Advanced Metallization and Interconnect Systems for Ulsi by R. C. Ellwanger, S. Q. Wang

By R. C. Ellwanger, S. Q. Wang

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Here, they can experience operating plant start-ups and shut-downs, sampling, what mechanical things can be heard, felt and seen. In general, they can become used to equipment and processing and not be fearful of what happens during operation. Alternately, learning from manuals and training sessions is very helpful. I believe that the best way to learn to operate a piece of equipment or a section of the plant is with plant simulation software and computer screens. This allows interactive simulated situations to be learned, diagnosed, and corrected with the advice and help of a trainer.

However, many times, the reason that the plant has been built within budget and on time is that the client management demanded this. Corners may have been cut to achieve time and/or cost targets. Equipment was selected on a cost or availability basis and not on a “fit for purpose” basis. Low bid constructors were contracted; these got the job done but not as well as should have been the case. Other examples of corner cutting, is the reduction of automation and monitoring instrumentation to levels less than adequate for start-up but adequate for a mature operation.

Often, this is not explicitly stated and explained. For example, I was on a project that was making a very high-tech metallic product. The purpose of the project was to bring the product to market early, before the competition, and produce a superior product. This would result in capturing the market when the price was high and securing clients for the long term. The product was to be used in a second product that could not fail without dire consequences. This was not explained clearly to the owner’s team and the consulting engineer and, consequently, both strove to keep the capital and operating costs down.

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