Quality Initiative

The Paperless Integrated Manufacturing System (PIMS) is a project that arose from real and urgent needs in Motorola final manufacturing. Semiconductor final-manufacturing sites exhibit many problems indicative of a lack of integrated systems support. Five years ago, there were few automated systems to support manufacturing — a single Tandem computer at each site provided simple inventory tracking, and a variety of small, homegrown data collection systems were available. The systems that existed were not integrated between factories or even within factories. High-quality production information was unavailable or, at best, held in isolated islands of automation within the factory.

Over and above the systems problems are severe logistics and coordination difficulties. Products from just one of the Motorola Austin divisions can be produced in any of ten assembly sites and six final test sites around the world. This leads to coordination problems (often the product owner is thousands of miles from the producer), as well as problems stemming from language and cultural differences.

All these difficulties led to multiple environments where paper has prevailed. Even today, 87 separate paper documents must be completed to have a product assembled in the Malaysia factory. This paperwork is time-consuming, difficult to track, often inaccurate, and wasteful.

The factories understood these problems only too well; unfortunately, there were few resources to help fix them. The traditional line of support — the IS organization — was focused on legacy system maintenance and on solutions for accounting and financial needs. Consequently, in 1989, the Austin Final Manufacturing Group (FMG)

Computer Integrated Manufacturing (CIM) organization agreed to initiate a paperless shop order system, contracting Sterling Information Group as the primary project developer to Motorola.

The factory system needs were defined as:

■ Online access to factory information and data collection on the manufacturing process

■ A means to input the necessary data easily through interfaces usable by all operators in all factories

■ Current tracking and history of all production lots through the manufacturing process (e.g., where and how they were processed, lot splits, combines, bonuses)

■ Ease of querying and reporting of all production data

Online shop order creation and maintenance to control the process specification and the data collection

■ All these functions available in a general-purpose manner to support multiple, diverse factories throughout the world

This undertaking would form the central nervous system of a 24-hour-a-day, 7-day-a-week production facility — a true mission-critical system.

Project Management Made Easy

Project Management Made Easy

What you need to know about… Project Management Made Easy! Project management consists of more than just a large building project and can encompass small projects as well. No matter what the size of your project, you need to have some sort of project management. How you manage your project has everything to do with its outcome.

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