Streamlining Product Development
at Applied Materials With Siemens
PLM and Microsoft
External Use
Author’s Information
Herman Harwell, Senior Member in Design For Excellence (DFx)
Group of Applied Materials Global Operations Manufacturing
Engineering Organization (GOME)
200mm – 300mm Wafer Semiconductor Processing Systems
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External Use
Applied Materials Overview
Applied Materials is the global leader in Nanomanufacturing Technology™
solutions with a broad portfolio of innovative equipment, service and
software products for the fabrication of semiconductor chips, flat panels,
solar photovoltaic cells, flexible electronics and energy efficient glass.
Results for Third Quarter of Fiscal 2007
Net
Sales: $2.56 billion
Net
Income: $474 million
EPS:
New
$0.34
Orders: $2.28 billion
Flat Panel Display Processing Systems
200mm – 300mm Wafer Inspection Systems
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External Use
Product Development Roadmap
People Driven Framework
Research
and Plan
Concept
Design/
Develop
Validate/
Source
Market/
Promote
Produce/
Sell
Support/
Retire
Idea management
Project and portfolio management
Management
Regulatory compliance
Configuration management
Sales and
marketing
Customer needs
Product marketing and publishing
Requirements management
Design data creation
R&D and
Engineering
Visualization and digital mockup
Product structure record
Engineering change management
Sourcing
Direct material sourcing
Manufacturing process management
Mfg
Aftermarket support
Customer
Service
EOL
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External Use
New Product Development Challenges
 Common Issues In New Product Development
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Design Issue capture mostly done with Excel spreadsheets
Issue closure difficult to track at all project levels (many ad hoc)
No consistent process for design issue identification in WIP
Design project management varies by business group & size
Lotus Notes databases most often utilized tool for design task
tracking (EWR/PRIME/HSR/SPS)
Lack of consistent approach with PLC phase task deliverables
Few people proficient in use of all the new tools TcE/TcVis/NX
E-mail most often used tool to notify team members of project
issues or changes
Supplier collaboration is needed earlier in design process
Cross-Functional team members aren’t involved early enough to
identify design changes needed
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External Use
PLC Product Development Roadmap
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SMR
Detail Product Design
BOM (Preliminary)
Preliminary OMS/SOE
Preliminary Tool/Fixture
Critical Parts List
PLC Task Assignments
Digital Mockup - DMU
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PRS
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PDSS
Product Planning Process PPP
Controlled (2nd Beta) Build
• Strategy Verification
• Cost Goals Achieved
• MIT Goals Achieved
• BOM (EVAL Status)
• Material Status @ EVAL
• Critical Parts FAI’d
• OMS/SOE Released @ EVAL
• Tool/Fixture Implementation
• Engineering Issue List Addressed
• Train the “Trainer” Completed
• Field NC Input
Engineering (Alpha) Build
Strategy Trial
BOM (Draft)
OMS/SOE Draft
Tool/Fixture Trial
Initial Engineering Issue List
Virtual Build - VB
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Alpha
Stage
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Beta
Stage
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Product Development Process PDP
Gamma
Stage
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Vol
Mfg
Volume Manufacturing VM
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Mature
Product
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Mature Products
Use Case Roadmap for TcCommunity
supporting PLC Deliverables & Tasks
Pre-Build Requirements
• Strategies
• Manufacturing
• Test
• Sourcing
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Managed (1st Beta) Build
OMS/SOE Verification
Train the “Trainer” Started
Engineering Issues Verification
Digital Validation - DV
TcCommunity-Based Activities: 
External Use
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Validation (Gamma) Build
Strategy Validation
BOM(97% Accurate)
Tooling/Fixture Validation
Engineering Issues Closed
Work Center Train Plan Complete
Field NC Goals Met
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Collaboration Objectives
 Utilize Teamcenter Community in Design Reviews
 Conduct DMU activities on WIP design data in TcEngineering
regardless of geographic location (PLC deliverables in Phase 4)
 Capture design issues and disposition them before design freeze and
procurement of physical materials
 Provide extended design team with non-CAD tools to enable design
reviews using most current TcEngineering data
 Utilize Teamcenter Community in global design environment
 Engage a product development team during PLC Phase 4 to conduct
DMU tasks using TcCommunity, TcEngineering & TcVisualization tools
 Have the team execute the Visualization process workflow and it’s
discrete tasks utilizing the capabilities of TcC, TcE & TcVis
Evaluate TcCommunity performance when combined with TcE & TcVis
against existing processes with only TcE and TcVis tools.
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External Use
Applied’s New Product Development Tools
PLM System – All Tools are Integrated via TeamCenter
TcVisualization
Direct
Integration
TcCommunity
TcEngineering
UG - NX
VisMockup
VisViewPro
Web
Portal - Web
Portal
 3D Clearance Analysis
(Static & Dynamic)
 Animation/Motion Authoring
 3D Model Filters & Groups
 VisVSA Analysis
(PMI Verify – Tolerance
Simulations & Stack Up)
 VisJack – Classic Jack Analysis
(Serviceability – Ergo – Safety –
Access Evaluation & Viewing)
 Path Planning Authoring
(Component & Assembly
Extraction – Installation Analysis)
 JT 3D Model/Structure Viewing
 Alt Hierarchy Authoring
(Mfg Build Sequence – Reports)
 3D Model Section Viewing
 3D Model Measurement
 3D Model Markup
(JT models w/TcE Identification)
 VisPublish Authoring
(OMS - Assembly Documents)
 Visual Issue Authoring
(Linked to TcE Models)
 2D Drawing Overlay & Compare
 2D Drawing Redlining & Markup
 Design Issues Management.
(Closed Loop Corrective Action)
 PLC Tasks Management
(External Linked Spreadsheet)
 Tools For Internal Multi-Site TcE
Dynamic Design Collaboration
 Tools For External Supplier
Static TcE Design Collaboration
(i-Series Embedded Viewer)
 PLC Deliverables Library
(Linked PLC Documentation)
 Conferencing Server Options
(AppShare Or VisConference)
 Design Data Management
(WIP & Release Designs)
 3D Solid Models Revisions
 2D Drawings Revisions
 Manufacturing Documents Library
 Commercial Part Library
 Product Structure BoMs
(Product Core & Options Config)
 Multi-Site Design Data Sources
 Release Data Management
 Part Number Issuance Workflow
 Part Status Workflows
 Document Status Workflows
 3D Model Authoring
(NX parts & assemblies)
 Model As Master Authoring
(GD&T – PMI data content)
 JT 3D Model Creation
(Attributes - PMI data content)
 2D Drawing Authoring
(NX dwg - .cgm)
 Assembly Structure Authoring
(Multiple Product Configurations)
 Large Model Management
(Load Options & View Options)
 CAD Data Import & Export
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External Use
New Product Development Process
Deliverables
 Governance By The Applied Materials PLC Phase
Gated Development Model
 Identified Use Cases** For TcCommunity Applications
– Phase 3: Product Definition (Program Charter)
 3 Deliverables [4 Tasks with 6** Sub-Tasks]
– Phase 4: Alpha Development
 9 Deliverables [18 Tasks with 56** Sub-Tasks]
– Phase 5: Beta Development
 7 Deliverables [19 Tasks with 59** Sub-Tasks]
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External Use
Applied Materials Visualization Process: DMU
DMU Coordination
(Facilitator)
- New Product Mfg Engineer
- Program Management
- Design Engineering
DMU Closed Loop Corrective Action
(DMU Issues Team)
- Resolution Owner
- Issue Owner (Reviewers)
- DMU Coordinator (Facilitator)
Digital Mockup
Teamcenter
DMU Issues Review & Disposition
(DMU Issues Team & Reviewers)
- New Product & Manufacturing,
Design, Industrial, Service,
Safety & Packaging Engineers
- Materials & Sourcing Management
- Suppliers & Vendors**
- Community
- Engineering
-Visualization
- MS Excel
- MS Word
DMU Evaluation Tasks
(Reviewers)
- New Product & Manufacturing, Industrial,
Service, Safety, & Packaging Engineers
- Materials & Sourcing Management
- Suppliers & Vendors**
DMU Issues Reporting
(Facilitator)
-New Product & Manufacturing, Design, Industrial, Service, Safety, & Packaging Engineers
- Materials & Sourcing Management - Suppliers & Vendors**
** Future Implementation
Cross-Functional Collaboration
External Use
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TcCommunity Deployment Configuration
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AMAT Community Home Login Page
External Use
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TcCommunity Deployment Configuration
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AMAT Community Home Login Page (cont.)
External Use
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TcCommunity Deployment Configuration
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PLC Program’s Design Review Workspace (Home Tab)
External Use
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TcCommunity Deployment Configuration
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PLC Program’s Design Review Workspace (My Workspace Tab)
External Use
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Applied DMU 2D Drawing Review Example
2D DRAWING VISUAL ISSUE
2D DRAWING & MARKUP ARE STORED IN TCE:
VISUAL ISSUES ARE CREATED AND STORED IN
TCCOMMUNITY DATABASE
MARKUP CONTENT CONSISTS OF 3-ELEMENTS:
OBSERVATION [O]; RECOMMENDATION [R];
FEEDBACK [F]
2D MARKUPS ARE POSITIONED OUTSIDE THE DRAWING:
ALL MARKUPS ARE MERGED & POSITIONED OUTSIDE
THE DRAWING BORDER TO ALLOW READABILITY
2D Drawing Issues Tracking Prior To Product MRP Release
External Use
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Closed Loop Corrective Action Process
End
Start
PLC Deliverable
From Task
Assignment
(Reviewer)
Task Assignment
Scope From
Facilitator Using
Review Module
(Reviewer)
T1
Email Notification
Approval Status
(Res Owner)
(VI Owner)
(Facilitator)
Reviewer Finds
Problem; Creates
Visual Issue
Active
(VI Owner)
Lotus Notes
Team Conference
For Review Date
Visual Issue
Dispositioned
(Facilitator)
Dispositioned
Visual Issue
Status Changed
Resolved
[VI Owner]
T2
Visual Issue
Form With
Audit History
& Routing Slip
Dispositions
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Disposition Of
Visual Issue
Complete
Approved
(Facilitator)
Visual Issue
Resolution Verified
& Status Changed
Closed
[VI Owner]
Visual Issue
Actions Complete
& Content Frozen
Locked
[Facilitator]
3
Resolution Of
Visual Issue
Verified
Approved
(VI Owner)
Reason for Issue
Visual
Issue
Resolution Owner
Identified
[Observation]
[Assigned To]
Proposed solution
Resolution
Determined
[Recommendation]
[Feedback]
Assign To A
Team Conference
Resolution Due
Date Assigned
[Review Date]
[Due Date]
Product Design Issues Tracking Prior To MRP Release
External Use
Create Routing
Slip Link To
Visual Issue
(1- Res Owner)
(2- VI Owner)
(3-Facilitator)
1
Visual Issue
Resolution
Implemented
CAD a/o TcE
[Res Owner]
Visual Issue
Resolution
Completed
Approved
[Res Owner]
2
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Closed Loop Corrective Action Process
ROUTING SLIP APPROVAL:
STATUS OF EACH REVIEWER
IN THE ORDER OF REVIEW
LINK TO VISUAL ISSUE CONTENT
CLCA HISTORY FOR ROUTING SLIP:
CLCA HISTORY STORED IN VISUAL ISSUE
VISUAL ISSUE PROVIDES EVIDENCE OF ALL ACTIONS:
FROM DISCOVERY OF ISSUE, THROUGH RESOLUTION
OR FINAL DISPOSITION, TO VERIFICATION AND
CLOSING OF ISSUE.
Product Design Issues Tracking Prior To MRP Release
External Use
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New Product Development Integration
TcCommunity Return On Investment
60
TcCommunity's Application
Advantages In Each Virtual
Design Review Category
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TcC-Based
TcVis-Based
CAD-Based
% of Total; Cumulative All Categories = 100%
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Administration
Data Management
PLC Tasks
Issue Management
Review Effort
Resource Burden In Each DMU Method Evaluated
TcC Resource Usage Efficiencies
– Lowest Administration Burden
 Design Review Sites & Workspaces
 DMU Roles Established Within TcC
 Managed Review Tasks Assignments
 Managed Review Scope & Agendas
 TcC Event Links in Lotus Notes eMail
– Lowest Data Management Burden
 DMU Data Linked To TcE, Not Copied
 DMU BOM Synced To TcE Eng_BOM
 All TcE Sites Accessible Within TcC
– Lowest PLC Deliverables Burden
 PLC Deliverables Doc Libraries in TcC
 TcE Item Issues Linked To PLC Docs
– Lowest Issues Management Burden
 Visual Issue Data Capture & Tracking
 Visual Issues Link To TcE Design Data
 Issue Routing Via Lotus Notes email
 Issue Reporting, Rollups & Dashboards
– Highest Reviewer Time Availability
 83% Increase Over Vis-Based Reviews
 175% Increase Over CAD-Based
Basis: Equal Resource Allocation / Method / Assembly Reviewed (Avg.)
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External Use
Future Direction
 Applied Materials Roadmap
– Deploy Teamcenter
Engineering 2007 during
FY 2008
– Deploy Microsoft Office
SharePoint Server
(MOSS) during FY 2009
– Deploy Teamcenter
Community 2007 on
MOSS during FY2009
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External Use
Thank You,
Herman Harwell
Applied Materials
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External Use
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External Use