The Extreme Programming Methodology

Published Date: 02 Nov 2017

The Endura5500 setup project plan will provide a definition of the project, including the project’s goal and objective. The plan also will guide the project management to calculate the budget and timeline to meet the committee.

BACKGROUD AND INFORMATIOM

Statschippac. Ltd is fourth largest semiconductor Testing and Assemble Company in the world. The company provide the packaging and testing solution to customer to bring products faster to the market. The company headquarter is in Singapore and manufacturing facilities are all over the world.(1)

Wafer Process department is from Statschippac Singapore. The department provide wafer level bumping technology to customer for metal deposition, lithograph and backend (ball drop). (See picture 1)

Within Global electronics marketing rise up, the marketing of electronics increase a lot and customer expect high volume of the products from Statschippac. Company decide to expand the department and purchase more Equipment to produce more wafers to satisfy the customer’s request.

Endura 5500 machine (Picture 2) is for metal deposition process under ThinFilm process. The theory is using vacuum system for physical vapour deposition (PVD)

(Picture 1)

(Picture 2)

GOALS AND OBJECTIVE

BUSINESS GOALS AND OBJECTIVE

The business goals and objectives for this project will focus on increasing wafer outputs and improve quality that:

Increasing the daily/monthly output of wafers to meet customer’s target

Improving the wafer quality with new operation software and hardware implementation.

Provide higher technology to keep customer’s wafer safety

Provides an open, flexible, reliable technology base for the future

Easy to operate

PROJECT GOALS AND OBJECTIVE

Project goals and objective is as follow:

Minimize impact to standard business operations within the affected units

Craft a favourable and secure agreement between the Department and the selected vendor.

Accomplish project business goals and objectives within defined budget and time parameters.

SCOPE

SCOPE DEFINITION

The scope of project is as follow:

3 of Endura 5500 machines need to be setup

400 wafers will be produced daily per machine

Start date will be on 01/01/2013 and Finish date will be on 01/04/2013

All machine setup need to meet 100K cleanroom standard

PROJECT BUDGET

Total Amount: 2,500,000 SGD

RISK MANAGEMENT

This project plans to start at beginning of the year, but because of Singapore culture, normally company will control the budget before Chinese New Year, so the management may not approve this project due to 2.5 million high costing.

The spacing of department is limited, 3 Endura machines are difficult to locate in a suitable place.

The project also require high qualification vendor to support, but the original vendor is from USA, they may not come to Asia to support the machine setup due to distance is far, other vendors may lower the machine quality with low qualification.

The cash return will be a major risk due to global economy is unstable and customer may reduce the production and the company profit may be reduced.

MILESTONES

Milestone Estimated Completion Date

Initial Steering Committee Meeting 01/01/2013

Machine installation …………………………………………...11/02/2013

Machine facilities installation…………………………………..07/02/2013

Machine calibration & buyoff………………………………….25/03/2013

Machine operation training……………………………………...04/02/2013

CONSTRAINTS

PROJECT CONSTRAINTS

Project budget is limited, with no other contingency

Project completion date is fixed, Project could not be delayed

Due to the Singapore workforce law, the manpower schedule needs to follow government policy. The manpower is difficult to re-schedule and may cause more costing (overtime) if re-schedule.

PROJECT METHODOLOGIES（2）

Before start to make a plan, project methodology need to be consider. Here are some most useful methodologies.

PRINCE2 Project framework

PRINCE2 is an acronym for Projects in controlled Environments and is now the UK’s de facto standard for IT project management. It provides a defined project management structure, and has flexible decision-making points. It also provides a set of control procedures and focus on products.

But this methodology does not consider human factor and soft issues. It is not a solution for any project, people still need to think more.

The Extreme Programming Methodology

The Extreme Programming Methodology is the new promising breeds of lightweight methodologies and is one of the agile processes. It has new rules and a modest number of best practices, it is easy to use. Base on iterations that embody several practices, such as small release, simple design, testing, and continuous integration.It has 4 core values: (1) communication, (2) feedback, (3) simplicity, (4) courage.

But this methodology requires a lot of programming and only for small and simple project use only.

The Scrum Methodology

The Scrum Methodology’s purpose is to restart play quickly, safely, and fairly after a minor infringement or stoppage. Scrum refers to the mechanism used in rugby for getting an out-of0play ball back into play. Scrum is lightweight methodology and one of agile methodologies.

But this methodology is suitable for software development, and not suitable for Endura 5500 setup project.

Critical Chain Project Management(3)

Critical chain project management (CCPM) is a method of planning and managing projects that puts the main emphasis on the resources required to execute project tasks. This is in contrast to the more traditional methods derived from critical path and PERT algorithms. A Critical Chain project network will tend to keep the resources levelly loaded, but will require them to be flexible in their start times and to quickly switch between tasks and task chains to keep the whole project on schedule. The critical chain is the sequence of both precedence- and resource-dependent terminal elements that prevents a project from being completed in a shorter time, given finite resources. If resources are always available in unlimited quantities, then a project's critical chain is identical to its critical path.

Critical chain project management is the suitable methodology for this project , because the start times is flexible and tasks are easy to be switched with task chains to make sure whole project on schedule.

PROJECT MANAGEMENT APPROACH

PROJECT TASKS TIME REQUIREMENT

To complete this project step by step, here is the list of the task processing days required. The day requirement is after seriously calculation and assumption, the actual days may be less than planning.

Task

Days required

Machine Body setup

20 days

System rack setup

10 days

Power rack setup

4 days

Cooling system setup

6 days

Pump setup

5 days

Water supply installation

7 days

Gas supply installation

10 days

Power supply installation

7 days

Mechanical handsoff calibration

15 days

Metal deposition thickness/uniformity calibration

30 days

Temperature/Vacuum calibration

20 days

Machine training

21 days

PROJECT PROCESS PLAN

The duration of this project requires 60 days and finish on 25th March, 2013. This calculation was done by MS project.

After calculation with slack, put the buffer at final of the processing step, the project period reduce to 36 days and finish on 19th Feb, 2013. (See Appendix 1)

PROJECT WBS

In this project, multiple tasks need to be completed. (See picture 4) Some of tasks should be done by vendor/contractor, and some of tasks should be done by company staffs. To setup machine, the installation and calibration are majority parts need to highlight, training provide also need to be considered as an important element. Here will list the content of work tasks need to be done in the 3 months schedule.

(Picture 4)

Machine installation(See picture 5)

Endura Matrix body installation

System rack installation

Power rack installation

Cooling system installation

Pump system installation

(Picture 5)

Facilities installation

(f) Water supply installation

(g) Gas supply installation

(h) Power supply installation

Machine Calibration

(i) Chambers mechanical handsoff calibration

(j) Metal deposition thickness/uniformity calibration

(k) Chamber temperature/Vacuum calibration

Machine operation training

To start the working tasks, the machine matrix body installation and water supply installation can start at the same time, then follow by the sequence with other machine installation and machine calibration and training.

PROJECT OBS

There are some vendors/contractors and company staff join together to complete this project, some from local, and some from overseas. Here provides the list of the company teams and vendors

Statschippac Teams

Interface team

Process engineering team

Equipment engineering team

Project management team

Facility team

Vendors

Applied Materials

Genetic

Polymid

Interface team supposes to communicate with internal and external resource. It is a portal of company. Process engineering team supposes to monitor the whole process of project and have a right to make any changes and final decision. Equipment engineering team supposes to work together with vendors to satisfy the machine calibration and installation requirement. Project management team supposes to monitor the vendors/contractors working flow and quality. Facility team provide the support to the vendors/contractor with the materials and manpower.

Applied Material is a USA semiconductor Equipment supplier, Genetic is a local equipment setup support company and Polymid is a facilities support company.

Issue Management

People issues

People with little experience of working within this project will make the machine setup quality is low and need to spend more cost to re-install, re-calibration the machine.

People has different race and religion may cause the process speed is slow, and fail to meet the project deadline. Because people may take leaves for their own religion or traditional festivals

Machine issues

Machine parts may not be good from directly ship from USA without company audit, this problem may cause the machine setup and calibration face more difficulties and lower the machine quality.

Machine need to do more modification due to the power adaptors is different and the Voltage for Singapore is 220V and for USA is 110V.

FINACIAL ANALYSIS

COST CONTENTS

Contents

Costs

Endura 5500 machine

2,100,000 SGD

Endura body installation

30,800 SGD

Power rack installation

20,560 SGD

System rack installation

24,400 SGD

Cooling system installation

21,840 SGD

Pump installation

21,200 SGD

Water supply installation

27,800 SGD

Gas supply installation

40,000 SGD

Power supply installation

38,800 SGD

Mechanical handsoff calibration

27,600 SGD

Metal deposition thickness/uniformity calibration

37,200 SGD

Temperature & Vacuum calibration

30,800 SGD

Total Amount

2,421,000 SGD

Machine Operation Training is Free of Charge provided by Vendor

5 YEARS CASH RETURN

The costing of fabricating1 wafer is around SGD2850, customer is going to pay SGD3000 per wafer. So the profit for 1 wafer is around SGD150. For PVD process the share of profit is around SGD15.The daily output of 3 Endura machines is around 400 pieces of wafers. So the daily profit is around

15 X 400 = 6000SGD

Base on the operation of company is 24 hours a days, 7days a week. Annual profit is around

6000 X 365 = 2,190,000 SGD

Because the investment is $2,500,000 and the annual return is around $2,190,000, and the minimum return rate is around 11%

YEAR

NET FLOW

DISCOUNT

NPV

0

-$2,500,000

1.0000

-$2,500,000

1

$2,190,000

0.9009

$1,972,971

2

$2,190,000

0.8116

$1,777,404

3

$2,190,000

0.7312

$1,601,328

4

$2,190,000

0.6587

$1,442,553

5

$2,190,000

0.5935

$1,299,765

$5,594,021

From the 5 years cash return plan, the NPV is around $5,594,021. So this project is considered as a successful project to process.

CONCLUSION

For Endura 5500 setup project, CCPM is the most suitable methodology to apply here. CCPM allows the resource and tasks re-schedule immediately and easily. It is flexible and intelligent, but it does not provide complete solution, unproven at the portfolio level and cultural changed unattainable.

In this project, slack is very important to the project manager because it represent the degree of flexible and have allowance to rearrange the manpower and resources to meet the project completion date and prevent some unnecessary issues which will cause the project process speed slow and machine quality is lower.

From this project, in theory, the cash return is very high, but that does not mean the return is stable without risk. The semiconductor marketing is still strong now, but the global economy is up and down, so many uncertain is unable to be calculated and prepared. So if in theory, cash return is high may reduce the actual risk of return is low or even minus.

This project plan is suitable for 5 years use only because within the technology is developing faster and faster and electronics marketing demand is higher and higher, Endura 5500 machine is not the suitable machine for fabricating the high technological and producing high quantity wafers. Endura 5500 machine only can produce 200 mm (8 inch) size wafers, but 300 mm (12 inch) size wafer has been come to the market. It contained more dies (chips) on 1 wafer and easier meet the high demand market. So Endura 5500 machine will become a history after 10 years, the process of machine installation, calibration will not be satisfied the future new model machine.

REFERENCE

Website:

StatsChippac company website(online) available at:

<http://www.statschippac.com> Access on 05/01/2013

Tutorialspoint.com website(online) available at:

<http://www.tutorialspoint.com/management_concepts/project_management_methodologies.htm> Access on 11/01/2013

Wikipedia, the free encyclopedia(online) available at:

< http://en.wikipedia.org/wiki/Critical_Chain_Project_Management> Access on 07/01/2013

APPENDENCIES