Work-in-Process Tracking Implementation for Semiconductor Fabrication Facility
Deployed advanced RFID-based work-in-process tracking system for semiconductor fabrication facility, enabling real-time visibility of wafer lots through 400+ production steps, improving lot traceability, reducing cycle time, and ensuring seamless ERP integration for accurate financial reporting.
Limited WIP Visibility in Complex Fabrication Process
The semiconductor fabrication facility struggled with limited real-time visibility into work-in-process inventory as wafer lots moved through hundreds of production steps, resulting in inefficiencies, quality issues, and inaccurate financial reporting.
Lack of Real-Time Visibility
Manual tracking methods couldn't keep pace with 2,500+ active lots moving through 400+ production steps. Lot locations and status often unknown, causing delays and inefficiencies.
Traceability Gaps
Incomplete lot history and process tracking made root cause analysis difficult when quality issues arose. Regulatory compliance requirements for full traceability not consistently met.
Extended Cycle Times
Lots frequently delayed searching for materials or waiting for equipment. Bottlenecks not identified quickly. Average cycle time 15-20% longer than industry benchmarks.
Inaccurate WIP Valuation
Manual WIP tracking led to inaccurate inventory valuations for financial reporting. Month-end close process extended due to WIP reconciliation challenges and adjustments.
Advanced RFID-Based WIP Tracking System
We implemented a comprehensive RFID tracking solution integrated with the facility's manufacturing execution system (MES) and ERP, providing real-time visibility and automated data capture throughout the production process.
RFID Infrastructure
Deployed 150+ RFID readers at critical process steps and storage locations throughout the fab. Tagged all wafer carriers and lot containers with high-temperature resistant RFID tags for automatic identification.
MES Integration
Integrated RFID system with existing MES to automatically capture lot movements, process completions, and equipment usage. Real-time data synchronization eliminated manual data entry and errors.
Real-Time Dashboard
Created comprehensive visualization dashboard showing lot locations, status, and cycle time metrics. Enabled production managers to identify bottlenecks and optimize workflow in real-time.
Complete Traceability
Implemented full lot genealogy tracking capturing every process step, equipment used, materials consumed, and operator actions. Created comprehensive audit trail for quality and compliance requirements.
ERP Integration
Connected tracking system to ERP for automated WIP valuation based on actual production stage and costs incurred. Enabled accurate real-time financial reporting and eliminated month-end reconciliation issues.
Automated Alerts
Configured intelligent alerts for lots exceeding target cycle times, approaching hold limits, or requiring special handling. Proactive notifications enabled quick intervention to prevent delays.
Dramatic Improvements in Efficiency and Visibility
The RFID-based WIP tracking system transformed fab operations with real-time visibility, reduced cycle times, and accurate financial reporting.
18% Cycle Time Reduction
Reduced average lot cycle time by 18% through better workflow optimization and bottleneck elimination. Improved on-time delivery performance from 82% to 96%.
100% Real-Time Visibility
Achieved complete real-time visibility of all 2,500+ active lots across 400+ production steps. Lot location and status queries answered instantly instead of requiring manual searches.
99.8% Data Accuracy
Eliminated manual data entry errors with automated RFID capture. Improved WIP data accuracy from 87% to 99.8%, enabling reliable financial reporting and decision-making.
75% Faster Month-End Close
Reduced month-end WIP reconciliation time by 75% with automated, accurate WIP valuation. Finance team can close books 3 days faster with higher confidence in inventory values.
"The WIP tracking system has been transformational for our operations. We now have complete visibility into our production flow, which has enabled us to optimize processes and significantly reduce cycle times. The financial reporting benefits have been equally impressive."
Implementation Results
Comprehensive WIP tracking transformation
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