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Intelligent Manufacturing Solutions

We continually add to this library so check back frequently. Additional papers on technologies, methodologies, business and market trends affecting the Intelligent Manufacturing Solutions industry can be found in the papers archive section. Be sure to check it out and share your findings with colleagues.

Stop Drifting. Turn Around and Catch the Wave. | 2014
Tom Mariano

A wave of change is taking place in the manufacturing sector, brought on by continuous advances in technology that promise to transform the landscape of this industry forever. The confluence of connectivity, computing power, software and the ability to manage large amounts of data will drive large productivity gains in manufacturing. Capital equipment suppliers who realize this and act decisively will benefit from the added value that they can bring to their customers. This Foliage Insights article discusses how capital equipment suppliers can take advantage of this trend with a proactive approach to succeed in this rapidly shifting market.

Controlling Cost in Complex Systems Development | 2013
Tim Bowe, Amit Shah, Chris Miles

A key goal of an effective product development process is to reduce and manage risk. Understanding the source of these risks is fundamental to developing strategies to mitigate them. A comprehensive mitigation strategyfor complex systems must include the use of sophisticated simulation tools to provide an effective testing base throughout the development process and beyond. Use of simulators has shown to not only improve the overall quality of the delivered product, but also reduce both the development time and associated product lifecycle costs. This paper focuses on the benefits to be gained by using simulators in the development and testing of complex systems, along with an ROI model.

450mm Product Development: A Systematic Approach for Success | 2013
Aamir Chaudhry, Myron Pugh

The race for 450mm production tools has begun and the pressure to respond in a timely manner is intense. However, the focus on developing new 450mm tools will not alleviate the equal need to continue the development of 300mm tools. To address this dual need for engineering, semi equipment companies must have a strong systems view of the new products under development, and to use this systems view to determine how to carve out, control and integrate truly separable efforts. This paper looks at using systems engineering as a key component to meeting this need and explores the implications of this from the manager's perspective.

Improving Business Results through Value Engineering (PoV) | 2012
Sree Iyer, Myron Pugh

Capital Equipment manufacturers are faced with the constant challenge to drive down product costs for a variety of reasons – lower cost targets aligned with emerging markets, competitive need to improve product margins, or a desire to extend the life of legacy products that are experiencing parts obsolescence. These goals can be addressed by well-run Value Engineering (VE) projects with a proper focus on upfront assessment and Return on Investment (ROI) analysis aligned with business goals. This Point-of-View paper will examine three key aspects for a successful VE project and explain why, in combination, they are likely to yield success.

The Impact of EUV and 450mm on Next-generation Equipment Product Development (PoV) | 2012
Tim Bowe

The demand for 450mm equipment running parallel with support for the 11nm node in 2015 requires a strong product development capability. To be competitive through the 2015 node, equipment manufacturers must recognize and act upon the criticality of building both experienced and cost-effective development teams. This paper takes a look at the challenge and provides thoughts on how to best leverage engineering resources available to hit the next market window.

What Product Software Costs to Build and Own | 2011
Software Development and Maintenance Effort/Cost Models
Wayne Lobb, David Warburton, Tim Bosch

In Foliage's extensive experience developing products, we have found that, on average over time, professional software R&D staffs create or modify about 700 lines of software logic per person per month, and own about 50,000 lines of software source code per person. The cost to build and own one line of product-software source for its whole lifetime ranges between $10-$50 or more and these numbers are dependent on numerous factors. This paper describes how Foliage measures software size, categorizes staff for comparison purposes and includes recommended actions if your numbers appear to be out of line with the rest of your industry.

Not Just Hardware Anymore: Hardware-Software Systems | 2011
Wayne Lobb, Tim Bowe

Software has long contributed to machine control and to integration of machines into the enterprise. But equipment makers are realizing that software features can also be critical product differentiators, in some cases even the most important differentiators. Transitioning from a hardware-centric company to a systems-and-software-centric product company is now an essential strategic initiative for many equipment makers. This paper discusses the challenges that companies addressed when undergoing the transition, and provides practical insights into overcoming them.

Transition to 450mm (PoV) | 2011
Scott Evans, David Warburton

The introduction of 450mm wafers into semiconductor production will be more expensive than the introduction of 300mm wafers several years ago. Because of the expense and risk, industry experts predict that only a few large customers will make the investment. Whether one believes that 450mm production is inevitable, or just an intellectual exercise for a few leading manufacturers, the possibility of the larger wafer size has to be factored into product roadmaps, and management will need to know what the equipment development effort might cost, how long it will take, and what technical problems will need to be solved. This paper provides insights into formulating technical approaches, product development plans, and estimated development costs to enable management to make informed decisions.

Tapping the Power of Systems Engineering | 2010
Charlie Alfred, Jesse Ambrosina, Tom Mariano

Effectively applying a systems-view to business and technology enables the delivery of a product or system without latent defects - on schedule and within budget. Without this view, it can be difficult to consistently make a profit on the products under development. This paper will show various ways that an absent or incapacitated systems engineering role leads to a series of problems with delivering competitive products, especially when product complexity and specialization increase. It will conclude with a discussion of why featuring systems engineering as a central discipline is a major step in improving effectiveness in product development.

Technical Debt in the Semiconductor Equipment Market: It's Time to Pay it Down | 2009
Dan O'Connor

As the semiconductor market begins to recover and customers begin to order new products, competitiveness and time-to-market will be absolutely critical. This paper provides a quick introduction to the technical debt metaphor as it applies to best practices in software development, and applies these concepts to the particular complexities in developing semiconductor equipment control systems. Specific guidelines are provided on how to assess your legacy product software for technical debt, as you prepare to participate in the anticipated upturn.

The Solar Manufacturing Edge: Software Design-for-Test | 2009
Wayne Lobb, Karl Aeder

Solar cell and solar panel manufacturers are in a highly competitive worldwide race to attain grid parity for the cost of solar generated electricity. A small fraction of manufacturing costs come from equipment control software and automation software. But this software can have a profound effect on the calendar time it takes a solar manufacturing line to evolve from research to reliable high-volume production. This paper discusses several cost-effective software design-for-test techniques such as strict isolation of test code from production code, deterministic functional testing of event-driven control, judicious use of semiconductor manufacturing software-interface standards in solar manufacturing, and much more.

Avoiding Pitfalls in Incremental Product Line Adoption | 2009
Mark Hersey, Dan O'Connor

Although the concept of forming a product line may be new to you, many before have faced the dual challenges of making strategic progress towards a more efficient software development model while still meeting the urgent needs of existing development plans. This paper offers industry experience that Foliage has gained in helping clients make a successful transition from a "product-centric" approach to a "product-line based" approach to software development; and, focuses specifically on the most important issues that inevitably arise when beginning to form a product line by adopting an incremental migration approach.

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