siltroniC INSIGHT
4| 09
Our Employee Magazine
do you speak silicon?
Technical Terms From the Wafer and Silicon Business
open Heart surgery
IT-System “WorkStream� Changed to More Modern Software
muda: Combating Wastage
Efficiency Concept Cuts Wastage at Siltronic
04
06
10
e d i to r i a l
We had a difficult year in 2009, with the semiconductor market again showing its darker side amid the financial crisis. We responded to these changes by introducing structural adjustments, and you all contributed to stabilizing Siltronic during the crisis – through your commitment to the company and your willingness to do what was necessary. On behalf of the Executive Board I sincerely thank you for all your efforts. Today’s economic landscape is brighter than last winter’s, but we definitely can’t afford to relax. Prices remain very unsatisfactory for all diameters. On the capacity utilization front, the situation is more varied. Some plants are well loaded, while others still have spare capacity. Our solar business has slumped and sales are currently back to the levels of the presolar boom days. Although 2009 impacted our finances, I can assure you that we still will have the financial strength to invest in key technologies to secure our global market position. Nevertheless, we must remain extremely prudent with our resources in 2010. Given the nature of our business, it has never been our policy to waste resources. And, after a year like 2009, we certainly won’t be dropping our guard. Dr. Joachim Manke, CFO
ContinUity in HUman resoUrCes issUes In November, I additionally took over Executive Board responsibility for Human Resources from Dr. Michael Peterat. I am looking forward to my new role and am eager to continue my predecessor’s excellent work. I, too, intend to seek Human Resources solutions that conciliate the interests of all groups inside the company. After all, it was the high level of cooperation with employee representatives that enabled us to respond to the crisis in 2009 so quickly and successfully. Another equally important issue will be continuous employee development. Such training programs ensure that our workforce has the skills to master the years ahead. To be successful, we need employees with truly cutting-edge expertise. So, I’m sure that, during my term, new issues will be added to those of 2009 as we help employees to keep up with the rapid pace of change in semiconductors. Dear employees, I have no way of knowing at this point how 2010 will turn out. But there’s no doubt it will be an eventful year again. I look forward to tackling whatever it throws at us with you and I wish you all health, happiness and plenty of success! Sincerely yours,
Joachim Manke
SILTRONIC INSIGHT 4|09 02
Content / international
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editorial dr. Joachim manke
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towerJazz recognizes siltronic as their supplier of the year
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do you speak silicon?
04
open Heart surgery
06
siltronic is Wafertech's number one
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When Back Pain flares Up, exercise is the Best therapy
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muda: Combating Wastage
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Cover: An employee looks at a wafer notch. Find out more about this and other technical terms on page 4.
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TOWERJAZZ RECOGNIZES SILTRONIC AS THEIR SUPPLIER OF THE YEAR From left: Günter Sachs, Neil Nelson, Russell Ellwanger (CEO, TowerJazz), Bill Kramer and Nabil Alala (Senior Vice President of Operations at TowerJazz).
TowerJazz, the globally active Israeli IC foundry, has hon-
since the two semiconductor companies Tower and Jazz
ored Siltronic as its 2009 Supplier of the Year. On Novem-
merged in 2008. Siltronic already supplied both companies.
ber 4, Neil Nelson, President of our Portland site, accepted
The foundry chiefly uses our 150 mm wafers (polished or
this accolade on behalf of all Siltronic employees during a
epi) and 200 mm wafers (polished, epi or annealed), pro-
ceremony in Newport Beach (California, USA). With this
curing them from all Siltronic sites. An international team
award, TowerJazz recognizes Siltronic’s competitive pricing,
from Italy, Germany and the US coordinates supplies to this
outstanding quality and excellent service in Germany, Japan,
customer.
Pietro Italiano
Singapore and the US. It is the first time that Siltronic has received an award of this kind from the IC manufacturer,
SILTRONIC INSIGHT 4|09 03
?...?...?...?...?...
ASP...epitaxy... flatfinder...lapping... sticky mat...
DO YOU SPEAK SILICON? ASP? DSP? Poly? The silicon and wafer industry is full of technical terms. Siltronic Insight has compiled some of the key concepts. From ASP to wax mounting. So that you will always be in the know when the need arises. ASP: Average selling price. Specifies the average price that was achieved for a product in a particular period. At Siltronic, the ASP is often calculated in euros per square centimeter so that the different diameters may be compared. Boron: A chemical element often used with silicon in production to give an ingot with the properties desired by the customer. Center thickness: Is the name for – make an educated guess – the thickness of the wafer at its center. This value is important because it reveals, e.g. how much of the wafer has been removed by polishing. Several measurements (5 or 9) are often made at different points. The wafer thickness is also an important specification imposed on Siltronic by cuspolishing machines. By the way, the difference between lap-
tomers.
ping and polishing is that polishing makes the wafer smooth, As cut slices: A freshly cut wafer that can be shipped and
while lapping makes it flat.
sold right away without further processing. Sometimes jarEdge-rounding: A freshly sawn wafer is very sharp and
gon is as simple as that.
brittle. To avoid both injury to personnel and damage to the Czochralski process:
Named after its Polish discoverer,
wafer, the edge is grinded to a round finish.
Jan Czochralski [pronounced: Chockrallsky]. In this process, a monocrystal is produced by dipping a small seed crystal
Epitaxy: A finishing step in wafer production. It consists of
into a crucible full of molten polysilicon and then slowly pull-
depositing an additional layer of monocrystalline silicon onto
ing it out. The molten silicon hardens on the seed crystal in
the wafer in a reactor from the vapor phase. This enhances
monocrystalline form.
the surface properties of the wafer even further.
DSP: Abbreviation for double sided polishing. This is a pro-
Flatfinder: A device for determining the crystallographic ori-
cess by which the top and bottom of the wafer are polished
entation of a wafer. A flat is a straight edge cut into the wa-
simultaneously. It requires very specialized, extremely sensitive
fer. The orientation of a wafer can be thought of as a check-
SILTRONIC INSIGHT 4|09 04
ered piece of paper, with an atom at every intersection of the
from which monocrystalline silicon ingots are pulled by the
lines. Since the wafer is circular, the orientation of the lines is
Czochralski or float-zone methods. Siltronic obtains nearly all
unclear. The flat indicates the orientation (e.g. exactly north-
its poly from WACKER.
south or east-west). Orientation is important in the production of some devices. On modern wafers (200 and 300 mm),
Quartz crucible: Quartz crucibles are used to melt polysili-
the flat has been replaced by a notch to save space.
con, so that it can be converted into a monocrystal by the Czochralski process. The crucible is made of quartz, because
Float-zone pulling: Like the Czochralski process, this is a
so few impurities can get into the melt and because quartz
process for producing a monocrystal. First, an ingot of poly-
acts as a source of oxygen during crystal growth. Oxygen is
crystalline silicon is made. A section (zone) of the ingot is
needed for trapping impurities. This process is called “get-
then melted by an induction coil. This zone of liquid silicon is
tering.”
brought into contact with a seed crystal, whereupon it hardens in monocrystalline form. The zone then migrates along
Reference wafer: A wafer for calibrating equipment and in-
the ingot, transforming it into a monocrystal. This process
struments, or for comparing technologies. Siltronic makes its
does not require a crucible.
own reference wafers or gets them from customers or other specialist companies.
Heat treatment: Controlled heating of a wafer. Heat treatment at elevated temperatures of around 1,200 degrees
Seed crystal: A small elongated crystal of monocrystalline
centigrade is used to remove defects. At lower temperatures
structure which is suspended in molten silicon (see Czochral-
(around 700 degrees centigrade), it prevents oxygen from ad-
ski or float zone process). The molten silicon hardens on the
versely affecting the wafer’s electrical properties.
seed crystal in monocrystalline form.
Lapping: A process used for flattening wafer surfaces that is
Sticky mat: Placed on the ground before or in the airlock
frequently found in wafer production. A special liquid (slurry)
to the cleanroom. It prevents particles which are clinging to
is introduced between the wafer and the lapping machine. It
shoes from being walked into the cleanroom. The particles
contains tiny particles which remove even the smallest irregu-
cling to the sticky mat instead.
larities on the wafer to render it perfectly flat. Supersaturation: A state in which the solubility of one Lattice atom: This is the term for an atom which is con-
substance in another has been exceeded. When this state is
nected to other atoms in the crystal lattice.
reached, precipitation can occur. Supersaturation with oxygen, for example, causes bulk micro defects (BMD).
Low-pressure chemical vapor deposition: Like epitaxy, this involves depositing a layer of silicon onto the wafer. Un-
Surface finish: the last step which alters the surface of a wa-
like epitaxy, however, the deposited layer is not monocrys-
fer. The treatment may be mechanical, thermal or chemical
talline.
(e.g. etching, polishing, annealing, or involve deposition).
Megasonic nozzle: Megasonic cleaning is performed with
Wax mounting: In the past, the wafers really were mounted
a very high-pitched, strong pulse of sound. It removes the
with wax to the polishing plate during polishing. Today this is
tiniest particles from the wafer much in the way opticians
done with a special epoxy that hardens before the polishing
use ultrasonic waves to clean glasses. The megasonic waves
process begins.
come from special nozzles. For optimum cleaning, the sound is transmitted to the wafer surface via a special fluid.
Note: Translations of all common terms into German and Japanese can be found on the intranet:
Polycrystalline silicon: Also called poly, this is an impor-
Siltronic Services / Siltronic Dictionary
Florian Ranner
tant starting material in wafer production. It is the material
SILTRONIC INSIGHT 4|09 05
New and comfortable: The Operator Interface makes daily work easier.
OPEN HEART SURGERY After 20 years in operation, “WorkStream,” an IT sys-
there is something else, something invisible, that flows
tem for controlling material flow at Siltronic, is gradu-
through every fab – data. “Each individual wafer, each con-
ally making way for more modern software. The new
sumable and each order is accompanied by a whole set of
tool is designed to increase automation and thus boost
data,” says project manager Peter Mader of Burghausen’s
efficiency. Production workers are already benefiting
IT department. “We have countless parameters, specifica-
from a much improved user interface that combines all
tions and rules governing the precision manufacturing of
the previous functions. Once the new system has been
wafers. So, the set of options for a particular wafer must
installed at Fab 300-1 in Burghausen, it will be rolled
be clear at every production step. Handling this information
out at other sites, too.
is one of the main tasks of the manufacturing execution system (MES). It is more or less the backbone of the fab,
Sometimes it is the things you cannot see that are the most
and oversees the exchange of information between each
interesting. The processing of ingots into perfect wafers is
workplace and production step. In Germany, Siltronic has
an everyday sight in a modern wafer fab. The production
been using WorkStream for around twenty years. Now it is
steps are familiar and the machines for processing and fin-
time for a change of system. The difficult part is to manage
ishing the wafers are a part of the visible landscape. But
the migration without hindering ongoing production.
SILTRONIC INSIGHT 4|09 06
neW User interfaCe for oPerators
the really complicated parts are tucked away inside the en-
“The new system’s most striking aspect, from the IT side,
gine compartment,” says Matthäus Wimmer, responsible
is that its interface has been tidied up for the operators,”
for IT at the grinding section. Since safety is more impor-
says Christian Leiner, who is in charge of shop-floor auto-
tant than speed (after all, a mistake would seriously impact
mation during the changeover. Until now, most production
production), the new MES interface is being installed on
workers have had to cope with as many as four different
top of the existing background system. Once it is function-
systems: PAC (an equipment control system), the operator
ing properly, Siltronic’s IT experts will proceed to the next
station, SPC (a kind of fever chart showing key control vari-
stage. “Of course, we’re entirely dependent on its accep-
ables, such as “metal on the wafer”) and a variety of differ-
tance by the production staff,” says Wimmer. “That’s vital
ent web applications. The new system features OIFplus (an
if the changeover is to run smoothly.” The new MES will
operator interface), which enables employees to read their
not be fully up and running until mid-2011. But even after
most important data from the screen at a glance.
that, Mader and his colleagues won’t be twiddling their thumbs. The next project – Fab 300-2 – is waiting in the
gradUal imPlementation
wings. Meanwhile, other sites, such as Singapore, are look-
More technically demanding, though quite invisible in the
ing on with interest.
Florian Ranner
background, is the installation of the MES at the fab. “It’s a bit like a car. From the outside, we only see the body, but
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SILTRONIC IS WAFERTECH’S NUMBER ONE Siltronic has again won the “1st Place Wafer Supplier Award” of US-based TSMC subsidiary WaferTech. With a total score of 95.5, Siltronic was ranked first among all the semiconductor company’s wafer suppliers. Siltronic was even able to improve on its previous score – already a benchmark for other wafer suppliers in 2008. It is the second consecutive time Siltronic has been honored by WaferTech for outstanding quality, competitive pricing,
This certificate testifies Siltronic's outstanding performance.
reliable delivery and its level of service. “This achievement would not have been possible without the support of all our Siltronic colleagues, from order entry through shipping,” comments Todd Slayton, Vice President of Sales, USA.
Matt Kleinke
SILTRONIC INSIGHT 4|09 07
WHEN BACK PAIN FLARES UP, EXERCISE IS THE BEST THERAPY Lift a box awkwardly or sit for hours in front of a computer – and suddenly you have backache. Almost all adults experience this at least once in their lives. “Any twinge of back pain could be a warning signal that something is amiss,” explains Dr. Gerhard Schillinger, a doctor at AOK (Germany’s largest health insurer). Taking it easy and waiting for the pain to go away by itself is the wrong approach. Exercise is the best therapy. It’s good for you – and it’s even fun. Backaches often go away by themselves, yet many people experience them repeatedly. Lower back pain is the most widespread affliction; nearly one out of three adults in Germany, for example, has gone to the doctor because of it. According to German government statistics, it is among the most common reasons for medical visits and short-term disability leave. tense mUsCles aCHe Why is that? Our spine is sheathed in muscle fibers and liga-
sWimming is good for yoU
ments. These three components must all interact efficiently
Two days – at the latest – after a backache, patients should
to enable us to walk upright, turn, bend and stretch. “Back-
start exercising again, maintains Dr. Schillinger, although
aches are usually caused by muscle pain,” points out Dr. Schil-
only gently at first. Strengthening the back allows it to with-
linger, a neurosurgeon. “If the muscles are tense, that means:
stand stress better in the future. “Swimming is best of all,
I am expecting them to do more than they can handle.” The
because it doesn’t overly burden the back,” says the doc-
back’s weak points are located in the lower (lumbar) and top
tor. The water buoys the body’s weight – which is usually
(cervical) regions of the spine. Pain often emanates from the
borne by the spinal column – thus often relieving the pain.
cervical region to the shoulders.
Heated, thermal spa water can especially help to relax tense muscles.
taking it too easy Can Weaken yoU Many people initially react to a backache by staying in bed
Not everyone takes to swimming, though. “It is important
and waiting until it gets better. However, we now know that
that exercise is fun; otherwise, you wouldn’t stick with it for
underusing muscles only weakens them further. Thus, pa-
very long,” the doc explains. So everyone should choose an
tients fall into a vicious cycle of pain, tension and enfeebled
activity they enjoy. This increases the chance of continuing
muscles. The objective is therefore to quickly become active
to remain active. Ultimately, exercise is not only the best
again to strengthen the back.
therapy for lower back pain – it is also the best prevention.
SILTRONIC INSIGHT 4|09 08
What Experts Recommend for Backaches: Stepped beds in particular can offer relief: the back lies flat while the legs are elevated at a 90° angle to rest on a thick cushion. This takes the load off the spine. If pain becomes intense, pain killers can be useful; this breaks the cycle of pain and tension. However, medication is not a long-term solution. Take a hot bath or use infrared light: they help to relax tense muscles.
Sports is fun and strengthens the back. Experts especially recommend swimming, jogging and hiking.
Work oUt mUsCles evenly
Problems when urinating or a numbness on the inner thighs
A rule of thumb: activities that work out muscles in as bal-
could be warning signals that require immediate medical
anced a manner as possible are the most suitable. In addition
attention.
to swimming, other good sports are jogging, nordic walking, hiking and cross-country skiing; all of them stretch and relieve
finding tHe CaUses
the back alternately in a positive way. Wearing appropriate
It is also important to investigate the causes of backaches.
footwear is a priority, though. Sports such as golf, skydiv-
Carrying heavy loads, sitting too long in the same position,
ing or weightlifting, on the other hand, greatly overexert
worn out mattresses or obesity can all trigger twitches and
lower back muscles. Should you take up sport again after
pangs in the lower back. It is important to apply your strength
prolonged inactivity, and also suffer from other ailments, first
properly when lifting loads, for example. “Always lift heavy
consult your doctor.
objects from a squatting position, keeping the object close to your body,” recommends Schillinger. If you spend a lot
Even though exercise helps – sometimes there is no alterna-
of time working at a computer, make sure you have a good
tive but to see a doctor. A physician should always be con-
office chair, i.e. one that allows dynamic sitting. To prevent
sulted in the case of persistent pain, after a fall or when there
muscle tension, it also makes sense to stand up, walk around
are paralysis symptoms in the arms or legs. The same is true
a bit and stretch your back muscles.
if discomforts worsen during sneezing, coughing or pressing.
Gabriele Hauser-Allgaier / AOK-Mediendienst
SILTRONIC INSIGHT 4|09 09
Muda is the japanese word for wastage. Within the Lean Six Sigma approach it defines eight ways to fight wastage in an organization.
MUDA: COMBATING WASTAGE efficiency Concept Cuts Wastage at siltronic “Having our own costs under control is vital, especially
inCreasing ProdUCtivity
for a company like Siltronic,” says Ulrich Köhler, head of
An interesting way to reduce costs without compromis-
Siltronic’s efficiency project Proflex. In plain language, there
ing on such key criteria as customer proximity, quality and
are three factors that influence our success. The price we
technical innovation is to address each unnecessary cost.
obtain for a wafer on the world market. The total quantity
This is the job of Sven Jeschke of Quality Management in
of wafers we sell, and the cost of making them. The price
Freiberg. For help, he draws on muda, a concept developed
multiplied by quantity equals sales. The profit is what re-
at Japanese carmaker Toyota, as part of its LEAN manage-
mains when the costs (e.g. of materials, energy and person-
ment program (see Insight 03/09). Muda is the Japanese
nel) have been deducted.
word for wastage. The concept is based on systematically analyzing and eliminating wasteful processes within an or-
“At Siltronic, we have little or no influence over two of
ganization. Eight different types of wastage are defined (see
these factors,” explains Köhler. “The price is determined by
box on page 12).
the world market, and is largely beyond our control. And we have limited influence over the quantity of wafers we can
The effects of muda can be significant. Toyota’s studies have
sell at any given price. That’s because we are dependent on
shown that it is not unusual for muda to consume up to
both the customer and what our competitors are offering”.
90 percent of working hours – due to administrative tasks,
The only thing we can control, then, is cost.
meetings, idling, mistakes and walking/traveling distances.
SILTRONIC INSIGHT 4|09 10
All these can cause time to slip away unproductively. Reduc-
get the information they needed. This simple, cost-neutral
ing or eliminating this time boosts productivity.
measure was implemented immediately. Now employees no longer have the hassle of searching for an SAP computer.
Catalyst for Potential imProvements Jeschke has already implemented several muda projects in
A further example is when external companies repair certain
Freiberg and Burghausen. His approach is always the same.
components. Often, it was not clear exactly what had been
“We basically do an audit,” says the 33-year-old. “The first
repaired, and this had to be clarified with the manufacturer.
step is to inspect the work areas and talk with employees.”
Now, Siltronic’s office administrators request a detailed re-
However, he sees himself not so much as an unforgiving
port that provides the necessary transparency. This not only
auditor but rather as a catalyst for unlocking improvement
makes the administrators’ work easier but also provides
potentials within a factory or department.
valuable information about repairs, enabling our own personnel to perform similar repairs in the future.
Wastage: seek and destroy Jeschke has identified numerous practical applications of
Another part of muda consists of jointly analyzing the obser-
muda in the daily working environment. Take, for example,
vations, identifying the problems and devising specific solu-
the walking/traveling distances inherent in a work system. If
tions to address the wastage. The data is then presented to
they are too long, they tie up too many resources, keeping
managers so that specific steps can be taken.
staff and products idle and waiting. “At our Freiberg fab, for example, we discovered that more SAP stations should be
The results speak for themselves, as Dr. Christian Heedt
installed in the vicinity of production,” he says. Employees
and Bernhard Schmidt can affirm. The two Engineering
were having to seek out a computer with SAP software to
Continued on page 12
With on-the-spot talks, Muda-Expert Sven Jeschke (l.) finds out how to fight waste best.
SILTRONIC INSIGHT 4|09 11
Continued from page 11
heads at Freiberg and Burghausen have both used Jeschke’s
do is take a look at their working environment and check it
services. “Sometimes it can be very useful to ask someone
for the eight types of muda.” Incidentally, the concept is just
from outside the department to take a fresh look at daily
as effective in traditional office environments as in manufac-
operations. After a while, people just get used to process-
turing. Often it is the simple things that can be improved.
es and methods that are not optimal, and than you need
“You might weigh up whether it’s better to phone a col-
someone to help identify the potential improvements and
league to clarify something, or to write an e-mail and then
to present them constructively,” says Schmidt. “It’s amazing
wait half an hour for the answer,” says Jeschke. Phoning
how easy it is to streamline costs and work practices when
will certainly save time, which can be used productively.
you set aside two hours to review your daily operations,” adds Heedt.
Another example of wastage is poorly structured project disk-drives. No one should have to spend more than 15
Jeschke is now no longer the sole muda expert at Siltronic
minutes searching for a document. The correct structure
in Germany – the technique is a standard element of the re-
saves time and money, boosts workplace productivity and is
cently launched training course for the “LEAN Black Belt.”
far easier on the nerves.
Florian Ranner
mUda in everyday Work “The great thing about the concept is that every employee can spot muda in their own personal surroundings by spending a little bit of time on it,” says Jeschke. “All they need to
THE EIGHT TYPES OF WASTAGE
info
Overproduction: Using more resources for products than
accurate, more complex or more costly than those needed
necessary to supply customers is called overproduction in
to fulfill a customer request.
muda language. Examples:
Inventory: Whether in the form of raw materials, semi-
Producing more than the customer ordered
finished or finished products, inventory is just tied-up capi-
Storing superfluous intermediate and end products
tal. Each of the three forms constitutes wastage if it is not
Overproduction is considered the worst type of wastage be-
immediately fed into the production process.
cause it costs money (storage costs, etc.) and also spawns several other types of muda.
Motion: Does not mean the transport of products, but rather employees’ movements. Long routes and access paths,
Unnecessary transportation: Every time a product is trans-
for example, slow down work processes and are therefore
ported, there is a danger that it will be damaged or lost, or
wastage.
will arrive late at its destination. Transportation does not generate any additional benefits that customers would be
Waiting: Whenever products are not being processed
willing to pay more for.
or transported, they are waiting. In this state, they tie up corporate capital and add nothing to the financial results.
Defects: Every defect wastes money. Customers do not buy
Waiting products constitute wastage.
defective wafers. Untidiness: Any tool, product, auxiliary or document that Over-processing: Every time more work is done than is
is out of reach or cannot be found immediately, wastes
needed to meet the specifications of the customer, wastage
time because someone must look for it. This time could
occurs. This also applies to the use of tools that are more
have been spent productively.
SILTRONIC INSIGHT 4|09 12
A M E R I C A
4|09
C o n te n ts / A merica
17
Frustrated With Insurance Paperwork?
14
Lighting the Way for Cost Savings
15
Up Through the Ranks
16
The Three R’s Made Easy
17
Bringing Comfort and Joy
18
Employee Anniversaries
18
Climb Every Mountain
19
Š 2009 by Siltronic Corporation. All rights reserved. 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, or otherwise without prior permission in writing from Siltronic Corporation.
15
16
Executive release: Dr. Wilhelm Sittenthaler Executive review: Kai Knitter Managing Editor: Ben Rigall Contact: Ben.Rigall@Siltronic.com
be n efits
Frustrated with insurance paperwork? Manage your benefits through your computer Are you trying to find out what insurance coverage is
To get information fast online about your health insurance
provided for flu shots? Has your medical claim been denied
coverage and take charge of managing your benefits:
or only partially paid, and you want to know why? 1. Check your I.D. and plan number on your wallet insurance The Navigator feature on the Aetna website lets you check
card before you access the Aetna website.
records for medical, dental, and pharmacy visits; request a review of claims submitted; and more. Click on the Docfind
2. Access the Aetna website by a link on the Siltronic
link and you can search for doctors by specialty or zip code.
intranet home page. Outside the plant, go to the Aetna
Print the results so you don’t have to write down all those
website (www.Aetna.com).
choices. Before going to the doctor or dentist, you can check whether a procedure is a covered expense or whether charges may exceed the amount allowed in your policy. Aetna no longer mails paper copies of the Explanation of
3. Register for a user account on the Aetna website, then log in to find a page that Aetna personalized for you. GO … Use the DocFind link on the left side of the screen.
Benefits statement.
Find Claims on the menu at the top of the page and navigate
If you have questions or disagree with a decision about how a
remarks to check the status of the claim (for example, the
claim was processed, use the Navigator to view information
claim may be in a Pending status and not yet paid).
down to the Explanation of Benefits section. Look for any
about the doctor visit. Click on Send a Message to use Aetna’s secure e-mail system that automatically attach details about the claim. Aetna provides a response to online messages within 24 hours. TIP: Do not use the general “Contact Us”
If you do not have computer access, call Aetna Customer Service at 1-(888) 587-1696 with your I.D. card in hand. Knowledge is power. The tools are just a click away. The more information you have, the better equipped you
link on the Aetna website, because the
will be to handle any questions about your health insurance
message does not include details
coverage. Go to the Aetna website today and check your
about the claim, which may delay
personalized page.
any decision.
Benefits Specialist Ben Rigall shows Sostenes “Tito” Mendoza, slicing operator, how to access his insurance information using Aetna’s DocFind feature on the facility’s computers in Fab2.
SILTRONIC INSIGHT 4|09 14
Lighting the Way for Cost Savings While the economic outlook has been gloomy, the Portland site has some bright spots… literally Site Engineering Manager Craig Driggs and Facilities
Fine tuning the controls
Engineering Team Leader Moe Khorsandian recently
The team upgraded technology to optimize two air handlers.
implemented a capital improvement project to retrofit
The older pneumatic controls sometimes allowed heating and
lighting in the utility buildings. Replacing about 120 existing
cooling to run at the same time, similar to driving your car
High-Intensity Discharge (HID) fixtures with more efficient
with one foot on the brake and one on the gas. Converting to
fluorescent fixtures and lamps saves almost 50% in lighting
a computer-controlled system separates the actions and saves
energy consumption and almost $16,000/year on Siltronic’s
about $10,000 (with other air handlers still to be updated).
electric bill. Optimizing the pump A manufacturing area is required to maintain a certain level of
Another project underway is to optimize pump efficiency on
light for production, safety, and quality. This new project does
the UPW Grade B water distribution system to Fab2. Instead
not impact luminance – the light from the fixture. In fact, the
of running a pump at full force and using energy at maximum
new T5 fluorescent lamps use almost 50% less energy and
capacity, Facilities installed a Variable Frequency Device (VFD)
produce 30% more light.
– basically a controller – to the existing system. This project should result in a 30% cost savings compared to running the
More projects
motor without it.
The Facilities group is responsible for everything that runs right up to the process equipment—all water, compressed air,
Trends
exhaust, and so on. Because these facilities use most of the
The Facilities group works hard to identify and implement
power at the site, the group has an opportunity to identify
energy-saving programs that show significant and sustainable
savings by reducing energy usage.
results. Even when production went up in 2007, electric usage between 2003 and 2009 went down by at least 10%. Some
These projects make the company more competitive and
savings may not be easy to see, but all improvements reduce
help the environment. With the site employing close to 1,000
costs each and every month.
employees, a sense of community becomes a real incentive for the group to look for every penny, nickel, and dime they can
Moe and Craig modestly insist that what their team does is
save. As Moe says, “Anything we can do on our side to reduce
simply part of their job – to be responsible and do things in
costs means one more job saved.”
an efficient way to maintain the company’s viability. They say the really fun part of their jobs is to figure out solutions to
Capturing the heat In 2008, the Facilities group initiated a project to capture the Fab’s waste heat and use it to warm the buildings—reducing not only the amount of steam lost from the boilers but energy usage as well. Reducing small leaks Any air system will have minor leaks, according to Craig. Reducing the compressed air pressure by just 3 to 5 psi (pounds per square inch) made no difference in the process but saved $6,200 this year … and every dollar adds up. Moe Khorsandian explains the benefits of installing a Variable Frequency Device (VFD).
engineering challenges.
Dan Owens and George do some fine tuning on one of the polishing machines.
Ability Creates Career Path Aptitude and interests guide his rise through the ranks
As a child, George Condy liked to take things apart just to
In his current role, George looks at how different slurries could
figure out how they worked… to the point where his father
be improved; analyzes how to change volumes or compositions,
had to lock up his tools.
and works with vendors to learn about changing processes or supplies. If something breaks down or there is contamination,
Born in Detroit, Michigan, where winters blow cold, George
George does the analysis and hands-on work to figure out
once watched his father put a snowplow attachment on a
whether it’s a quality, machine, or process problem.
lawnmower. George figured out how to take it apart and then hooked it up to his wagon. George was just 6 years old.
The goal is to manufacture the best quality wafers in the most cost-effective manner. He gets great satisfaction in solving
Developing expertise
problems, knowing that the end result is a process running
That curiosity has helped George throughout his career.
well.
He started work at Siltronic as an operator in Polishing, progressed through the ranks of Operator, and was selected
Managing George
to be a trainer to educate others about polishing. George also
His natural aptitude has contributed to George rising through
set up polishing equipment in Fab2 and helped qualify the
the ranks in the polishing area, where his knowledge is
first 200mm products.
extensive. “George thinks like an engineer in the work that he does and the test methodology he proposes,” according
A more typical career pathway at Siltronic after working as an
to Tom D’Silva, his manager over the past eight years. Tom
Operator is to become a cell leader. Because of his aptitude
said that George needs minimal direction and generally has
and interests though, George applied for the position as a
analyzed a technical problem before bringing it to him.
process technician when an opening became available. In March of 2009, George reached his 25th anniversary with SCO has seen great improvements in wafer flatness and
Siltronic. The job George is doing today did not exist when
surface finish tolerances over the years. As customers tighten
he started his career. He keeps current by reading about
specifications to make next-generation products, processes
new methods and technologies. “Basically, it’s incremental
and products must improve to meet those challenges and
learning,” says George. “I read and learn over time about
remain competitive.
things that might work for us.” When asked if he still takes things apart at home to see how they work, George just smiled and said, “I have my own tools now.”
George and Tech Operator Bill Bell do some on-the-spot troubleshooting. SILTRONIC INSIGHT 4|09 16
Koreen shares information at the Fix-It Recycling Fair. She proudly wears her Master Recycler badge.
The Three R’s Made Easy A passion to reduce waste led her to become a certified Master Recycler
Koreen Lail works as an Environmental Engineer at the
years ago. For example, many people think they must sort all
Portland site. During her time off work, she attended an eight-
recycled materials.
week course (evenings and weekends) to learn about waste prevention, recycling processes, alternatives to hazardous
Generally, you can toss newspapers, magazines, junk mail,
household products, composting and deconstruction, and
cans, cardboard, egg cartons and plastic bottles into curbside
“green” building.
recycling bins. Any juice or food containers—including pizza boxes, Styrofoam, and plastic shopping bags are the excep-
On a class field trip to a transfer station, the class witnessed
tions. Also place glass in a separate bin, both for safety’s sake
towering stacks of garbage. Did you know that 86 compacted
as well as separate processing.
truck trailer loads of garbage are shipped out of the Portland metro area every single day to a landfill in Arlington (half way
With several companies serving the Portland metropolitan
across the state)?
area, check with your local provider for specific guidelines or contact Koreen at ext. 7994. For materials you can’t recycle in
According to the Department of Environmental Quality (DEQ),
a curbside program, contact Metro at (503) 234-3000 to find
Oregonians generated 5.8 million tons of waste in 2006.
a recycling point.
That is enough to fill the Rose Garden Arena 3.3 times each week. EPA calculates that the average American generates
The Master Recycling Program is administered by the
4.62 pounds of trash per day, not including construction and
City of Portland Office of Sustainable Development and
demolition waste.
serves Multnomah, Clackamas and Washington counties (other programs are available statewide). Master Recyclers
These figures inspire graduates of the program to gladly
staff information booths at community events, write articles,
volunteer 30 hours to help others learn the three “Rs”:
make presentations to other homeowners, and work on special projects in their communities to motivate people to
• Reduce the amount of natural resources used
reduce waste.
in the first place What action could you take today?
• Reuse material • Recycle what cannot be salvaged Despite her own beliefs about reducing waste, though, Koreen’s husband was slow to join. She had learned in the program that making it easy would encourage people to recycle, so Koreen simply placed a recycling bin right next to the garbage can inside her home. With it so convenient, her husband began to recycle right away. Technology and new processes make recycling easier than ever. Koreen points out that some people still have misconceptions based on early recycling programs from The Community Fix-It Recycling Fair educates everyone
Director of Quality Dwain Oster and Admin Assistant to the CEO Candyce Hoeye carry bags of gifts to donate.
Dianne Irish and Glen DeWater give the donaitons a last minute check before they’re delivered.
Left: Jarrod Gillihan’s team from Logistics shows off some of the gifts collected during this year’s toy drive. Top from left: Jon Kemhus (retired), Jarrod Gillihan, David Alferd. Kneeling: Allen Wong, Eric Wright, Josh Craig, and Ruth Underwood.
Bringing comfort & joy The spirit of giving is alive and well this holiday season. Even in these
employees as they provide clothes, food, toys, gift cards, household
difficult economic times, employees working at the Siltronic Portland
supplies, and more. These benefitted 16 local families who are
site continue to open their hearts to support others in need.
struggling due to unemployment, illness, or life’s responsibilities. Gifts were donated to the Bradley-Angle House (a domestic violence shelter),
HR Coordinator Ruth Underwood has seen the generosity of
Children’s Cancer Association, and Doernbecher Children’s Hospital.
Employee Anniversaries The following employees had service anniversaries in the months of October, November, and December. Twenty-five years: Debra Long, Nam Dang. Twenty years: Matthew J. Donaldson, Nick Frederick, Esther Gani, Fen Lu, Khanthaly Ounaphom, Don
Nam Dang
Matthew Donaldson
Nick Frederick
Esther Gani
Hanh Truong
Thu Van
Pastorino, Thong Sounalath, Viengsay “La” Thilavanh, Hanh Truong, Thu Van. Fifteen years: Roxanne Dulas, Kathy Hoang, Oanh Huynh, Thao Le, Vu Le, Connie Maplethorpe, Carol Nelson, Ron Nelson, Thien V. Pham, Hoyt Sharpe, Keolakhonsy Vongnath, Sherri Webster, Paul Wittke, David Zielinski. Ten years: Analiza Alvarez, Bob Berrigan, Charlie D. Charley, Michael Lynn Dunn, Yoko Ezikiel, Errol Griffith, Long Ho, Nada Holovcuk, Tommy Huang, Suada Karaselimovic, Chris Lalangan, Toan Quoc Le, Lucy Leopold, Beverly K. Powers, Patience Shannon, Lannie Tierney, Trung The Vuong, Lorena Willard.
Debra Long
Khanthaly Ounaphom
SILTRONIC INSIGHT 4|09 18
Thong Sounalath
Don Pastorino
Viengsay Thilavanh
Climb Every Mountain How would you celebrate the big 5-0? As a Buyer for wet technologies, Vance Jones orders supplies and spare parts to keep production moving. Yet for his 50th birthday, Vance wanted to get moving himself and climb Mount Kilimanjaro in the East African country Tanzania. Why Kilimanjaro? A former employee talked about his experience there and inspired Vance to see the mountain and its glaciers. The climb Vance scheduled a seven-day climb up the Western Breach of Mount Kilimanjaro, with five and a half days to go up to the top and just a day and a half to come back down. The group started at 5,000 feet, then climbed to 8,000 feet the next day, and then to 11,000 feet, camping each day to acclimate their bodies to the altitude. They reached the top, an elevation of 19,335 feet (compared to an elevation of 11,249 feet for Oregon’s Mount Hood). The party consisted of four hikers and 16 porters (including guides and cooks), each carrying a backpack with food, water, camera equipment, a change of clothes, and other supplies. Vance recalls the last day of the climb: “We left late that morning, waiting an extra hour in our base camp due to high winds—gusts that can blow a man right off the ridge. I was the slowest one going up, and started to get blurry vision after a 3,500’ gain in altitude. We stopped for lunch by a crater,
Head Guide - Jamaica, Kevin Annotti (photographer) John Leary, David Edgerton, Vance Jones, Asst. Guide - Ally.
the summit, taking pictures and resting while they took in the wonder of the surrounding view. From the desert to the beaches Next on the trip was a safari into the Serengeti National Park. Vance saw a female leopard with her kits – a sighting so rare that it made their guide weep. Vance ended his travels on the beaches of Zanzibar, an island about 25 miles off the coast of Tanzania. Touring historical Stone Town, Vance wandered the labyrinth of narrow streets and witnessed the contrast between tourist resorts and the daily poverty. When Vance stopped in a small shop to buy a Coke, the shop owner asked Vance to purchase a second Coke because the owner could not afford his own.
and our guides told us we would go ‘polé polé’ from then on,
Despite the endemic poverty, Vance was struck by the warmth
which in Swahili means ‘slow–slow’. We were the last group
and spiritual connection of the people he met. Striking up a
to reach the peak that day.”
conversation with two men sitting on a curb, Vance discovered
Coming in last sometimes works out for the best. Earlier groups who climbed the mountain were able to spend only 15 minutes at the top because they had to make way for other groups to ascend the peak. As the last group, Vance and his fellow hikers were able to spend almost an hour at
that they were the best of friends—living in harmony, although one was a Christian and one a Muslim. That attitude of tolerance was demonstrated in Tanzania as well, which has 117 different tribal entities. What about future trips? Vance likes to make a major trip every few years and is planning only local trips now. He says planning for travel gives him something to look forward to and motivates him to keep fit. Ask Vance to show you the photos of his trips, but be prepared—he has about 4200 digital images from the trip.
SILTRONIC INSIGHT 4|09 19
siltronic
p erfect silicon solutions
7200 NW Front Avenue Portland, OR 97210
siltronic
p erfect silicon solutions