日月光半導(dǎo)體e化之進(jìn)程與問(wèn)題之分享ppt課件

1、日月光半導(dǎo)體化之進(jìn)程與問(wèn)題之分享日月光高雄廠資訊中心盛敏成Nov. 23, 2006Agendaw ASE Groupw Our business modelsw Our IT strategyw A follower, a partner and a leaderw 由服務(wù)中學(xué)習(xí),由學(xué)習(xí)中改善服務(wù)w ASEKH IT system evolutionw Case studyw 晶采計(jì)劃w Smart customer SAP II projectw Experience sharingw ConclusionASE offers the Best Design Manufacturing S

2、ervices for IC Packaging, IC Substrates, IC Testing, and Systems. ASE will act as an Extension of Our Customers Own Operations in Achieving the Maximum Business Objectives with Minimum Resources. ASE MISSION ASE GroupTest Substrate Design Manufacturing Service Modeling & Simulation Program Devel

3、opment Wafer Probing IC & Module Test Burn-In Warehousing Drop-Shipment Package & Module Design IC Assembly Multi-chip Assembly Micro & Hybrid ModuleAssemblySystem DMS (Design Manufacturing Services) Board Assembly Hybrids & Electronic Packaging Logistic Management MaterialASE VISION

4、: THE COMPLETE SOLUTIONEngineering TestWafer Bumping/ProbingMaterialsAssemblyFinal TestModule, Board Assembly & Test (DMS)FoundryCircuit DesignASE VISION: THE COMPLETE SOLUTIONwOperation siteswASEKH(A/T/M), ASECL(A/T/M), ASEKr(A/T), ASEM(A/T), ASESg(T), ISE(T)wUSIElectronics Industry Supply Chai

5、nCustomerOEMEMSSub-AssemblyComponentscustomerscustomerscustomerssuppliers50+ suppliers180+ suppliers1200+ othersuppliersJapan, US, TaiwanOther suppliers15+customers100+ suppliersGSTFoundry, Pkging & TestOur Business Modelw Engineering/Manufacturing service providerw Make the parts upon customer

6、specification and instructionw Key success factor: operation excellence and qualityw Compete with other service provider and customers MFG teamsw Without ERP system until 2004w Business guidelinew Easy for customer to do business with ASEw Seamless integration with customers process floww Quality, F

7、lexibility, EfficiencySupply Chain & Quality StrategyDemand UncertaintyLaunch PhenomenonCost PressureHigh Quality ExpectationsSpeed & Flexibility Security of Supply Efficient Supply ChainProactive & ResponsiveEnvironmental ConditionsBest Customer ExperienceCustomers Supply Chain Objectiv

8、eswCollaborative forecast, order and inventory management solution connected with key suppliers.wException based managementwScalable business process integration with supplierswCentralized visibility to business processeswPerformance metrics for supplier management“Building sustainable competitive a

9、dvantage into the collective supply chainLEANSPEEDFLEXIBILITYMulti-tier ExecutionBusiness ValueProcess Breadth, Number of Trading Partners Multi-Company Process ManagementOne-way InformationPostingTwo-way Information ExchangeClosed-loop, Positive Response With Exception AlertsSynchronized Processes,

10、 Timely and Quality InformationMulti-tier VisibilityException Management Across Multiple Tiers of the Value Chain Data ExchangeMulti-Company Process Management enables a synchronized Supply-ChainDecision SupportException ManagementData AggregationExceptionAlertsCustomers GoalAllentownThailandSingapo

11、reOrlandoTwin CitiesSub Con AssemblersFoundriesForecastsPurchase OrdersShipping NoticesShipping NoticesIndirectMaterialsSuppliersConsignmentMaterialsSuppliersI-BOXApproach for I-BoxFunctionality at the edgePoint-to-Point IntegrationOne trading partner at a timeClient-Server Architecture“Thick at the

12、 Edge“Point-to-PointService Oriented Architecture“Thin at the Edge“Intelligent NetworkFunctionality in the networkConnect once and leverageShared service economics Partner FPartner CPartner EPartner APartner BPartner DPartner FPartner EPartner APartner BPartner DIntelligentNetworkPartner COur IT Str

13、ategyw A followerLearnw Leverage the best practice from customers, competitors, and industry leadersw ASE has the fortune to work with the most competitive companies in the IC supply chainw Research: Re-Searchw A partnerDow Build up quality information links with customerw Provide process integratio

14、n solution model to customersw A leaderContinuous Improvementw Identify the core function of information integration processw Develop systematic approach to identify the critical information links to make business model successfulASE IT System Evolutionw Home grown legacy systemsw Two independent op

15、eration company for different services (Assembly and Test)w Did not build up integrated process with well-organized information linksw IRS system build up for short term solutionw Big-Bang Approachw Driving force: to provide turnkey service to customersw GRP project: kicked off on March, 2002w Syste

16、m went live Jan/5/2004w Material operation: KH/CL Jan/2005; SH Sep/2005w Continuous Improvementw Separated instance for Material operation: Aug/2006w PLM system go live Dec/2006w SAP/e project kicked off Dec. 2005wASE_Assy_ IT 系統(tǒng)關(guān)聯(lián)圖(2003)採(cǎi)購(gòu)管理(Purchase)庫(kù)存管理(Inventory)進(jìn)口系統(tǒng)(Import)保稅系統(tǒng)(Bond)IQA系統(tǒng)應(yīng)收帳款(A

17、/R)應(yīng)付帳款(A/P)總帳(G/L)固定資產(chǎn)(A/M)產(chǎn)品本錢(qián)系統(tǒng)(Product COST)Forecast出口系統(tǒng)/Price(Export/Price)投料系統(tǒng)(T/T)晶片庫(kù)系統(tǒng)WaferBank廢品庫(kù)管理Finish Goods Stock工程資料庫(kù)(PEDB)獎(jiǎng)工系統(tǒng)(Bonus)MESHR出口系統(tǒng)廢品系統(tǒng)保稅系統(tǒng)本錢(qián)系統(tǒng)出口廢品系統(tǒng)SAPCobol+InformixAccessOtherSystemInterfaceData FlowReferenceT/TControlling(CO)ShippingPlanSalesReportPackingInstructionNotes

18、 APSPEC/ECNIMQRVB+OracleASRSPackingPEDBLabelPTSetupProcedureTDRPShippingPricePOSAPGUIMESInvoiceMMAOLIntranetInternetEqu TimeRecord BonusCostSpare PartsToolingExtricityOthers :FCSTTSMCShip Instr.MES MenuPlanTEVHold BankSPECCARTesterConfigHold LotE-PRHRE-HRuASE_Test_ IT 系統(tǒng)關(guān)聯(lián)圖 (2003) GRP=ERP+SCMERPInve

19、ntory Sales Order takingPricing PurchaseWafer pur. planPurchasingFinancial GL AR APFixed asset Budget/Cost Cash managementReceiveCustomerVendorQuotationPOTransferPick/PackShipInventory DocumentsBillingValidationInvoice發(fā)料記錄PaymentPaymentInvoiceInvoiceInvoiceQuotationPRAssemblyFinish GoodsWafer consum

20、eOrder to productionWafer SortFinal testProduction PlanForecastMRPCapacity optimization, Material planning and production plan optimizationSCMInternal Business FlowASEKH- ASSYASEKH-TESTCustomerWafer SortPackagePlant 1Plant 9Plant 2Final TestOrderWIP/ENG/BillingCentral OTCentral PlanningManufactureWa

21、ferIn Fab PlanningASSYTESTTurnkey$WIP/ENG/Billing(TEST)WIP/ENG/Billing(ASSY/TK)Finish Goods(ASSY)Finish Goods (TEST/Turnkey)BumpingPlant 1Plant 2Goal of ASE GRP ProjectShipPhase IBusiness processes Included：Assy & Test in KH siteSystem To Be ImplementedERP(Enterprise Resource Planning)SCM(Supply

22、 Chain Management)Middleware (System Integration)Order TackingIntegration SystemSCM SystemERP SystemASE GroupProcurementASETASEKProcurementProcurementProcurementProcurementProcurementASE-CLAssyTestShipASE-ChinaAssyTestShipASE-KoreaAssyTestShipASE- MalaysiaAssyTestShipASE- othersAssyTestShipProcureme

23、ntOrder fulfillmentCost DownCurrent IT ArchitectureLegacySystemMESPDMIntegrated Customer InterfaceHRSMiddlewareMiddlewareERPNotes(w/f)IRSDataCenterSCMNoImageInterfaceLegacySystemMESPEDBHRSNotes(w/f)CustomerVendorInterfaceASSYTESTFor CRP and MRPOrder taking and Execution, MM, and FI/COEnterprise Appl

24、ication IntegrationGRP System (1/5/2004)w ERP: SAP R3w SD (Sales and Distributions)w PP (Production Planning)w MM (Material Management)w CO (Controlling)w FI (financial)w SCM: Adexaw SCP (Supply Chain Planning) with CRP and MRP for monthly and weekly planningw PP (Plant planning) for daily planningw

25、 System Integrationw Tibco BW (Business Work)Application ArchitectureFuture Planw Strategyw Align with our Group strategyw Provide same information service for customersw Integrate cross operations and cross departments information for quality operation and efficient managementw Approachw Continuous

26、 process improvements with internal customersw Refine IT system architecture to enhance management information provisionw Leverage best practice from customers, partners and competitorsFuture Plan - 1w Phase 1.1w Include Material operation into GRP systemw Project kick off on July/2004w Best practic

27、e deployment, including ASECL Materialw More customer B2B enhancementw To facilitate the information links with customersw Proactive initiator for ASN and W/O B2B projectsw Analytic information standardization and provisionw Business intelligence data warehouse projectw Provide more integrated infor

28、mation for SCPMContinuous Improvementw Customer portal enhancementw Phase 1: July/2004; phase 2: Mar/2006w Phase 3: Dec/2006w Sales IT function supportw Sales management: opportunity/quotation/forecast/order/revenue/profitw Customer activity managementw SCM system enhancementsw Planning/Scheduling/D

29、ispatchingw Supply management enhancementw Group ENG data architecture w PLM and morew Central vs. Distributed vs. HybridCase Studyw TSMC ePO, Work order projectw Document transfer handlingw Smart customer SAP II projectw WIP transaction messageWork Order Business Flow (Before)Customer ProcessTransa

30、ction ProcessASE ProcessBuyerERP ( SAP)Create Work OrderNew WO RequestWO Request Flow WO Reply Flow Work OrderMail or FAXMail or FAX衍生問(wèn)題衍生問(wèn)題 : : 流程中人為操作錯(cuò)誤流程中人為操作錯(cuò)誤 BatchBatch人工操作人工操作, ,作業(yè)時(shí)間過(guò)長(zhǎng)作業(yè)時(shí)間過(guò)長(zhǎng) 不易確認(rèn)資料傳送勝利性不易確認(rèn)資料傳送勝利性 缺乏資料傳送的不可否認(rèn)性缺乏資料傳送的不可否認(rèn)性Work Order Business Flow (Before)Customer ProcessTransa

31、ction ProcessASE ProcessBuyerERP ( SAP)Create Work OrderNew WO RequestWO Request Flow WO Reply Flow Work OrderMail or FAXMail or FAXPlannerWOsSpec.Manually key in WO & Spec. data to system ERP 衍生問(wèn)題衍生問(wèn)題 : : 登打資料錯(cuò)誤頻繁登打資料錯(cuò)誤頻繁 規(guī)格參照錯(cuò)誤規(guī)格參照錯(cuò)誤 人工操作時(shí)間過(guò)長(zhǎng)人工操作時(shí)間過(guò)長(zhǎng) 過(guò)於依賴(lài)人為判斷過(guò)於依賴(lài)人為判斷Work Order Business Flow (B

32、efore)Customer ProcessTransaction ProcessASE ProcessBuyerERP ( SAP)Create Work OrderNew WO RequestWO Request Flow WO Reply Flow Work OrderMail or FAXMail or FAXPlannerWOsSpec.Manually key in WO & Spec. data to system ERP Check the WO statusInvestigate can meet the Order or not衍生問(wèn)題衍生問(wèn)題 : : 溝通時(shí)間過(guò)長(zhǎng)

33、溝通時(shí)間過(guò)長(zhǎng) 人為溝通呵斥達(dá)交率降低人為溝通呵斥達(dá)交率降低- - 雙方認(rèn)定標(biāo)準(zhǔn)不同雙方認(rèn)定標(biāo)準(zhǔn)不同TelephoneTelephoneFollow up the Work OrderFollow up the Work OrderContact with ASE for SOD & key in systemBuyerCustomer ProcessTransaction ProcessASE ProcessWork Order Business Flow (Current)WO 7B5 Flow WO 7B6 Flow A New WO RequestERP ( SAP)Create

34、 Work OrderRosettaNet GatewayInternetFirewallFirewallPip7B5解決問(wèn)題解決問(wèn)題 : : 自動(dòng)化自動(dòng)化, ,減少流程中人為操作錯(cuò)誤減少流程中人為操作錯(cuò)誤 無(wú)紙化無(wú)紙化, ,無(wú)須人工列印傳真無(wú)須人工列印傳真 提高資料傳送確實(shí)性提高資料傳送確實(shí)性 減少人為判斷錯(cuò)誤減少人為判斷錯(cuò)誤 標(biāo)準(zhǔn)化規(guī)格溝通容易標(biāo)準(zhǔn)化規(guī)格溝通容易- - 大大減少資料溝通時(shí)間大大減少資料溝通時(shí)間BuyerCustomer ProcessTransaction ProcessASE ProcessWork Order Business Flow (Current)MES Con

35、firm SOD and release to production lineWO 7B5 Flow WO 7B6 Flow A New WO RequestERP ( SAP)Create Work OrderRosettaNet GatewayRosettaNet GatewayInternetFirewallFirewallPip7B5Planner ERP New WO Notice解決問(wèn)題解決問(wèn)題 : : 減少流程中人為操作錯(cuò)誤減少流程中人為操作錯(cuò)誤 WOWO資料直接進(jìn)入系統(tǒng)資料直接進(jìn)入系統(tǒng), ,無(wú)須人工介入無(wú)須人工介入 減少大量登打資料減少大量登打資料, ,人力節(jié)省人力節(jié)省 減少人

36、為錯(cuò)誤判斷減少人為錯(cuò)誤判斷BuyerCustomer ProcessTransaction ProcessASE ProcessWork Order Business Flow (Current)Query WO reply by vendorMES Issue to WIP according to WO & PDMReply WO according to SCM systemWO 7B5 Flow WO 7B6 Flow A New WO RequestERP ( SAP)Create Work OrderRosettaNet GatewayRosettaNet GatewayI

37、nternetFirewallFirewallPip7B5Pip7B6Planner ERP New WO Notice解決問(wèn)題解決問(wèn)題 : : 回覆資料直接進(jìn)入系統(tǒng)回覆資料直接進(jìn)入系統(tǒng) 回覆登打資料錯(cuò)誤減少回覆登打資料錯(cuò)誤減少 縮短資料覆核時(shí)間縮短資料覆核時(shí)間ASE PO Process (Before)PO Request Flow PO Reply Flow Purchasing Officer creates PO in ERP A NewPO RequestSend PO through Fax to suppliersSupplier received PO through Fax

38、POERP-衍生問(wèn)題衍生問(wèn)題 : :- 流程中人為操作錯(cuò)誤流程中人為操作錯(cuò)誤- BatchBatch人工操作人工操作, ,作業(yè)時(shí)間過(guò)長(zhǎng)作業(yè)時(shí)間過(guò)長(zhǎng)- 不易確認(rèn)資料傳送勝利性不易確認(rèn)資料傳送勝利性- 缺乏資料傳送的不可否認(rèn)性缺乏資料傳送的不可否認(rèn)性ASE PO Process (Before)Send PO through Fax to suppliersSupplier received PO through FaxPO1. Entry the PO into system 2. Manually file the documentSales Order System / Spreadshee

39、t Manually files it PO Request Flow PO Reply Flow Purchasing Officer creates PO in ERP A NewPO RequestERP衍生問(wèn)題衍生問(wèn)題 : : 流程中人為操作錯(cuò)誤流程中人為操作錯(cuò)誤 人工操作時(shí)間過(guò)長(zhǎng)人工操作時(shí)間過(guò)長(zhǎng) 登打資料錯(cuò)誤頻繁登打資料錯(cuò)誤頻繁 過(guò)於依賴(lài)人工判斷過(guò)於依賴(lài)人工判斷 檔案保管不易檔案保管不易POPOASE PO Process (Before)Send PO through Fax to suppliersSupplier received PO through FaxSupplier

40、deliver goodsPurchasing Officer follow-up with suppliers manuallySales Order System / Spreadsheet Manually files it POPO Request Flow PO Reply Flow Purchasing Officer creates PO in ERP A NewPO RequestERPReview inventory and confirm SODBackend SystemReply the PO confirmation衍生問(wèn)題衍生問(wèn)題 : : 溝通時(shí)間過(guò)長(zhǎng)溝通時(shí)間過(guò)長(zhǎng)

41、雙方認(rèn)定標(biāo)準(zhǔn)不同雙方認(rèn)定標(biāo)準(zhǔn)不同 人為溝通呵斥達(dá)交率降低人為溝通呵斥達(dá)交率降低 資料正確性易產(chǎn)生糾紛資料正確性易產(chǎn)生糾紛 易產(chǎn)生斷料危機(jī)易產(chǎn)生斷料危機(jī)1. Entry the PO into system 2. Manually file the documentRN PO 3A4/7/8/9 with Vendors (Current)PO created in customers ERPPOERPRN PO Request Flow RN PO Reply Flow A NewPO RequestTransport, Translate, Map & LoadB2B ServerI

42、nternetFirewallFirewall3A4/8/9PIP解決問(wèn)題解決問(wèn)題 : : 自動(dòng)化自動(dòng)化, ,減少流程中人為操作錯(cuò)誤減少流程中人為操作錯(cuò)誤 無(wú)紙化無(wú)紙化, ,無(wú)須人工列印傳真無(wú)須人工列印傳真 提高資料傳送確實(shí)性提高資料傳送確實(shí)性 減少人為判斷錯(cuò)誤減少人為判斷錯(cuò)誤- - 大大減少資料溝通時(shí)間大大減少資料溝通時(shí)間- - 標(biāo)準(zhǔn)化規(guī)格溝通容易標(biāo)準(zhǔn)化規(guī)格溝通容易R(shí)N PO 3A4/7/8/9 with Vendors (Current)PO created in customers ERPERPRN PO Request Flow RN PO Reply Flow A NewPO Req

43、uestTransport, Translate, Map & LoadB2B ServerInternetFirewallFirewall3A4/8/9PIPB2B ServerERPPOs appear in suppliers ERP SystemTransport, Translate, Map & Load3A4/8/9NotificationConfirmPO Data解決問(wèn)題解決問(wèn)題 : : 減少流程中人為操作錯(cuò)誤減少流程中人為操作錯(cuò)誤 POPO資料直接進(jìn)入系統(tǒng)資料直接進(jìn)入系統(tǒng), ,無(wú)須人工介入無(wú)須人工介入 減少大量登打資料減少大量登打資料, ,人力節(jié)省人力節(jié)省

44、減少人為錯(cuò)誤判斷減少人為錯(cuò)誤判斷 資料系統(tǒng)化資料系統(tǒng)化PORN PO 3A4/7/8/9 with Vendors (Current)PO created in customers ERPERPSupplier deliver goodsRN PO Request Flow RN PO Reply Flow A NewPO RequestTransport, Translate, Map & LoadB2B ServerInternetFirewallFirewall3A4/8/9PIP3A7 Notification3A7PIPB2B ServerERPPOs appear in s

45、uppliers ERP SystemTransport, Translate, Map & Load3A4/8/9Notification解決問(wèn)題解決問(wèn)題 : : 回覆資料直接進(jìn)入系統(tǒng)回覆資料直接進(jìn)入系統(tǒng) 回覆登打資料錯(cuò)誤減少回覆登打資料錯(cuò)誤減少 減少人為判斷錯(cuò)誤減少人為判斷錯(cuò)誤POConfirmPO DataRN PO 3A4/7/8/9 with Vendors (Current)PO created in customers ERPERPSupplier deliver goodsRN PO Request Flow RN PO Reply Flow A NewPO Reque

46、stTransport, Translate, Map & LoadB2B ServerInternetFirewallFirewall3A4/8/9PIP3A7 Notification3A7PIPB2B ServerERPPOs appear in suppliers ERP SystemTransport, Translate, Map & Load3A4/8/9NotificationTouch-less, seam-less and trading partners information in your own systemPOConfirmPO DataResul

47、tw TSMC provide turnkey service to customersw ASE provide turnkey service to customers, toow Most complete data link among our customersw Frontier project and benchmarkingw More variants of turnkey model coming upw Material flow, information flow, cash flowProject Objective SAP II Projectw A Fabless

48、 customer started the WIP tracking project w Can consolidate WIP data from global sub-contractor sites, with multiple data formats. w Allows quick reporting and analysis using data from one system, which is SAP. w Has been particularly challenging for virtual manufacturing companies. The company is

49、looking forward to building a strategic alliance with its manufacturing partners. This venture should be mutually beneficial to all parties.w Took this opportunity to establish an end-to-end business process tying together its operations, costing, purchasing, and accounting departments. This is expe

50、cted to give the company more finance and purchasing control. System DualSAPPPSDMMMESPPSDMMTxnRecordBizTalkBCTxnRecordD/NABR/MBRCustomerWIP TxnSHIPVendorsSystem Dual in WIP TrackingW0 : Represent the WIP status at time=0.Ti: Represent the WIP transaction during that period.SubconCustomerW1W0WiWi+1W1

51、W0WiWi+1T1T2Ti+1.Resultsw Come from behindw Reach 98.5% accurate for consecutive 3 monthw A generic WIP-TS system modelw Build up for other three customersw Fast deployment, reliable system performanceExperience Sharingw Product consultant vs. Business consultantw Learn from SAP projectw Your projec

52、t vs. Our projectw Expectation managementw Training and coachingw The wayw Methodologyw Disciplinew ManagementExperience Sharingw Systemw The output from project: the least importantw Loading test, stress testw Processw Business process review, re-engineerw Integration test, user acceptance testw Pe

53、oplew Teaming, vendor selectionw Change management, expectation management, training, coaching, change enablementw Dataw Data conversion, legacy system integrationw Timew Schedule control, scope control, environmental factorsConclusionw PDCA-embedded IT systemw Plan/Operation/Comparison/Action, instead of operation support onlyw Build up business intelligence to support Strategic Enterprise Management (SEM)w Process centric information linksw Business process is the keyw IT vs. domain knowledgew Customer-oriented