半導(dǎo)體業(yè)生產(chǎn)計(jì)劃課件1

1、半導(dǎo)體業(yè)生產(chǎn)計(jì)劃1Supply Chain 供應(yīng)鏈Advanced Planning/Scheduling (APS) 先進(jìn)生產(chǎn)計(jì)劃及調(diào)度Advanced Planning System Case Study 先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda 提綱2Supply Chain 供應(yīng)鏈Advanced Planning/Scheduling (APS) 先進(jìn)生產(chǎn)計(jì)劃及調(diào)度Advanced Planning System Case Study 先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda 提綱3Supply Chain in Semiconductor Manufacturing 半導(dǎo)體制造企業(yè)的供應(yīng)鏈Mate

2、rial Supplier原材料供應(yīng)商Retail銷售Capital Eqpt Supplier設(shè)備供應(yīng)商Subcontractor分包商OEMProduction生產(chǎn)Distribution派送4Reduce inventories 減少庫存Move to build-to-order 按訂貨制造Reduce planning cycle time 縮短計(jì)劃制訂時(shí)間Improve delivery performance 提高計(jì)劃制訂水平Focus on total Supply Chain Management (SCM) 專注于供應(yīng)鏈整體優(yōu)化Collaborative planning

3、and execution 整合計(jì)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5Supply Chain 供應(yīng)鏈Advanced Planning/Scheduling (APS) 先進(jìn)生產(chǎn)計(jì)劃及調(diào)度Advanced Planning System Case Study 先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda 提綱6PurchasingSupply PlanSchedulingLogisticsPlanningOrder MgmtDemand PlanSupplyDistributionProductionProcess Co

4、ntrolManufacturing Execution SystemInfrastructuresSCM Strategic PlanReal-time DispatchingVirtual Factory PlanningSalesFrequencyMonth/QuarterWeek/MonthDay/HourMinuteSCM Architecture 供應(yīng)鏈管理構(gòu)架StrategyPlanExecutionSupply Chain Management7Semiconductor Industry: Challenges 產(chǎn)業(yè)現(xiàn)狀：挑戰(zhàn)Marketing environment cha

5、nges 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(shí)間，特別是生產(chǎn)計(jì)劃的制定周期。 The 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。 Semiconductor 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。Many enterprises lack expertise in IE/OR to apply

6、 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 中國國情： No domestic APS provider 無國內(nèi)APS提供者。國外APS提供者產(chǎn)品價(jià)格高，服務(wù)尚未本地化Production Management: guesswork, manual work 生產(chǎn)管理：主觀臆斷、手工計(jì)算8Lack of supply chain visibility 企業(yè)供應(yīng)鏈透明度低Inefficient production/distribution planning and execution 低效率生產(chǎn)/派送計(jì)劃和執(zhí)行Long responsiveness TP

7、T 客戶響應(yīng)速度慢Lack of flexibility 生產(chǎn)計(jì)劃柔性差Lack of optimization 生產(chǎn)計(jì)劃優(yōu)化程度差Poor on-time delivery 低及時(shí)交貨率High inventory, low turnover 高庫存、低周轉(zhuǎn)率Competing 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9Solution (Resource: ITRS*)解決方案（源自ITRS*）Significant improvements in factory planni

8、ng/scheduling are required. 必須通過先進(jìn)生產(chǎn)計(jì)劃和調(diào)度系統(tǒng)來提高半導(dǎo)體制造的生產(chǎn)率Improvements in 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，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 scheduling and dispatching must be

9、 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(jìn)裝備的利用率，提高工廠的可擴(kuò)展性* International 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10Data Sources (ROO)RoutingProductsBOMResourcesDemandData Storage (ROR)APS SolverAPS SystemsPlanLong-RangeMid-RangeDaily/Weekly ChangeS

10、cheduleDispatchAPS Architecture先進(jìn)生產(chǎn)計(jì)劃及調(diào)度之構(gòu)架LP/MIPSimulation/ Rule-basedJ2EE/ .Net11Unified Data Model (UDM) 統(tǒng)一數(shù)據(jù)模型Fast Solve Speed 快速求解Multiple Levels of Optimization 多層次優(yōu)化Rapid Implementation 易于實(shí)施High Reliability 高可靠性Customer-Oriented Solution 面向用戶的解決方案Strength of “What-if” Capability 強(qiáng)大假設(shè)分析能力Advan

11、tage of APS先進(jìn)生產(chǎn)計(jì)劃及調(diào)度之優(yōu)勢12Supply Chain 供應(yīng)鏈Advanced Planning/Scheduling (APS) 先進(jìn)生產(chǎn)計(jì)劃及調(diào)度Advanced Planning System Case Study 先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda 提綱13APS Planning System “X” 先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)“X”Assembly & Test Manufacturing Capacity Planning Tool used in mid-range horizon (next half year) 芯片封裝生產(chǎn)計(jì)劃決策支持軟件系統(tǒng)Modeling Su

12、pply 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Optimizing 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14Industry Benchmark行業(yè)對(duì)比Critical Success FactorIndicatorRangeMedianBICAPS Planning System “X”SpeedFrequencyWeekly - Quar

13、terlyQuarterlyWeeklyWeeklyCycle time1 5 days1 day1 day1 hourAccuracyHorizon6 months 2 years6 months6 months6 monthsEfficiencyToolExcel - LegacyExcelLegacyAPSResource: PricewaterhouseCoopers. Surveyed companies include: Intel, Texas Instruments, Motorola, NEC, Fujitsu, National Semiconductor, Conexan

14、t, and Fairchild Semiconductor15Benefits of “X” System Application “X”系統(tǒng)的優(yōu)勢Faster: Shorten Capacity Planning TPT; Improve responsiveness 更快：生產(chǎn)計(jì)劃周期；客戶響應(yīng)速度Better: Optimize Virtual Factory resource utilization; Minimize material inventory 更好：提高設(shè)備利用率；減少庫存量Cheaper: Save huge amount of man hours 更便宜：節(jié)約大量用

15、于制定生產(chǎn)計(jì)劃的人力成本16Summary總結(jié)Production 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)Many great opportunities for APS! 同時(shí)也為APS造就了無數(shù)機(jī)遇！17Q & A 18Backup附件 19采購供給計(jì)劃生產(chǎn)調(diào)度系統(tǒng)物流計(jì)劃生產(chǎn)計(jì)劃系統(tǒng)訂單管理需求計(jì)劃供給物流生產(chǎn)過程控制系統(tǒng)整合共享信息平臺(tái)實(shí)施戰(zhàn)術(shù)戰(zhàn)略供應(yīng)鏈戰(zhàn)略規(guī)劃系統(tǒng)生產(chǎn)實(shí)時(shí)分派系統(tǒng)虛擬企業(yè)生產(chǎn)管理系統(tǒng)銷售供 應(yīng) 鏈 管 理計(jì)劃頻率虛擬企業(yè)生產(chǎn)管理

16、：月/季度生產(chǎn)計(jì)劃：周/月生產(chǎn)調(diào)度：小時(shí)/天生產(chǎn)實(shí)時(shí)分派：分SCM Architecture 供應(yīng)鏈管理構(gòu)架20芯片封裝生產(chǎn)計(jì)劃決策支持軟件系統(tǒng)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整合優(yōu)化工廠內(nèi)部和外包商的生產(chǎn)能力提供供應(yīng)鏈管理診斷分析工具先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)介紹21智域計(jì)劃的優(yōu)勢 * 資料源自PricewaterhouseCoopers；參加對(duì)比的公司包括：Intel, Texas Instruments, Motorola, NEC, Fujitsu, National Semiconductor, Conexant, and Fairchild Semiconductor智域計(jì)劃的優(yōu)勢包括：更快：生產(chǎn)計(jì)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(cuò)誤；增強(qiáng)計(jì)劃靈活性更便宜：節(jié)約大量用于制定生產(chǎn)計(jì)劃的人力成本主要因素范圍平均水平最好水平智域計(jì)劃表現(xiàn)速度：處理頻率每周一次 每季度一次每周一次每周一次每周一次速度：處理時(shí)間一天 五天一天一天 一小時(shí) 計(jì)劃時(shí)間尺度6 個(gè)月 18個(gè)月6個(gè)月6 個(gè)月6 個(gè)月效率：分析工具數(shù)據(jù)表格；軟件包數(shù)據(jù)表格軟件包軟件包22芯片制造