先進生產計劃系統(tǒng)及供應鏈管理(共25頁).ppt

1、1 11先進生產方案及調度先進生產方案及調度 (APS)在半導體制造業(yè)中面臨的挑戰(zhàn)和機遇在半導體制造業(yè)中面臨的挑戰(zhàn)和機遇張濤張濤(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) 先進生產方案及調度qAdvanced Planning System Case Study 先進生產方案系統(tǒng)實例Agenda 提綱3 33qSupply Chain 供給鏈qAdvanced Planning/Scheduling (APS) 先進生產方案及調度qAdvanced Planning System Case Study 先進生產方案系統(tǒng)實例Agenda 提綱4 44Supply Chain in Semiconductor Manufacturing 半導體制造企業(yè)的供給鏈Material Supplier原

3、材料供應商原材料供應商Retail銷售銷售Capital Eqpt Supplier設備供應商設備供應商Subcontractor分包商分包商OEMProduction生產生產Distribution派送派送5 55qReduce inventories 減少庫存qMove to build-to-order 按訂貨制造qReduce planning cycle time 縮短方案制訂時間qImprove delivery performance 提高方案制訂水平qFocus on total Supply Chain Management (SCM) 專注于供給鏈整體優(yōu)化qCollabor

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

5、ess ControlManufacturing Execution SystemInfrastructuresSCM Strategic PlanSalesSCM Architecture 供給鏈管理構架8 88Semiconductor Industry: Challenges 產業(yè)現狀：挑戰(zhàn)產業(yè)現狀：挑戰(zhàn)qMarketing environment changes dramatically. 半導體產業(yè)市場變化劇烈。企業(yè)必須縮短市場反響時間，特別是生產方案的制定周期。 qThe cost of equipments is very high. 半導體裝備本錢極高。主要設備使用率的提高，能

6、為公司節(jié)省巨額開支。 qSemiconductor manufacturing is among the most complex production problems encountered today. 半導體制造的復雜性和專業(yè)性，使其生產管理成為最具挑戰(zhàn)的課題。qMany enterprises lack expertise in IE/OR to apply APS. 優(yōu)秀的生產管理系統(tǒng)需要先進工業(yè)工程運籌學成果支持。In China 中國國情： No domestic APS provider 無國內APS提供者。國外APS提供者產品價格高，效勞尚未本地化Production Ma

7、nagement: guesswork, manual work 生產管理：主觀臆斷、手工計算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/派送方案和執(zhí)行qLong responsiveness TPT 客戶響應速度慢qLack of flexibility 生產方案柔性差qLack of optimization 生產方案優(yōu)化程度差qPoor on-time delivery 低及時交貨率qHigh inventor

8、y, low turnover 高庫存、低周轉率qCompeting management objectives 相互矛盾的生產管理目標Production Management: Current Status 生產管理現狀生產管理現狀101010Solution (Resource: ITRS*)解決方案源自ITRS*Significant improvements in factory planning/scheduling are required. 必須通過先進生產方必須通過先進生產方案和調度系統(tǒng)來提高半導體制造的生產率案和調度系統(tǒng)來提高半導體制造的生產率Improvements in

9、 factory forecasting and flexible factory information/control systems that can change with business conditions must be developed and implemented. 必須改進工廠的需求預測，建立柔性的工必須改進工廠的需求預測，建立柔性的工廠信息和管理軟件系統(tǒng)，使得工廠產能可以隨著市場環(huán)境廠信息和管理軟件系統(tǒng)，使得工廠產能可以隨著市場環(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展生產調度和分派技術，以改進裝備的利用率，提高工開展生產調度和分派技術，以改進裝備的利用率，提高工廠的可擴展性廠的可擴展性* International Technology Roadmap of Semiconductor 國際半導體技術路線圖 - 半導體技術權威資料111111Data Sources (ROO)Data Storage (ROR)APS SolverPlanAPS Architecture先進生產方案及調度之構架LP/MIPSimulation/ Rule-basedJ2EE/ .N

11、et121212qUnified Data Model (UDM) 統(tǒng)一數據模型qFast Solve Speed 快速求解qMultiple Levels of Optimization 多層次優(yōu)化qRapid 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 強大假設分析能力Advantage of APS先進生產方案及調度之優(yōu)勢131313qSupply Chain 供給鏈qAdvanced Planning/Sche

12、duling (APS) 先進生產方案及調度qAdvanced Planning System Case Study 先進生產方案系統(tǒng)實例Agenda 提綱141414APS Planning System “X 先進生產方案系統(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、工廠的設備投資和庫存水平，是半導體生產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)化工廠內部和外包商的生產能力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qFaster: Shorten Capacity Planning TPT; Improve responsiveness 更快：生產方案周期；客戶響應速度qBetter: Optimize Virtual

15、Factory resource utilization; Minimize material inventory 更好：提高設備利用率；減少庫存量qCheaper: Save huge amount of man hours 更廉價：節(jié)約大量用于制定生產方案的人力本錢171717Summary總結qProduction Management in semiconductor manufacturing faces serious challenges nowadays目前半導體生產管理面臨嚴重挑戰(zhàn)qMany great opportunities for APS! 同時也為APS造就了無數機

16、遇！181818Q & A 191919Backup附件附件 202020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劃供給供給物流物流生產生產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鏈戰(zhàn)略規(guī)劃系統(tǒng)供應鏈戰(zhàn)略規(guī)劃系統(tǒng)銷售銷售虛擬企業(yè)生產虛擬企業(yè)生產管理管理：月/季度生產計劃生產計劃：周/月生產調度生產調度：小時/天生產實時分派生產實時分派：分SCM Architecture 供給鏈管理構架212121q芯片封裝生產方案決策支持軟件系統(tǒng)q決定工廠的設備投資和庫存水平人員配置，是半導體生產控制及管理軟件中最核心的局部q整合優(yōu)化工廠內部和外包商的

17、生產能力q提供供給鏈管理診斷分析工具先進生產方案系統(tǒng)介紹先進生產方案系統(tǒng)介紹222222智域方案智域方案的優(yōu)勢的優(yōu)勢 * 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)勢包括：更快：生產方案周期；客戶響應速度更好：提高設備利用率；減少庫存量；消除人為錯誤；增強方案靈活性更廉價：節(jié)約大量用于制定生產方案的人力本錢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劃智域計劃表現表現速度：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：分析工具數據表數據表格；軟件包格；軟件包數據表數據表格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