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Lot-to-order matching (LTOM) is a crucial process in semiconductor manufacturing since inefficient allocation and order release have strong adverse effects on factory performance. Although prior research proposes several heuristics for the mathematical optimization of the LTOM process, successful real-world implementations following practical and comprehensive approaches are scarce. Our longitudinal case study addresses that issue by summarizing the results of an extensive research project on the automation and optimization of the LTOM process for 200 mm and 300 mm wafers at Infineon Technologies Dresden. Grounded in Action Design Research, we integrated different research methods to provide meaningful insights into the benefits, challenges, and best practices of our approach. Thereby, we also compare the results for 200 mm and 300 mm wafers. The project had positive impacts on multiple quantitative and qualitative key performance indicators, e.g., throughput, on-time delivery, tool utilization, cycle and working time savings, collaboration, and employee satisfaction. Finally, we provide managerial guidance for similar projects and implications for future research. [ABSTRACT FROM AUTHOR]

Customers demand more and more integrated functions on one chip; as a result, semiconductor product complexity is increasing tremendously. This development results in increasing production process complexity, reflected in the incorporation of additional lithography layers, for example, which causes longer cycle times, higher costs and extended feedback loops for making quality improvement. Each additional process step introduces at least five additional logistics steps, as each lot has to be handled and transported twice over and also stored temporarily. This scenario is leading to a ‘logistical trap’ in which there is a high proportion of non value-add time. The main leverage to improve long cycle times is the redesign of product workflow for excellence, which means aiming for short cycle times, low production costs and, at the same time, high product quality. [ABSTRACT FROM AUTHOR]