Process control system and process control method

A process control system that controls processing executed on workpieces by, at least, one processing apparatus installed in each area in a factory, the processing results of which are predictable, comprising:

• at least one measuring apparatus that is installed for the corresponding area, executes a measuring operation on workpieces processed in the area, and includes a means for self-diagnosis that executes a diagnosis to determine whether or not an abnormality has occurred in said measuring apparatus;
• a transfer apparatus provided for the corresponding area to transfer the workpieces among apparatuses which include said processing apparatus and said measuring apparatus in the area;
• and
• a control device installed for the corresponding area to control said processing apparatus, said measuring apparatus and said transfer apparatus in the area, wherein said control device:
• sets a processing condition for said processing apparatus based upon the results of a measuring operation executed by said measuring apparatus on workpieces processed by said processing apparatus,
• ascertains a correlation between operation data and processing result data by executing a multivariate analysis based upon the operation data related to an operation of said processing apparatus and the processing result data indicating the results of the processing executed by said processing apparatus,
• obtains a predictive value that predicts the processing results based upon the correlation by using operation data obtained through processing executed on a workpiece other than the workpiece for which the correlation has been ascertained, and
• engages said means for self-diagnosis at said measuring apparatus to execute a self-diagnosis if an error in the measurement value indicating the processing results relative to the predictive value is judged to be equal to or greater than a predetermined value and re-ascertains the correlation only if said measuring apparatus is determined to be error-free based upon the results of the self-diagnosis.

A method of process control executed by a control device in each area in a process control system having installed in each area at least one processing apparatus, the processing results of which are predictable, at least one measuring apparatus, a transfer apparatus, and said control device that controls said processing apparatus, said measuring apparatus and said transfer apparatus, comprising the steps of:

• setting a processing condition for said processing apparatus used to process a first workpiece,
• transferring the first workpiece at least having undergone the processing executed by said processing apparatus to said measuring apparatus by said transfer apparatus,
• obtaining a first workpiece measurement value that indicates the results of the processing executed on the first workpiece through a measuring operation executed by the measuring apparatus on the workpiece at least having undergone the processing,
• comparing said first workpiece measurement value with a processing result target value to determine an error in the measurement value relative to the target value,
• engaging in a self-diagnosis operation if the error in the first workpiece measurement value indicating the processing results relative to the target value is determined to be equal to or greater than a predetermined value, and
• resetting the processing condition for said processing apparatus in correspondence to the error, if the error is determined to be equal to or greater than the predetermined value only if said measuring apparatus is judged to be error-free based upon the results of the self-diagnosis operation.

A method of process control executed by a control device in each area in a process control system having installed in each area at least one processing apparatus, the processing results of which are predictable, at least one measuring apparatus, a transfer apparatus, and said control device that controls said processing apparatus, said measuring apparatus and said transfer apparatus, the method comprising:

• transferring a workpiece at least having undergone the processing executed by said processing apparatus to said measuring apparatus by said transfer apparatus,
• executing a measuring operation by a measuring apparatus on a workpiece processed by said processing apparatus to obtain a measurement value indicating the results of the processing executed on the workpiece;
• setting a processing condition for said processing apparatus based upon the results of the measuring operation executed by said measuring apparatus;
• generating a correlation between operation data obtained from said processing apparatus and processing result data indicating the results of the processing executed by said processing apparatus by executing a multivariate analysis based upon the operation data and the processing result data;
• calculating a predictive value predicting the result based upon the correlation by using operation data obtained by processing a workpiece other than the workpiece for which the correlation has been ascertained;
• comparing said measurement value with the predictive value to determine an error in the measurement value relative to the predictive value;
• engaging in a self-diagnosis operation by said measuring apparatus if the error in the measurement value indicating the processing results relative to the predictive value is equal to or greater than the predetermined value to determine if said measuring apparatus is error-free;
• and
• regenerating the correlation, if the error in the measurement value relative to the predictive value is judged to be equal to or greater than a predetermined value, only if said measuring apparatus is judged to be error-free based upon the results of the self-diagnosis operation.

A method of process control executed by a control device installed in each area in a process control system having installed in each area at least one processing apparatus, at least one measuring unit provided at said processing apparatus, at least one measuring apparatus, a transfer apparatus and said control device that controls said processing apparatus, said measuring apparatus, and said transfer apparatus, the process control method comprising:

• executing measurement processing by said measuring unit on a workpiece processed by said processing apparatus to obtain measurement results;
• setting a processing condition for said processing apparatus based upon the results of the measurement processing executed by said measuring unit;
• and
• transferring a workpiece to said measuring apparatus by said transfer apparatus,
• executing a measurement processing by said measuring apparatus on the workpiece, and
• setting the processing condition for said processing apparatus based upon the results of the measurement processing executed by said measuring apparatus while said measuring unit undergoes maintenance work.

A process control system that controls processing executed on workpieces by at least one processing apparatus installed in each area in a factory and having a processing chamber in which the processing is executed on the workpieces, a measuring unit that executes measurement processing on a workpiece before and after the processing is executed on the workpiece in said processing chamber, or either before or after the processing is executed on the workpiece in said processing chamber, and a means for in-apparatus transfer capable of transferring the workpiece at least between said processing chamber and said measuring unit, the process control system comprising:

• at least one measuring apparatus installed in each area and capable of executing measurement processing on workpieces undergoing the processing within the area and including a means for self-diagnosis that executes a diagnosis to determine whether or not an abnormality has occurred in said measuring apparatus;
• a transfer apparatus installed in the corresponding area to transfer the workpieces among apparatuses within the area including said processing apparatus and said measuring apparatus;
• and
• a control device installed in the corresponding area to control said processing apparatus, said measuring apparatus, and said transfer apparatus in the area,
• to generate a correlation between operation data and processing result data by executing a multivariate analysis based upon the operation data related to an operation of said processing apparatus and the processing result data indicating the results of the processing executed by said processing apparatus,
• to obtain a predictive value that predicts the processing results based upon the correlation by using operation data obtained through processing executed on a workpiece other than the workpiece for which the correlation has been generated,
• to engage said means for self-diagnosis at said measuring apparatus to execute a self-diagnosis if an error in the measurement value indicating the processing results relative to the predictive value is judged to be equal to or greater than a predetermined value,
• to regenerate the correlation only if said measuring apparatus is determined to be error-free based upon the results of the self-diagnosis, and to engage the measuring unit of another processing apparatus to execute the measuring processing on a workpiece undergoing the processing executed by a given processing apparatus if the measuring unit of the given processing apparatus is not available for use, wherein said measurement value indicating the processing result is the measurement value that is measured by the measuring unit of another processing apparatus.