先进生产计划系统实例及调度.pptx

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,*,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to edit Master title style,*,*,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,1,1,Click to edit Master title style,*,先进生产计划及调度,(APS),在半导体制造业中面临挑战和机遇,张涛,(,英特尔，上海,)/,郑力,(,清华，北京,),12.,03 IE&EM,Advanced Planning/Scheduling(APS)in Semiconductor Manufacturing:Challenges and Opportunities,Mike ZHANG(Intel,Shanghai)/Li ZHENG(Tsinghua Univ.,Beijing),1,先进生产计划系统实例及调度,第1页,Supply Chain,供给链,Advanced Planning/Scheduling(APS),先进生产计划及调度,Advanced Planning System Case Study,先进生产计划系统实例,Agenda,提要,2,先进生产计划系统实例及调度,第2页,Supply Chain,供给链,Advanced Planning/Scheduling(APS),先进生产计划及调度,Advanced Planning System Case Study,先进生产计划系统实例,Agenda,提要,3,先进生产计划系统实例及调度,第3页,Supply Chain in Semiconductor Manufacturing,半导体制造企业供给链,Material Supplier,原材料供给商,Retail,销售,Capital Eqpt Supplier,设备供给商,Subcontractor,分包商,OEM,Production,生产,Distribution,派送,4,先进生产计划系统实例及调度,第4页,Reduce inventories,降低库存,Move to build-to-order,按订货制造,Reduce planning cycle time,缩短计划制订时间,Improve delivery performance,提升计划制订水平,Focus on total Supply Chain Management(SCM),专注于供给链整体优化,Collaborative planning and execution,整累计划和执行,SCM Trend in Semiconductor Manufacturing,半导体制造企业供给链管理趋势,5,先进生产计划系统实例及调度,第5页,Supply Chain,供给链,Advanced Planning/Scheduling(APS),先进生产计划及调度,Advanced Planning System Case Study,先进生产计划系统实例,Agenda,提要6,先进生产计划系统实例及调度,第6页,Purchasing,Supply Plan,Scheduling,Logistics,Planning,Order Mgmt,Demand Plan,Supply,Distribution,Production,Process Control,Manufacturing Execution System,Infrastructures,SCM Strategic Plan,Real-time Dispatching,Virtual Factory Planning,Sales,Frequency,Month/Quarter,Week/Month,Day/Hour,Minute,SCM Architecture,供给链管理构架,Strategy,Plan,Execution,Supply Chain Management,7,先进生产计划系统实例及调度,第7页,Semiconductor Industry:Challenges,产业现实状况：挑战,Marketing environment changes dramatically.,半导体产业市场改变猛烈。企业必须缩短市场反应时间，尤其是生产计划制订周期。,The cost of equipments is very high.,半导体装备成本极高。主要设备使用率提升，能为企业节约巨额开支Semiconductor manufacturing is among the most complex production problems encountered today.,半导体制造复杂性和专业性，使其生产管理成为最具挑战课题。,Many enterprises lack expertise in IE/OR to apply APS.,优异生产管理系统需要先进工业工程（运筹）学结果支持。,In China,中国国情：,No domestic APS provider,无国内,APS,提供者。国外,APS,提供者产品价格高，服务还未当地化,Production Management:guesswork,manual work,生产管理：主观臆断、手工计算,8,先进生产计划系统实例及调度,第8页,Lack of supply chain visibility,企业供给链透明度低,Inefficient production/distribution planning and execution,低效率生产,/,派送计划和执行,Long responsiveness TPT,客户响应速度慢,Lack of flexibility,生产计划柔性差,Lack of optimization,生产计划优化程度差,Poor on-time delivery,低及时交货率,High inventory,low turnover,高库存、低周转率,Competing management objectives,相互矛盾生产管理目标,Production Management:Current Status,生产管理现实状况,9,先进生产计划系统实例及调度,第9页,Solution(Resource:ITRS*),处理方案（源自,ITRS,*,）,Significant improvements in factory planning/scheduling are required.,必须经过,先进生产计划和调度系统,来提升半导体制造生产率,Improvements in factory forecasting and flexible factory information/control systems that can change with business conditions must be developed and implemented.,必须改进工厂需求预测，建立柔性,工厂信息和管理软件系统,，使得工厂产能能够伴随市场环境改变而改变,scheduling and dispatching must be developed to improve equipment OEE and extendibility.,必须探索和发展,生产调度和分配,技术，以改进装备利用率，提升工厂可扩展性,*International Technology Roadmap of Semiconductor,国际半导体技术路线图,-,半导体技术权威资料,10,先进生产计划系统实例及调度,第10页,Data Sources(ROO),Routing,Products,BOM,Resources,Demand,Data Storage(ROR),APS Solver,APS Systems,Plan,Long-Range,Mid-Range,Daily/Weekly Change,Schedule,Dispatch,APS Architecture,先进生产计划及调度之构架,LP/MIP,Simulation/Rule-based,J2EE/.Net,11,先进生产计划系统实例及调度,第11页,Unified Data Model(UDM),统一数据模型,Fast Solve Speed,快速求解,Multiple Levels of Optimization,多层次优化,Rapid Implementation,易于实施,High Reliability,高可靠性,Custo,mer-Oriented Solution,面向用户处理方案,Strength 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,12,先进生产计划系统实例及调度,第12页,Supply Chain,供给链,Advanced Planning/Scheduling(APS),先进生产计划及调度,Advanced Planning System Case Study,先进生产计划系统实例,Agenda,提要,13,先进生产计划系统实例及调度,第13页,APS Planning System“X”,先进生产计划系统,“X”,Assembly&Test Manufacturing Capacity Planning Tool used in mid-range horizon(next half year),芯片封装生产计划决议支持软件系统,Modeling Supply Chain from Assy to Test with inventory control,决定工厂设备投资和库存水平，是半导体生产控制及管理软件中最关键部分,Optimizing Virtual Factory/subcontractors capacity with one demand signal,整合优化工厂内部和外包商生产能力,14,先进生产计划系统实例及调度,第14页,Industry Benchmark,行业对比,Critical Success Factor,Indicator,Range,Median,BIC,APS Planning System“X”,Speed,Frequency,Weekly-Quarterly,Quarterly,Week,ly,Week,ly,Cycle time,1 5 days,1 day,1 day,1 hour,Accuracy,Horizon,6 months 2 years,6 months,6 months,6 months,Efficiency,Tool,Excel-,Legacy,Excel,Legacy,APS,Resource:,PricewaterhouseCoopers,.,Surveyed companies include:,Intel,Texas Instruments,Motorola,NEC,Fujitsu,National Semiconductor,Conexant,and Fairchild Semiconductor,15,先进生产计划系统实例及调度,第15页,Benefits of“X”System Application“X”,系统优势,Faster:Shorten Capacity Planning TPT;Improve responsiveness,更加快：生产计划周期；客户响应速度,Better:Optimize Virtual Factory resource utilization;Minimize material inventory,更加好：提升设备利用率；降低库存量,Cheaper:Save huge amount of man hours,更廉价：节约大量用于制订生产计划人力成本,16,先进生产计划系统实例及调度,第16页,Summary,总结,Production Management in semiconductor manufacturing faces serious challenges nowadays,当前半导体生产管理面临严重挑战,Many great opportunities for APS!,同时也为,APS,造就了无数机遇！,17,先进生产计划系统实例及调度,第17页,Q&A,18,先进生产计划系统实例及调度,第18页,Backup,附件,19,先进生产计划系统实例及调度,第19页,采购,供给计划,生产调度系统,物流,计划,生产计划系统,订单管理,需求计划,供给,物流,生产,过程控制,系统整合,共享信息平台,实,施,战术,战,略,供给链战略规划系统,生产实时分配系统,虚拟企业生产管理系统,销售,供,应,链,管,理,计划频率,虚拟企业生产管理,：月,/,季度,生产计划,：周,/,月,生产调度,：小时,/,天,生产实时分配,：分,SCM Architecture,供给链管理构架,20,先进生产计划系统实例及调度,第20页,芯片封装,生产计划,决议支持软件系统,决定工厂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关键部分,整合优化工厂内部和外包商生产能力,提供供给链管理诊疗分析工具,先进生产计划系统介绍,21,先进生产计划系统实例及调度,第21页,智域计划,优势,*资料源自,PricewaterhouseCoopers,；参加对比企业包含：,Intel,Texas Instruments,Motorola,NEC,Fujitsu,National Semiconductor,Conexant,and Fairchild Semiconductor,智域计划,优势包含,：,更加快：生产计划周期；客户响应速度,更加好：提升设备利用率；降低库存量；消除人为错误；增强计划灵活性,更廉价：节约大量用于制订生产计划人力成本,主要原因,范围,平均水平,最好水平,智域计划,表现,速度：处理,频率,每七天一次 每季度一次,每七天一次,每七天一次,每七天一次,速度：处理时间,一天,五天,一天,一天,一小时,计划时间尺度,6,个月,18,个月,6,个月,6,个月,6,个月,效率：分析工具,数据表格；软件包,数据表格,软件包,软件包,22,先进生产计划系统实例及调度,第22页,芯片制造业,(Fab),投资,23,先进生产计划系统实例及调度,第23页,Demand,Sales Forecasts&Orders,Bill of Materials(BOM),Routings,Production Routings,Products,Raw Material,WIP,Finished Goods,Inventory Levels,Resource Availability,Available Labor Workpatterns,Production Capacities,Set-up Rqmts,etc.,Business Rules,APS Inputs,24,先进生产计划系统实例及调度,第24页,Production Plan,Feasible Plan Based on Constraints and Due Dates,Inventory Plan,Projected Inventory Levels Throughout Planning Horizon,Detailed Schedule,Detailed Schedule for Workcenters,MES,etc.,Visibility,Lots,Machines,Scheduling Conflicts,Rapid What if Planning Capability,APS Output,25,先进生产计划系统实例及调度,第25页,