  Scheduling analysis of time-constrained dual-armed cluster tools , 2003 .

[50]  MengChu Zhou,et al.  Petri Net Modeling and Cycle-Time Analysis of Dual-Arm Cluster Tools With Wafer Revisiting , 2013, IEEE Transactions on Systems, Man, and Cybernetics: Systems.

[51]  Han-Pang Huang,et al.  Colored timed Petri net based statistical process control and fault diagnosis to flexible manufacturing systems , 1997, Proceedings of International Conference on Robotics and Automation.

[52]  Hongtao Hu,et al.  A simulation-based two-stage scheduling methodology for controlling semiconductor wafer fabs , 2012, Expert Syst. Appl..

[53]  Han-Pang Huang,et al.  Modeling and emulation of a furnace in IC fab based on colored-timed Petri net , 1998 .

[54]  Jonghun Park,et al.  Setup Change Scheduling for Semiconductor Packaging Facilities Using a Genetic Algorithm With an Operator Recommender , 2014, IEEE Transactions on Semiconductor Manufacturing.

[55]  MengChu Zhou,et al.  Scheduling of Single-Arm Multi-cluster Tools With Wafer Residency Time Constraints in Semiconductor Manufacturing , 2015, IEEE Transactions on Semiconductor Manufacturing.