| Business Continuity Planning and Disaster Recovery |
- Determine need for fabrication continuity by microchip line –
profitability, projected volume need and market demand, point
in life cycle, alternate sources outside the business, alternate
product availability – these metrics quantified by line the required
strength of the fabrication continuity. - Identification of facilities, provisioning, environmentals, personnel
that could provide identical services (i.e., fabricate the same
chips) and then identical services with minimal alterations. - Grouping of those facilities and determination if facilities could
delegate their fabrication. There was an additional wrinkle in that
some fabrications were under DOD auspices and could not be
delegated outside the U.S. - Calculations of absolute capacities under primary, secondary,
tertiary shifts. This included equipment and personnel. Some
equipment had a recycling time requirement that would not
allow full-out 7x24 usage. There were union and other work-
related issues stemming from foreign workrules that were part of
the analysis. - These calculations allowed the manufacturer to maintain a level
of confidence against outages by redirecting production flow
where possible without extensive provisioning, duplications and
costs.
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| Problem at international microchip manufacturer |
The manufacturing process requires chemical facilities, fabrication
provisioning, specialized controlled environmentals and different levels
of personnel. There is similarity of the manufacturing process for only a
small number of interrelated microchip families, so that most microchip
families require different fabrication provisioning. Manufacturing
facilities exist in eighteen sites, seven in the United States and eleven
outside the U.S. Historically, these sites were built up by acquisitions of
ongoing concerns and by regional microchip demand, not through
any diversification planning. Nevertheless, there is good overlap of
manufacturing facilities for a large majority of its microchip families.
provisioning, specialized controlled environmentals and different levels
of personnel. There is similarity of the manufacturing process for only a
small number of interrelated microchip families, so that most microchip
families require different fabrication provisioning. Manufacturing
facilities exist in eighteen sites, seven in the United States and eleven
outside the U.S. Historically, these sites were built up by acquisitions of
ongoing concerns and by regional microchip demand, not through
any diversification planning. Nevertheless, there is good overlap of
manufacturing facilities for a large majority of its microchip families.
| The Incident |
An industrial incident occurred, when a drum containing hydrochloric
acid fell from a forklift and split open on the work floor, closing the
facility. The resultant haz-mat clean-up, health checks of personnel,
re-calibrations of equipment, and investigation by OSHA and other
governmental agencies resulted in a 20-day closure of the facility.
Manufacturer lacked a comprehensive Business Continuity Plan to
cover the outage, suffering order delays, late penalties and loss of
reputation. Workrules idled the facility personnel who were still paid.
acid fell from a forklift and split open on the work floor, closing the
facility. The resultant haz-mat clean-up, health checks of personnel,
re-calibrations of equipment, and investigation by OSHA and other
governmental agencies resulted in a 20-day closure of the facility.
Manufacturer lacked a comprehensive Business Continuity Plan to
cover the outage, suffering order delays, late penalties and loss of
reputation. Workrules idled the facility personnel who were still paid.
| Solution Requirements |
- Minimize the impact of outage of a portion or an entire facility
through Business Continuity Best Practices. - Quantify the results of various outage scenarios and state ROI for
proposed solutions.
| Solution |