In photomask production environments, increasing productivity of defect inspection and improving fidelity of defect
classification are important for mask makers to improve capacity of defect inspection tools and to enhance quality of
production. In particular, defect classification time corresponds directly to the cost and the cycle time of mask
manufacturing and new product development. KLA-Tencor has introduced an automatic defect grouping tool
"ReviewSmart" which automatically bins defects with high fidelity. ReviewSmart has been reported in engineering R&D
and evaluation. In this paper, we focus on implementation of ReviewSmart in photomask production. 592 plates
were processed during the evaluation period. Those plates are for products of logic, memory and flash. Technology
nodes are from 65nm to 180nm. With optimized production setting, the automatic defect grouping tool - ReviewSmart
improves productivity of defect inspection by 7% with 100% fidelity. In addition to improve productivity, ReviewSmart
is helpful to classify aggressive OPC caused nuisance, troubleshoot process issues and expedite product development and
improve usable inspection sensitivity as well.
For improving productivity and reducing manufacturing cost, it is critical for wafer fabs to reduce the frequency of
reticle re-clean and control the risk of missing defects of lithographic significance from overall haze defected. Haze
classification and haze behavior monitoring are highly time consuming processes. Many wafer fabs skip such operations
and instead re-clean reticles frequently in order to reduce the risk of missing killer haze defects. Such Reticle Re-Qual
rule leads to more than necessary reticle re-cleaning, shortening the life cycle of reticles and increasing the
manufacturing cost. In this paper, we investigate an efficient defect classification method - ReviewSmart, and defect
auto tracking method to classify defects and efficient tracking haze growth. A solution is discussed for wafer fabs to
monitor haze behaviors and improve Reticle Re-Qual rules for controlling and reducing manufacturing cost at lower risk.
A total of more then 30 production reticles of critical layers of OD, Poly, Contact and Metal 1 were inspected by
STARLight2TM on KLA-Tencor TeraScan SL516 system. ReviewSmart processed all the defects detected during Reticle
Re-Qual inspection. The results showed significant reduction in defect review times, with 100% fidelity rate.
Resolution limitations in the mask making process can cause differences between the features that appear in a database
and those printed to a reticle. These differences may result from intentional or unintentional features in the database
exceeding the resolution limit of the mask making process such as small gaps or lines in the data, line end shortening on
small sub-resolution assist features etc creating challenges to both mask writing and mask inspection. Areas with high
variance from design to mask, often referred to as high MEEF areas (mask error enhancement factor), become highly
problematic and can directly impact mask and device yield, mask manufacturing cycle time and ultimately mask costs.
Specific to mask inspection it may be desirable to inspect certain non-critical or non-relevant features at reduced
sensitivity so as not to detect real, but less significant process defects. In contrast there may also be times where
increased sensitivity is required for critical mask features or areas. Until recently, this process was extremely manual,
creating added time and cost to the mask inspection cycle. Shifting to more intelligent and automated inspection flows is
the key focus of this paper. A novel approach to importing design data directly into the mask inspection to include both
MDP generated MRC errors files and LRC generated MEEF files.
The results of recently developed inspection and review capability based upon controlling defect inspection using design
aware data base control layers on a pixel basis are discussed. Typical mask shop applications and implementations will
be shown.
As the design rule continues to shrink towards 65nm size and beyond the defect criteria are becoming ever more challenging. Pattern fidelity and reticle defects that were once considered as insignificant or nuisance are now becoming significant yield impacting defects. The intent of this study is to utilize the new generation DUV system to compare Die-to-Die Reflected Light inspection and Die-to-Die Transmitted Light Inspection to increase defect detection for optimization of the 65nm node process.
In addition, the ReviewSmart will be implemented to help categorically identify systematic tool and process variations and thus allowing user to expedite the learning process to develop a production worthy 65nm node mask process. The learning will be applied to Samsung's pattern inspection strategy, complementing Transmitted Light Inspection, on critical layers of 65 nm node to gain ability to find defects that adversely affect process window.
As design rule continues to shrink towards ITRS roadmap requirements, reticle defect capture criteria are becoming ever more challenging. Pattern fidelity and reticle defects that were once perceived as insignificant or nuisance are now becoming a significant considerable yield impacting factor. More defects are also detectable and presented with increase in implementation of new generation reticle inspection systems. Therefore, how to review and characterize defects accurately and efficiently is becoming more significant. In particular, defect classification time often corresponds directly to the cost and the cycle time of mask manufacturing or new technology development.
In this study we introduce a new mask defect review tool called ReviewSmart, which retrieves and processes defect images reported from KLA-Tencor's high sensitivity TeraScan inspection tool. Compared to the traditional defect review method, ReviewSmart provides a much better method to manage defects efficiently by utilizing the concept of defect grouping disposition.
Through the application and qualification results with respectable reticle production cases, the implementation of ReviewSmart has been proven to be effective for reducing defect classification loading and improving defect characterizing efficiency. Moreover, the new review tool is helpful to categorically identify tool or process variations thus allowing users to expedite the learning process for developing production worthy leading node processes.
With expected implementation of low k1 lithography on 193nm scanners for 65nm node wafer production, high resolution defect inspection will be needed to insure reticle quality and reticle manufacture process monitoring. Reticle cost and reticle defectivity are both increasing with each shrink to the next node. Simultaneously, system on chip (SoC) designs are increasing in which a large area of the exposure field typically contains dummy patterns and other features which are not electrically active. Knowing which defects will electrically impact device yield and performance can improve reticle manufacturing yield and cycle time -- resulting in lower reticle costs. This investigation examines the feasibility of using additional design data layers for die-to-database reticle inspection to determine in real time the relevance of a reticle defect by its location in the device (Smart InspectionTM). The impact to data preparation and inspection throughput is evaluated. The current prototype algorithm is built on the XPA and XPE die-to-database algorithms for chrome-on-glass and EPSM reticles, respectively. The algorithms implement variable sensitivity based on the additional design data regions. During defect review the defects are intelligently binned into the different predetermined design regions. Tests show the new Smart Inspection algorithm provides the capability of using higher than normal sensitivity in critical regions while reducing sensitivity in less critical regions to filter total defect counts and allow for the review of just defects that matter.
Performance characterization of a variable sensitivity Smart Inspection algorithm is discussed in addition to the filtering of the total defect count during review to show the defects that matter to device performance. Using seven critical layer production reticles from a system on chip device we examine the applications of Smart Inspection by layer including active, poly, contact, metal and via layers. Data volume for additional data layers show little impact to inspection data prep time. The total area of the reticle where defects do not matter is as high as 70% on some layers. Review capabilities will be examined for various applications such as reviewing defects in the various regions such as SRAM, dummy pattern, and redundant contact/via specified regions. Lastly, the economics of Smart Inspection will be modeled using the collected knowledge of the applications from the production reticle characterized in this investigation.
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