JMP visually investigates the frequency of defects discovered by downstream customers

Cree Inc. is widely recognized as a global leader and pioneer in the LED lighting industry. Based in Durham, North Carolina, USA, Cree specializes in LED epitaxial layers, chips, packages, and comprehensive lighting solutions. As a renowned manufacturer of compound semiconductor materials, power devices, and RF technologies, it also operates a production facility in Guangdong Province, China. LED, or Light Emitting Diode, is considered the fourth generation of lighting technology and is often referred to as a green light source. It offers energy efficiency, environmental friendliness, long lifespan, and compact size, making it suitable for various applications such as signage, displays, decoration, backlighting, general illumination, and urban lighting. With growing global emphasis on energy conservation and sustainability, LED has emerged as a key future trend. For example, during the 2008 Beijing Olympics, the Water Cube used 496,000 Clarion LED lighting products for its exterior, while the Bird’s Nest featured 258,000 energy-saving semiconductor lamps. We are now firmly in the era of LED lighting. These lamps offer decades of service life and consume significantly less energy than traditional incandescent or fluorescent bulbs. Although LED technology has been around for about 40 years, it wasn’t until recently that companies like Cree began applying it on a large scale to enhance lighting quality. Cree is at the forefront of replacing inefficient lighting with high-performance, energy-efficient alternatives. Cree's LED lighting range now exceeds 150 lumens, according to Ed Hutchins, an ongoing engineering manager at Cree Materials. “This is not the limit,” he said. “Our LED lights are brighter, and reducing LED usage can lower costs. Our customers—lighting equipment manufacturers—are well aware of these benefits.” Hutchins’ team focuses on developing silicon carbide wafer substrates, which serve as the foundation for all Cree products. They have used JMP for data analysis, process control, experimental design, and Six Sigma projects for many years. “Data mining and visualization are two major areas where we use JMP,” Hutchins explained. The team cuts silicon carbide crystals into wafers, polishes them, and prepares them for epitaxial growth, ensuring the final device functions as intended. The quality of the epitaxial layer determines the light output and color. Consistently high-quality wafers from Hutchins' team are essential for producing top-tier products. However, when downstream customers detect significant defects, tracing their origin becomes critical. “The first use of JMP was to visually analyze the frequency of defects reported by customers,” Hutchins said. This involved connecting to a database, retrieving data, and using JMP to generate control charts showing daily defect trends. “This is a great example of visual analysis with JMP,” he added. “There are false signals and real ones. A false signal might show a sudden increase in failure rates, but it could be due to more thorough inspections rather than actual issues.” To address this, the team developed a JMP script to query data, including dates, batch numbers, and production conditions. “Writing our own code to collect data takes hours, but doing it in JMP is much faster,” Hutchins noted. They then built a model focusing on the most important factors, such as process steps. By comparing these factors and using JMP’s predictive tools, they identified two critical steps in the process that had an unexpected interaction. “With JMP’s visual tools, we could clearly see this interaction, which was the root cause of the problem,” Hutchins said. This led to immediate corrective action. “JMP doesn’t just give answers—it guides you in the right direction,” Hutchins said. “It helps identify where the problem lies, which we couldn’t understand before. By focusing on the right areas, we were able to bring the defect rate back to zero.”

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