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

张涛(亚太，江苏)\郑力(星航，奉贤)\

刘丛龙（星航，奉贤）\史学东（江苏，亚太）

12.2003

’03IE&EM

AdvancedPlanning/Scheduling(APS)inSemiconductorManufacturing:

ChallengesandOpportunitiesMikeZHANG(Intel,Shanghai)/LiZHENG(TsinghuaUniv.,Beijing)

1SupplyChain 供应链AdvancedPlanning/Scheduling(APS)先进生产计划及调度AdvancedPlanningSystemCaseStudy先进生产计划系统实例Agenda提纲2SupplyChain供应链AdvancedPlanning/Scheduling(APS)先进生产计划及调度AdvancedPlanningSystemCaseStudy先进生产计划系统实例Agenda提纲3SupplyChaininSemiconductorManufacturing半导体制造企业的供应链MaterialSupplier原材料供应商Retail销售CapitalEqptSupplier设备供应商Subcontractor分包商OEMProduction生产Distribution派送4Reduceinventories减少库存Movetobuild-to-order按订货制造Reduceplanningcycletime缩短计划制订时间Improvedeliveryperformance提高计划制订水平FocusontotalSupplyChainManagement(SCM)专注于供应链整体优化Collaborativeplanningandexecution整合计划和执行SCMTrendinSemiconductorManufacturing半导体制造企业供应链管理趋势5SupplyChain供应链AdvancedPlanning/Scheduling(APS)先进生产计划及调度AdvancedPlanningSystemCaseStudy先进生产计划系统实例Agenda提纲6PurchasingSupplyPlanSchedulingLogisticsPlanningOrderMgmtDemandPlanSupplyDistributionProductionProcessControlManufacturingExecutionSystemInfrastructuresSCMStrategicPlanReal-timeDispatchingVirtualFactoryPlanningSalesFrequencyMonth/QuarterWeek/MonthDay/HourMinuteSCMArchitecture供应链管理构架StrategyPlanExecutionSupplyChainManagement7SemiconductorIndustry:Challenges

产业现状：挑战Marketingenvironmentchangesdramatically.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。Thecostofequipmentsisveryhigh.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。Semiconductormanufacturingisamongthemostcomplexproductionproblemsencounteredtoday.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。ManyenterpriseslackexpertiseinIE/ORtoapplyAPS.优秀的生产管理系统需要先进工业工程（运筹）学成果支持。InChina中国国情：

NodomesticAPSprovider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ProductionManagement:guesswork,manualwork生产管理：主观臆断、手工计算8Lackofsupplychainvisibility企业供应链透明度低Inefficientproduction/distributionplanningandexecution低效率生产/派送计划和执行LongresponsivenessTPT客户响应速度慢Lackofflexibility生产计划柔性差Lackofoptimization

生产计划优化程度差Pooron-timedelivery低及时交货率Highinventory,lowturnover高库存、低周转率Competingmanagementobjectives相互矛盾的生产管理目标ProductionManagement:CurrentStatus

生产管理现状9Solution(Resource:ITRS*)

解决方案（源自ITRS*）Significantimprovementsinfactoryplanning/schedulingarerequired.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Improvementsinfactoryforecastingandflexiblefactoryinformation/controlsystemsthatcanchangewithbusinessconditionsmustbedevelopedandimplemented.

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…schedulinganddispatching…mustbedevelopedtoimproveequipmentOEEandextendibility.

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*InternationalTechnologyRoadmapofSemiconductor国际半导体技术路线图--半导体技术权威资料10DataSources(ROO)RoutingProductsBOMResourcesDemandDataStorage(ROR)APSSolverAPSSystemsPlanLong-RangeMid-RangeDaily/WeeklyChangeScheduleDispatchAPSArchitecture先进生产计计划及调度度之构架LP/MIPSimulation/Rule-basedJ2EE/.Net11UnifiedDataModel(UDM)统一数据模模型FastSolveSpeed快速求解MultipleLevelsofOptimization多层次优化化RapidImplementation易于实施HighReliability高可靠性Customer-OrientedSolution面向用户的的解决方案案Strengthof““What-if””Capability强大假设分分析能力AdvantageofAPS先进生产计计划及调度度之优势12SupplyChain供应链AdvancedPlanning/Scheduling(APS)先进生产计计划及调度度AdvancedPlanningSystemCaseStudy先进生产计计划系统实实例Agenda提纲13APSPlanningSystem““X”先进生产计计划系统“X”Assembly&TestManufacturingCapacityPlanningToolusedinmid-rangehorizon(nexthalfyear)芯片封装生生产计划决决策支持软软件系统ModelingSupplyChainfromAssytoTestwithinventorycontrol决定工厂的的设备投资资和库存水水平，是半半导体生产产控制及管管理软件中中最核心的的部分OptimizingVirtualFactory/subcontractors’capacitywithonedemandsignal整合优化工工厂内部和和外包商的的生产能力力14IndustryBenchmark行业业对对比比CriticalSuccessFactorIndicatorRangeMedianBICAPSPlanningSystem“X”SpeedFrequencyWeekly-QuarterlyQuarterlyWeeklyWeeklyCycletime1–5

days1

day1day1

hourAccuracyHorizon6months–2years6months6months6monthsEfficiencyToolExcel-LegacyExcelLegacyAPSResource:PricewaterhouseCoopers.Surveyedcompaniesinclude:Intel,TexasInstruments,Motorola,NEC,Fujitsu,NationalSemiconductor,Conexant,andFairchildSemiconductor15Benefitsof““X””SystemApplication““X””系统统的的优优势势Faster:ShortenCapacityPlanningTPT;Improveresponsiveness更快快：：生生产产计计划划周周期期；；客客户户响响应应速速度度Better:OptimizeVirtualFactoryresourceutilization;Minimizematerialinventory更好好：：提提高高设设备备利利用用率率；；减减少少库库存存量量Cheaper:Savehugeamountofmanhours更便便宜宜：：节节约约大大量量用用于于制制定定生生产产计计划划的的人人力力成成本本16Summary总结结ProductionManagementinsemiconductormanufacturingfacesseriouschallengesnowadays……目前前半半导导体体生生产产管管理理面面临临严严重重挑挑战战…ManygreatopportunitiesforAPS!同时时也也为为APS造就就了了无无数数机机遇遇！！17Q&A18Backup附件件19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应链战略规划系统生产实时分派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/天生产实时分派：分SCMArchitecture供应应链链管管理理构构架架20芯片片封封装装生产产计计划划决策策支支持持软软件件系系统统决定定工工厂厂的的设设备备投投资资和和库库存存水水平平人人员员配配置置，，是是半导体生产控控制及管理软软件中最核心心的部分整合优化工厂厂内部和外包包商的生产能能力提供供应链管管理诊断分析析工具先进生产计划划系统介绍21智域计划®的优势*资料源自自PricewaterhouseCoopers；参加对比的的公司包括：：Intel,TexasInstruments,Motorola,NEC,Fujitsu,NationalSemiconductor,Conexant,andFairchildSemiconductor智域计划®的优势包括：更快：生产计计划周期；客客户响应速度度更好：提高设设备利用率；；减少库存量量；消除人为为错误；增强强计划灵活性性更便宜：节约约大量用于