半導(dǎo)體業(yè)生產(chǎn)計(jì)劃1(共25).ppt

1、1 11先進(jìn)生產(chǎn)方案及調(diào)度先進(jìn)生產(chǎn)方案及調(diào)度 (APS)在半導(dǎo)體制造業(yè)中面臨的挑戰(zhàn)和機(jī)遇在半導(dǎo)體制造業(yè)中面臨的挑戰(zhàn)和機(jī)遇張濤張濤(英特爾，上海英特爾，上海) / 鄭力鄭力(清華，北京清華，北京)12.2003 03 IE&EMAdvanced Planning / Scheduling (APS) in Semiconductor Manufacturing: Challenges and OpportunitiesMike ZHANG (Intel, Shanghai) / Li ZHENG (Tsinghua Univ., Beijing)2 22qSupply Chain 供給鏈

2、qAdvanced Planning/Scheduling (APS) 先進(jìn)生產(chǎn)方案及調(diào)度qAdvanced Planning System Case Study 先進(jìn)生產(chǎn)方案系統(tǒng)實(shí)例Agenda 提綱3 33qSupply Chain 供給鏈qAdvanced Planning/Scheduling (APS) 先進(jìn)生產(chǎn)方案及調(diào)度qAdvanced Planning System Case Study 先進(jìn)生產(chǎn)方案系統(tǒng)實(shí)例Agenda 提綱4 44Supply Chain in Semiconductor Manufacturing 半導(dǎo)體制造企業(yè)的供給鏈Material Supplier原

3、材料供應(yīng)商原材料供應(yīng)商Retail銷(xiāo)售銷(xiāo)售Capital Eqpt Supplier設(shè)備供應(yīng)商設(shè)備供應(yīng)商Subcontractor分包商分包商O(píng)EMProduction生產(chǎn)生產(chǎn)Distribution派送派送5 55qReduce inventories 減少庫(kù)存qMove to build-to-order 按訂貨制造qReduce planning cycle time 縮短方案制訂時(shí)間qImprove delivery performance 提高方案制訂水平qFocus on total Supply Chain Management (SCM) 專(zhuān)注于供給鏈整體優(yōu)化qCollabor

4、ative planning and execution 整合方案和執(zhí)行SCM Trend in Semiconductor Manufacturing 半導(dǎo)體制造企業(yè)供給鏈管理趨勢(shì)6 66qSupply Chain 供給鏈qAdvanced Planning/Scheduling (APS) 先進(jìn)生產(chǎn)方案及調(diào)度qAdvanced Planning System Case Study 先進(jìn)生產(chǎn)方案系統(tǒng)實(shí)例Agenda 提綱7 77PurchasingSupply PlanLogisticsOrder MgmtDemand PlanSupplyDistributionProductionProc

5、ess ControlManufacturing Execution SystemInfrastructuresSCM Strategic PlanSalesSCM Architecture 供給鏈管理構(gòu)架8 88Semiconductor Industry: Challenges 產(chǎn)業(yè)現(xiàn)狀：挑戰(zhàn)產(chǎn)業(yè)現(xiàn)狀：挑戰(zhàn)qMarketing environment changes dramatically. 半導(dǎo)體產(chǎn)業(yè)市場(chǎng)變化劇烈。企業(yè)必須縮短市場(chǎng)反響時(shí)間，特別是生產(chǎn)方案的制定周期。 qThe cost of equipments is very high. 半導(dǎo)體裝備本錢(qián)極高。主要設(shè)備使用率的提高，能

6、為公司節(jié)省巨額開(kāi)支。 qSemiconductor manufacturing is among the most complex production problems encountered today. 半導(dǎo)體制造的復(fù)雜性和專(zhuān)業(yè)性，使其生產(chǎn)管理成為最具挑戰(zhàn)的課題。qMany enterprises lack expertise in IE/OR to apply APS. 優(yōu)秀的生產(chǎn)管理系統(tǒng)需要先進(jìn)工業(yè)工程運(yùn)籌學(xué)成果支持。In China 中國(guó)國(guó)情： No domestic APS provider 無(wú)國(guó)內(nèi)APS提供者。國(guó)外APS提供者產(chǎn)品價(jià)格高，效勞尚未本地化Production Ma

7、nagement: guesswork, manual work 生產(chǎn)管理：主觀臆斷、手工計(jì)算9 99qLack of supply chain visibility 企業(yè)供給鏈透明度低qInefficient production/distribution planning and execution 低效率生產(chǎn)/派送方案和執(zhí)行qLong responsiveness TPT 客戶響應(yīng)速度慢qLack of flexibility 生產(chǎn)方案柔性差qLack of optimization 生產(chǎn)方案優(yōu)化程度差qPoor on-time delivery 低及時(shí)交貨率qHigh inventor

8、y, low turnover 高庫(kù)存、低周轉(zhuǎn)率qCompeting management objectives 相互矛盾的生產(chǎn)管理目標(biāo)Production Management: Current Status 生產(chǎn)管理現(xiàn)狀生產(chǎn)管理現(xiàn)狀101010Solution (Resource: ITRS*)解決方案源自ITRS*Significant improvements in factory planning/scheduling are required. 必須通過(guò)先進(jìn)生產(chǎn)方必須通過(guò)先進(jìn)生產(chǎn)方案和調(diào)度系統(tǒng)來(lái)提高半導(dǎo)體制造的生產(chǎn)率案和調(diào)度系統(tǒng)來(lái)提高半導(dǎo)體制造的生產(chǎn)率Improvements in

9、 factory forecasting and flexible factory information/control systems that can change with business conditions must be developed and implemented. 必須改進(jìn)工廠的需求預(yù)測(cè)，建立柔性的工必須改進(jìn)工廠的需求預(yù)測(cè)，建立柔性的工廠信息和管理軟件系統(tǒng)，使得工廠產(chǎn)能可以隨著市場(chǎng)環(huán)境廠信息和管理軟件系統(tǒng)，使得工廠產(chǎn)能可以隨著市場(chǎng)環(huán)境的改變而改變的改變而改變 scheduling and dispatching must be developed to improve

10、 equipment OEE and extendibility. 必須探索和必須探索和開(kāi)展生產(chǎn)調(diào)度和分派技術(shù)，以改進(jìn)裝備的利用率，提高工開(kāi)展生產(chǎn)調(diào)度和分派技術(shù)，以改進(jìn)裝備的利用率，提高工廠的可擴(kuò)展性廠的可擴(kuò)展性* International Technology Roadmap of Semiconductor 國(guó)際半導(dǎo)體技術(shù)路線圖 - 半導(dǎo)體技術(shù)權(quán)威資料111111Data Sources (ROO)Data Storage (ROR)APS SolverPlanAPS Architecture先進(jìn)生產(chǎn)方案及調(diào)度之構(gòu)架LP/MIPSimulation/ Rule-basedJ2EE/ .N

11、et121212qUnified Data Model (UDM) 統(tǒng)一數(shù)據(jù)模型qFast Solve Speed 快速求解qMultiple Levels of Optimization 多層次優(yōu)化qRapid Implementation 易于實(shí)施qHigh Reliability 高可靠性qCustomer-Oriented Solution 面向用戶的解決方案qStrength of “What-if Capability 強(qiáng)大假設(shè)分析能力Advantage of APS先進(jìn)生產(chǎn)方案及調(diào)度之優(yōu)勢(shì)131313qSupply Chain 供給鏈qAdvanced Planning/Sche

12、duling (APS) 先進(jìn)生產(chǎn)方案及調(diào)度qAdvanced Planning System Case Study 先進(jìn)生產(chǎn)方案系統(tǒng)實(shí)例Agenda 提綱141414APS Planning System “X 先進(jìn)生產(chǎn)方案系統(tǒng)“XqAssembly & Test Manufacturing Capacity Planning Tool used in mid-range horizon (next half year) 芯片封裝生產(chǎn)方案決策支持軟件系統(tǒng)qModeling Supply Chain from Assy to Test with inventory control 決定

13、工廠的設(shè)備投資和庫(kù)存水平，是半導(dǎo)體生產(chǎn)控制及管理軟件中最核心的局部qOptimizing Virtual Factory / subcontractors capacity with one demand signal 整合優(yōu)化工廠內(nèi)部和外包商的生產(chǎn)能力151515Industry Benchmark行業(yè)比照Critical Success FactorIndicatorRangeMedianBICAPS Planning System “X”SpeedFrequencyWeekly - QuarterlyQuarterlyWeeklyWeeklyCycle time1 5 days1 day

14、1 day1 hourAccuracyHorizon6 months 2 years6 months6 months6 monthsEfficiencyToolExcel - LegacyExcelLegacyAPSResource: . Surveyed companies include: 161616Benefits of “X System Application “X系統(tǒng)的優(yōu)勢(shì)qFaster: Shorten Capacity Planning TPT; Improve responsiveness 更快：生產(chǎn)方案周期；客戶響應(yīng)速度qBetter: Optimize Virtual

15、Factory resource utilization; Minimize material inventory 更好：提高設(shè)備利用率；減少庫(kù)存量qCheaper: Save huge amount of man hours 更廉價(jià)：節(jié)約大量用于制定生產(chǎn)方案的人力本錢(qián)171717Summary總結(jié)qProduction Management in semiconductor manufacturing faces serious challenges nowadays目前半導(dǎo)體生產(chǎn)管理面臨嚴(yán)重挑戰(zhàn)qMany great opportunities for APS! 同時(shí)也為APS造就了無(wú)數(shù)機(jī)

16、遇！181818Q & A 191919Backup附件附件 202020采購(gòu)采購(gòu)供給計(jì)劃供給計(jì)劃物流物流計(jì)劃計(jì)劃訂單管理訂單管理需求計(jì)劃需求計(jì)劃供給供給物流物流生產(chǎn)生產(chǎn)過(guò)程控制過(guò)程控制系統(tǒng)整合系統(tǒng)整合共享信息平臺(tái)共享信息平臺(tái)供應(yīng)鏈戰(zhàn)略規(guī)劃系統(tǒng)供應(yīng)鏈戰(zhàn)略規(guī)劃系統(tǒng)銷(xiāo)售銷(xiāo)售虛擬企業(yè)生產(chǎn)虛擬企業(yè)生產(chǎn)管理管理：月/季度生產(chǎn)計(jì)劃生產(chǎn)計(jì)劃：周/月生產(chǎn)調(diào)度生產(chǎn)調(diào)度：小時(shí)/天生產(chǎn)實(shí)時(shí)分派生產(chǎn)實(shí)時(shí)分派：分SCM Architecture 供給鏈管理構(gòu)架212121q芯片封裝生產(chǎn)方案決策支持軟件系統(tǒng)q決定工廠的設(shè)備投資和庫(kù)存水平人員配置，是半導(dǎo)體生產(chǎn)控制及管理軟件中最核心的局部q整合優(yōu)化工廠內(nèi)部和外包商的

17、生產(chǎn)能力q提供供給鏈管理診斷分析工具先進(jìn)生產(chǎn)方案系統(tǒng)介紹先進(jìn)生產(chǎn)方案系統(tǒng)介紹222222智域方案智域方案的優(yōu)勢(shì)的優(yōu)勢(shì) * 資料源自PricewaterhouseCoopers；參加比照的公司包括：Intel, Texas Instruments, Motorola, NEC, Fujitsu, National Semiconductor, Conexant, and Fairchild Semiconductor智域方案的優(yōu)勢(shì)包括：更快：生產(chǎn)方案周期；客戶響應(yīng)速度更好：提高設(shè)備利用率；減少庫(kù)存量；消除人為錯(cuò)誤；增強(qiáng)方案靈活性更廉價(jià)：節(jié)約大量用于制定生產(chǎn)方案的人力本錢(qián)主要因素主要因素范圍范圍平

18、均水平平均水平最好水平最好水平智域計(jì)劃智域計(jì)劃表現(xiàn)表現(xiàn)速度：處理速度：處理頻率頻率每周一次每周一次 每季度一次每季度一次每周一次每周一次每周一次每周一次每周一次每周一次速度：處理時(shí)間速度：處理時(shí)間一天一天 五天五天一天一天一天一天 一小時(shí)一小時(shí) 計(jì)劃時(shí)間尺度計(jì)劃時(shí)間尺度6 個(gè)月個(gè)月 18個(gè)月個(gè)月6個(gè)月個(gè)月6 個(gè)月個(gè)月6 個(gè)月個(gè)月效率：分析工具效率：分析工具數(shù)據(jù)表格；軟件包數(shù)據(jù)表格；軟件包數(shù)據(jù)表格數(shù)據(jù)表格軟件包軟件包軟件包軟件包232323芯片制造業(yè)芯片制造業(yè)(Fab)投資投資242424qDemand Sales Forecasts & OrdersqBill of Materials (BOM)qRoutings Production RoutingsqProducts Raw Material, WIP, Finished Goods Inventory LevelsqResource Availability Available Labor Workpatterns Production Capacities, Set-up Rqmts, etc.qBusiness RulesAPS Inputs25