半导体业生产计划1(1)

1 1先进生产计划及调度先进生产计划及调度(APS)在半导体制造业中面临的挑战和机遇在半导体制造业中面临的挑战和机遇张涛(英特尔，上海)/郑力(清华，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 供应链qAdvanced Planning/Scheduling(APS)先进生产计划及调度qAdvanced Planning System Case Study 先进生产计划系统实例Agenda 提纲23 3qSupply Chain 供应链qAdvanced Planning/Scheduling(APS)先进生产计划及调度qAdvanced Planning System Case Study 先进生产计划系统实例Agenda 提纲34 4Supply Chain in Semiconductor Manufacturing 半导体制造企业的供应链Material Supplier原材料供应商原材料供应商Retail销售销售Capital Eqpt Supplier设备供应商设备供应商Subcontractor分包商分包商OEMProduction生产生产Distribution派送派送45 5qReduce inventories 减少库存qMove to build-to-order 按订货制造qReduce planning cycle time 缩短计划制订时间qImprove delivery performance 提高计划制订水平qFocus on total Supply Chain Management(SCM)专注于供应链整体优化qCollaborative planning and execution 整合计划和执行SCM Trend in Semiconductor Manufacturing 半导体制造企业供应链管理趋势56 6qSupply Chain 供应链qAdvanced Planning/Scheduling(APS)先进生产计划及调度qAdvanced Planning System Case Study 先进生产计划系统实例Agenda 提纲67 7PurchasingSupply PlanLogisticsOrder MgmtDemand PlanSupplyDistributionProductionProcess ControlManufacturing Execution SystemInfrastructuresSCM Strategic PlanSalesSCM Architecture 供应链管理构架78 8Semiconductor Industry:Challenges 产业现状：挑战产业现状：挑战qMarketing environment changes dramatically.半导体产业市场变化剧烈。企业必须缩短市场反应时间，特别是生产计划的制定周期。qThe cost of equipments is very high.半导体装备成本极高。主要设备使用率的提高，能为公司节省巨额开支。qSemiconductor manufacturing is among the most complex production problems encountered today.半导体制造的复杂性和专业性，使其生产管理成为最具挑战的课题。qMany enterprises lack expertise in IE/OR to apply APS.优秀的生产管理系统需要先进工业工程（运筹）学成果支持。In China 中国国情：qNo domestic APS provider 无国内APS提供者。国外APS提供者产品价格高，服务尚未本地化qProduction Management:guesswork,manual work 生产管理：主观臆断、手工计算89 9qLack of supply chain visibility 企业供应链透明度低qInefficient production/distribution planning and execution 低效率生产/派送计划和执行qLong responsiveness TPT 客户响应速度慢qLack of flexibility 生产计划柔性差qLack of optimization 生产计划优化程度差qPoor on-time delivery 低及时交货率qHigh inventory,low turnover 高库存、低周转率qCompeting management objectives 相互矛盾的生产管理目标Production Management:Current Status 生产管理现状生产管理现状91010Solution(Resource:ITRS*)解决方案（源自解决方案（源自ITRS*）qSignificant improvements in factory planning/scheduling are required.必须通过先进生产计划和调度系统来提高半导体制造的生产率qImprovements in factory forecasting and flexible factory information/control systems that can change with business conditions must be developed and implemented.必须改进工厂的需求预测，建立柔性的工厂信息和管理软件系统，使得工厂产能可以随着市场环境的改变而改变q scheduling and dispatching must be developed to improve equipment OEE and extendibility.必须探索和发展生产调度和分派技术，以改进装备的利用率，提高工厂的可扩展性*International Technology Roadmap of Semiconductor 国际半导体技术路线图-半导体技术权威资料101111Data Sources(ROO)Data Storage(ROR)APS SolverPlanAPS Architecture先进生产计划及调度之构架先进生产计划及调度之构架LP/MIPSimulation/Rule-basedJ2EE/.Net111212qUnified Data Model(UDM)统一数据模型qFast Solve Speed 快速求解qMultiple Levels of Optimization 多层次优化qRapid Implementation 易于实施qHigh Reliability 高可靠性qCustomer-Oriented Solution 面向用户的解决方案qStrength of“What-if”Capability 强大假设分析能力Advantage of APS先进生产计划及调度之优势先进生产计划及调度之优势121313qSupply Chain 供应链qAdvanced Planning/Scheduling(APS)先进生产计划及调度qAdvanced Planning System Case Study 先进生产计划系统实例Agenda 提纲131414APS Planning System“X”先进生产计划系统先进生产计划系统“X”qAssembly&Test Manufacturing Capacity Planning Tool used in mid-range horizon(next half year)芯片封装生产计划决策支持软件系统qModeling Supply Chain from Assy to Test with inventory control 决定工厂的设备投资和库存水平，是半导体生产控制及管理软件中最核心的部分qOptimizing Virtual Factory/subcontractors capacity with one demand signal 整合优化工厂内部和外包商的生产能力141515Industry Benchmark行业对比Critical Success FactorIndicatorRangeMedianBICAPS Planning System“X”SpeedFrequencyWeekly-QuarterlyQuarterlyWeeklyWeeklyCycle time1 5 days1 day1 day1 hourAccuracyHorizon6 months 2 years6 months6 months6 monthsEfficiencyToolExcel-LegacyExcelLegacyAPSResource:.Surveyed companies include:151616Benefits of“X”System Application“X”系统的优势qFaster:Shorten Capacity Planning TPT;Improve responsiveness 更快：生产计划周期；客户响应速度qBetter:Optimize Virtual Factory resource utilization;Minimize material inventory 更好：提高设备利用率；减少库存量qCheaper:Save huge amount of man hours 更便宜：节约大量用于制定生产计划的人力成本161717Summary总结qProduction Management in semiconductor manufacturing faces serious challenges nowadays目前半导体生产管理面临严重挑战qMany great opportunities for APS!同时也为APS造就了无数机遇！171818Q&A 181919Backup附件附件 192020采购采购供给计划供给计划物流物流计划计划订单管理订单管理需求计划需求计划供给供给物流物流生产生产过程控制过程控制系统整合系统整合共享信息平台共享信息平台供应链战略规划系统供应链战略规划系统销售销售虚拟企业生产虚拟企业生产管理管理：月/季度生产计划生产计划：周/月生产调度生产调度：小时/天生产实时分派生产实时分派：分SCM Architecture 供应链管理构架202121q芯片封装生产计划决策支持软件系统q决定工厂的设备投资和库存水平人员配置，是半导体生产控制及管理软件中最核心的部分q整合优化工厂内部和外包商的生产能力q提供供应链管理诊断分析工具先进生产计划系统先进生产计划系统介绍介绍212222智域计划智域计划的优势的优势 *资料源自PricewaterhouseCoopers；参加对比的公司包括：Intel,Texas Instruments,Motorola,NEC,Fujitsu,National Semiconductor,Conexant,and Fairchild Semiconductor智域计划的优势包括：更快：生产计划周期；客户响应速度 更好：提高设备利用率；减少库存量；消除人为错误；增强计划灵活性 更便宜：节约大量用于制定生产计划的人力成本主要因素主要因素范围范围平均水平平均水平最好水平最好水平智域计划智域计划表现表现速度：处理速度：处理频率频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：处理时间速度：处理时间一天一天 五天五天一天一天一天一天 一小时一小时 计划时间尺度计划时间尺度6 个月个月 18个月个月6个月个月6 个月个月6 个月个月效率：分析工具效率：分析工具数据表数据表格；软件包格；软件包数据表数据表格格软件包软件包软件包软件包222323芯片制造业芯片制造业(Fab)投资投资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 Inputs242525qProduction Plan Feasible Plan Based on Constraints and Due DatesqInventory Plan Projected Inventory Levels Throughout Planning HorizonqDetailed Schedule Detailed Schedule for Workcenters,MES,etc.qVisibility Lots,Machines,Scheduling ConflictsqRapid What if Planning Capability APS Output25