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Fundamentals of Semiconductor Manufacturing and Process Control
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FUNDAMENTALS OF
SEMICONDUCTOR
MANUFACTURING AND
PROCESS CONTROL

FUNDAMENTALS OF
SEMICONDUCTOR
MANUFACTURING AND
PROCESS CONTROL
Gary S. May, Ph.D.
Georgia Institute of Technology
Atlanta, Georgia
Costas J. Spanos, Ph.D.
University of California at Berkeley
Berkeley, California
A JOHN WILEY & SONS, INC., PUBLICATION

Copyright 2006 by John Wiley & Sons, Inc. All rights reserved
Published by John Wiley & Sons, Inc., Hoboken, New Jersey
Published simultaneously in Canada.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise,
except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without
either the prior written permission of the Publisher, or authorization through payment of the
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MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. Requests
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Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at
http://www.wiley.com/go/permission.
Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best
efforts in preparing this book, they make no representations or warranties with respect to the
accuracy or completeness of the contents of this book and specifically disclaim any implied
warranties of merchantability or fitness for a particular purpose. No warranty may be created or
extended by sales representatives or written sales materials. The advice and strategies contained
herein may not be suitable for your situation. You should consult with a professional where
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Library of Congress Cataloging-in-Publication Data:
May, Gary S.
Fundamentals of semiconductor manufacturing and process control / Gary S.
May, Costas J. Spanos.
p. cm.
“Wiley-Interscience.”
Includes bibliographical references and index.
ISBN-13: 978-0-471-78406-7 (cloth : alk. paper)
ISBN-10: 0-471-78406-0 (cloth : alk. paper)
1. Semiconductors—Design and construction. 2. Integrated circuits—Design
and construction. 3. Process control—Statistical methods. I. Spanos, Costas
J. II. Title.
TK7871.85.M379 2006
621.3815
2—dc22
2005028448
Printed in the United States of America
10987654321

To my children,
Simone and Jordan,
who inspire me.
—Gary S. May
To my family,
for their love and understanding.
—Costas J. Spanos

CONTENTS
Preface xvii
Acknowledgments xix
1 Introduction to Semiconductor Manufacturing 1
Objectives / 1
Introduction / 1
1.1. Historical Evolution / 2
1.1.1. Manufacturing and Quality Control / 3
1.1.2. Semiconductor Processes / 5
1.1.3. Integrated Circuit Manufacturing / 7
1.2. Modern Semiconductor Manufacturing / 8
1.2.1. Unit Processes / 9
1.2.2. Process Sequences / 11
1.2.3. Information Flow / 12
1.2.4. Process Organization / 14
1.3. Goals of Manufacturing / 15
1.3.1. Cost / 15
1.3.2. Quality / 17
1.3.3. Variability / 17
1.3.4. Yield / 17
1.3.5. Reliability / 18
1.4. Manufacturing Systems / 18
1.4.1. Continuous Flow / 19
1.4.1.1. Batch Processes / 20
1.4.1.2. Single Workpiece / 20
1.4.2. Discrete Parts / 21
1.5. Outline for Remainder of the Book / 21
Summary / 22
Problems / 22
References / 23
vii
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