In-line defect reduction from a historical perspective and its implications for future integrated circuit manufacturing

The enormous progress in integrated circuit manufacturing over the last 30 years would have been impossible without the science of yield enhancement and defect reduction. This paper traces the evolution of this science, reviewing the history of defect inspection tooling, the practices developed for finding root causes of defects, yield modeling techniques, and important defectivity issues for current generation copper and low-K dielectric metallization. Based on the historical perspective and current status of yield enhancement technology, the paper anticipates future developments required to extend yield learning to sub-0.1-/spl mu/m technology generations.

[1]  J.H. Bruning,et al.  An automated mask inspection system—AMIS , 1975, IEEE Transactions on Electron Devices.

[2]  C. H. Stapper,et al.  Evolution and accomplishments of VLSI yield management at IBM , 1982 .

[3]  Lawrence H. Lin,et al.  Patterned wafer inspection using laser holography and spatial frequency filtering , 1988 .

[4]  H. P. Lengkeek,et al.  A Comparative Study of Surface Particle Counters , 1989 .

[5]  Gary Dickerson,et al.  In-line wafer inspection using 100-megapixel-per-second digital image processing technology , 1991, Other Conferences.

[6]  Brian Grenon,et al.  Inspection of optical phase‐shifting masks with an automated electron‐beam system , 1994 .

[7]  John L. Sturtevant,et al.  Antireflection coating process characterization and improvement for DUV lithography at 0.25 um: ground rules , 1995, Advanced Lithography.

[8]  C. H. Stapper,et al.  Integrated circuit yield management and yield analysis: development and implementation" ieee trans , 1995 .

[9]  J. Li,et al.  Production use of an integrated automatic defect classification (ADC) system operating in a laser confocal/white light imaging defect review station , 1996, IEEE/SEMI 1996 Advanced Semiconductor Manufacturing Conference and Workshop. Theme-Innovative Approaches to Growth in the Semiconductor Industry. ASMC 96 Proceedings.

[10]  A. Berezin,et al.  Automating after develop inspection , 1996, IEEE/SEMI 1996 Advanced Semiconductor Manufacturing Conference and Workshop. Theme-Innovative Approaches to Growth in the Semiconductor Industry. ASMC 96 Proceedings.

[11]  Keith B. Wells,et al.  Lithography applications of the new Tencor Surfscan AIT laser-based defect inspection system , 1996, Advanced Lithography.

[12]  J. Li,et al.  Construction of a "Grand Pareto" for line yield loss, by process loop using limited data sets , 1997, 1997 IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop ASMC 97 Proceedings.

[13]  James F. Garvin,et al.  Improved defect detection performance at metal and contact etch levels using a new optical-comparison segmented-autothreshold technology , 1997, Advanced Lithography.

[14]  A.V.S. Satya,et al.  Microelectronic test structures for rapid automated contactless inline defect inspection , 1997 .

[15]  J. Pak,et al.  Advanced techniques for contact module development , 1997, 1997 IEEE International Symposium on Semiconductor Manufacturing Conference Proceedings (Cat. No.97CH36023).

[16]  Derek B. Dove,et al.  Development and application of a new tool for lithographic mask evaluation, the stepper equivalent Aerial Image Measurement System, AIMS , 1997, IBM J. Res. Dev..

[17]  Simon Chooi,et al.  Post Polysilicon Etch (Incorporating DUV Resist an BARC) Polymer Cleaning , 1998 .

[18]  Andrew Skumanich,et al.  Enhanced defect detection capability using combined brightfield/darkfield imaging , 1998, Advanced Lithography.

[19]  Paul Sandland Automated defect inspection: past, present, and future , 1998, Advanced Lithography.

[20]  Albert Ng,et al.  Evaluation of the KLA-Tencor 2138 for line monitoring applications , 1998, Advanced Lithography.

[21]  Ingrid B. Peterson Defect reduction methodology in the lithography module , 1999, Advanced Lithography.

[22]  Richard L. Guldi,et al.  Strategy and metrics for wafer handling automation in legacy semiconductor fab , 1999 .

[23]  Hung-Chih Chen,et al.  Local defect real-time monitor system in lithography , 1999, Smart Materials, Nano-, and Micro- Smart Systems.

[24]  A. Skumanich,et al.  Advanced process development and control based on a fully automated SEM with ADC , 1999, 10th Annual IEEE/SEMI. Advanced Semiconductor Manufacturing Conference and Workshop. ASMC 99 Proceedings (Cat. No.99CH36295).

[25]  S.Y. Lee,et al.  Highly manufacturable 1T1C 4 Mb FRAM with novel sensing scheme , 1999, International Electron Devices Meeting 1999. Technical Digest (Cat. No.99CH36318).

[26]  N. Sridhar,et al.  Application of defect inspection in development of 0.25 and 0.18 micron technology , 1999, 1999 IEEE International Symposium on Semiconductor Manufacturing Conference Proceedings (Cat No.99CH36314).

[27]  S. Lavangkul,et al.  "RF-on" polysilicon etch defectivity monitor for manufacturing and process development , 1999, 1999 IEEE International Symposium on Semiconductor Manufacturing Conference Proceedings (Cat No.99CH36314).

[28]  Kenneth M. Butler,et al.  Correlation of logical failures to a suspect process step , 1999, International Test Conference 1999. Proceedings (IEEE Cat. No.99CH37034).

[29]  L. Cheung,et al.  Defect control methods for SIMOX SOI wafer manufacture and processing , 2000, 2000 IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop. ASMC 2000 (Cat. No.00CH37072).

[30]  D. Farrington,et al.  In-line SEM based ADC for advanced process control , 2000, 2000 IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop. ASMC 2000 (Cat. No.00CH37072).

[31]  J. B. Shaw,et al.  Characterization of copper voids in dual damascene processes , 2002, 13th Annual IEEE/SEMI Advanced Semiconductor Manufacturing Conference. Advancing the Science and Technology of Semiconductor Manufacturing. ASMC 2002 (Cat. No.02CH37259).