先進生產(chǎn)計劃系統(tǒng)及供應(yīng)鏈管理

1、1 1先進生產(chǎn)計劃及調(diào)度先進生產(chǎn)計劃及調(diào)度 (APS)在半導(dǎo)體制造業(yè)中面臨的挑戰(zhàn)和機遇在半導(dǎo)體制造業(yè)中面臨的挑戰(zhàn)和機遇張濤(英特爾，上海) / 鄭力(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)12 2qSupply Chain 供應(yīng)鏈qAdvanced Planni

2、ng/Scheduling (APS) 先進生產(chǎn)計劃及調(diào)度qAdvanced Planning System Case Study 先進生產(chǎn)計劃系統(tǒng)實例Agenda 提綱23 3qSupply Chain 供應(yīng)鏈qAdvanced Planning/Scheduling (APS) 先進生產(chǎn)計劃及調(diào)度qAdvanced Planning System Case Study 先進生產(chǎn)計劃系統(tǒng)實例Agenda 提綱34 4Supply Chain in Semiconductor Manufacturing 半導(dǎo)體制造企業(yè)的供應(yīng)鏈Material Supplier原材料供應(yīng)商原材料供應(yīng)商Retai

3、l銷售銷售Capital Eqpt Supplier設(shè)備供應(yīng)商設(shè)備供應(yīng)商Subcontractor分包商分包商OEMProduction生產(chǎn)生產(chǎn)Distribution派送派送45 5qReduce inventories 減少庫存qMove to build-to-order 按訂貨制造qReduce planning cycle time 縮短計劃制訂時間qImprove delivery performance 提高計劃制訂水平qFocus on total Supply Chain Management (SCM) 專注于供應(yīng)鏈整體優(yōu)化qCollaborative planning a

4、nd execution 整合計劃和執(zhí)行SCM Trend in Semiconductor Manufacturing 半導(dǎo)體制造企業(yè)供應(yīng)鏈管理趨勢56 6qSupply Chain 供應(yīng)鏈qAdvanced Planning/Scheduling (APS) 先進生產(chǎn)計劃及調(diào)度qAdvanced Planning System Case Study 先進生產(chǎn)計劃系統(tǒng)實例Agenda 提綱67 7PurchasingSupply PlanLogisticsOrder MgmtDemand PlanSupplyDistributionProductionProcess ControlManuf

5、acturing Execution SystemInfrastructuresSCM Strategic PlanSalesSCM Architecture 供應(yīng)鏈管理構(gòu)架78 8Semiconductor 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)市場變化劇烈。企業(yè)必須縮短市場反應(yīng)時間，特別是生產(chǎn)計劃的制定周期。 qThe cost of equipments is very high. 半導(dǎo)體裝備成本極高。主要設(shè)備使用率的提高，能為公司節(jié)省巨額開支。 qSemi

6、conductor manufacturing is among the most complex production problems encountered today. 半導(dǎo)體制造的復(fù)雜性和專業(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)需要先進工業(yè)工程（運籌）學(xué)成果支持。In China 中國國情： qNo domestic APS provider 無國內(nèi)APS提供者。國外APS提供者產(chǎn)品價格高，服務(wù)尚未本地化qProduction Management: gu

7、esswork, manual work 生產(chǎn)管理：主觀臆斷、手工計算89 9qLack of supply chain visibility 企業(yè)供應(yīng)鏈透明度低qInefficient production/distribution planning and execution 低效率生產(chǎn)/派送計劃和執(zhí)行qLong responsiveness TPT 客戶響應(yīng)速度慢qLack of flexibility 生產(chǎn)計劃柔性差qLack of optimization 生產(chǎn)計劃優(yōu)化程度差qPoor on-time delivery 低及時交貨率qHigh inventory, low turno

8、ver 高庫存、低周轉(zhuǎn)率qCompeting management objectives 相互矛盾的生產(chǎn)管理目標Production Management: Current Status 生產(chǎn)管理現(xiàn)狀生產(chǎn)管理現(xiàn)狀91010Solution (Resource: ITRS*)解決方案（源自解決方案（源自ITRS*）qSignificant improvements in factory planning/scheduling are required. 必須通過先進生產(chǎn)計劃和調(diào)度系統(tǒng)來提高半導(dǎo)體制造的生產(chǎn)率qImprovements in factory forecasting and flex

9、ible factory information/control systems that can change with business conditions must be developed and implemented. 必須改進工廠的需求預(yù)測，建立柔性的工廠信息和管理軟件系統(tǒng)，使得工廠產(chǎn)能可以隨著市場環(huán)境的改變而改變q scheduling and dispatching must be developed to improve equipment OEE and extendibility. 必須探索和發(fā)展生產(chǎn)調(diào)度和分派技術(shù)，以改進裝備的利用率，提高工廠的可擴展性* Inter

10、national Technology Roadmap of Semiconductor 國際半導(dǎo)體技術(shù)路線圖 - 半導(dǎo)體技術(shù)權(quán)威資料101111Data Sources (ROO)Data Storage (ROR)APS SolverPlanAPS Architecture先進生產(chǎn)計劃及調(diào)度之構(gòu)架先進生產(chǎn)計劃及調(diào)度之構(gòu)架LP/MIPSimulation/ Rule-basedJ2EE/ .Net111212qUnified 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q

11、Rapid Implementation 易于實施qHigh Reliability 高可靠性qCustomer-Oriented Solution 面向用戶的解決方案qStrength of “What-if” Capability 強大假設(shè)分析能力Advantage of APS先進生產(chǎn)計劃及調(diào)度之優(yōu)勢先進生產(chǎn)計劃及調(diào)度之優(yōu)勢121313qSupply Chain 供應(yīng)鏈qAdvanced Planning/Scheduling (APS) 先進生產(chǎn)計劃及調(diào)度qAdvanced Planning System Case Study 先進生產(chǎn)計劃系統(tǒng)實例Agenda 提綱131414APS

12、Planning System “X” 先進生產(chǎn)計劃系統(tǒng)先進生產(chǎn)計劃系統(tǒng)“X”qAssembly & Test Manufacturing Capacity Planning Tool used in mid-range horizon (next half year) 芯片封裝生產(chǎn)計劃決策支持軟件系統(tǒng)qModeling Supply Chain from Assy to Test with inventory control 決定工廠的設(shè)備投資和庫存水平，是半導(dǎo)體生產(chǎn)控制及管理軟件中最核心的部分qOptimizing Virtual Factory / subcontractors

13、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141515Industry Benchmark行業(yè)對比Critical Success FactorIndicatorRangeMedianBICAPS Planning System “X”SpeedFrequencyWeekly - QuarterlyQuarterlyWeeklyWeeklyCycle time1 5 days1 day1 day1 hourAccuracyHorizon6 months 2 years6 months6 months6 monthsEfficiencyTo

14、olExcel - LegacyExcelLegacyAPSResource: . Surveyed companies include: 151616Benefits of “X” System Application “X”系統(tǒng)的優(yōu)勢qFaster: Shorten Capacity Planning TPT; Improve responsiveness 更快：生產(chǎn)計劃周期；客戶響應(yīng)速度qBetter: Optimize Virtual Factory resource utilization; Minimize material inventory 更好：提高設(shè)備利用率；減少庫存量qC

15、heaper: Save huge amount of man hours 更便宜：節(jié)約大量用于制定生產(chǎn)計劃的人力成本161717Summary總結(jié)qProduction Management in semiconductor manufacturing faces serious challenges nowadays目前半導(dǎo)體生產(chǎn)管理面臨嚴重挑戰(zhàn)qMany great opportunities for APS! 同時也為APS造就了無數(shù)機遇！171818Q & A 181919Backup附件附件 192020采購采購供給計劃供給計劃物流物流計劃計劃訂單管理訂單管理需求計劃需求計

16、劃供給供給物流物流生產(chǎn)生產(chǎn)過程控制過程控制系統(tǒng)整合系統(tǒng)整合共享信息平臺共享信息平臺供應(yīng)鏈戰(zhàn)略規(guī)劃系統(tǒng)供應(yīng)鏈戰(zhàn)略規(guī)劃系統(tǒng)銷售銷售虛擬企業(yè)生產(chǎn)虛擬企業(yè)生產(chǎn)管理管理：月/季度生產(chǎn)計劃生產(chǎn)計劃：周/月生產(chǎn)調(diào)度生產(chǎn)調(diào)度：小時/天生產(chǎn)實時分派生產(chǎn)實時分派：分SCM Architecture 供應(yīng)鏈管理構(gòu)架202121q芯片封裝生產(chǎn)計劃決策支持軟件系統(tǒng)q決定工廠的設(shè)備投資和庫存水平人員配置，是半導(dǎo)體生產(chǎn)控制及管理軟件中最核心的部分q整合優(yōu)化工廠內(nèi)部和外包商的生產(chǎn)能力q提供供應(yīng)鏈管理診斷分析工具先進生產(chǎn)計劃系統(tǒng)先進生產(chǎn)計劃系統(tǒng)介紹介紹212222智域計劃智域計劃的優(yōu)勢的優(yōu)勢 * 資料源自Pricewaterh

17、ouseCoopers；參加對比的公司包括：Intel, Texas Instruments, Motorola, NEC, Fujitsu, National Semiconductor, Conexant, and Fairchild Semiconductor智域計劃的優(yōu)勢包括： 更快：生產(chǎn)計劃周期；客戶響應(yīng)速度 更好：提高設(shè)備利用率；減少庫存量；消除人為錯誤；增強計劃靈活性 更便宜：節(jié)約大量用于制定生產(chǎn)計劃的人力成本主要因素主要因素范圍范圍平均水平平均水平最好水平最好水平智域計劃智域計劃表現(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

18、周一次每周一次每周一次速度：處理時間速度：處理時間一天一天 五天五天一天一天一天一天 一小時一小時 計劃時間尺度計劃時間尺度6 個月個月 18個月個月6個月個月6 個月個月6 個月個月效率：分析工具效率：分析工具數(shù)據(jù)表數(shù)據(jù)表格；軟件包格；軟件包數(shù)據(jù)表數(shù)據(jù)表格格軟件包軟件包軟件包軟件包222323芯片制造業(yè)芯片制造業(yè)(Fab)投資投資232424qDemand 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 Inputs242525qP