生產(chǎn)計劃及調(diào)度

先進生產(chǎn)計劃及調(diào)度(APS)

在半導(dǎo)體制造業(yè)中面臨的挑戰(zhàn)和機遇

張濤(亞太，江蘇)\鄭力(星航，奉賢)\

劉叢龍（星航，奉賢）\史學(xué)東（江蘇，亞太）

12.2003

’03IE&EM

AdvancedPlanning/Scheduling(APS)inSemiconductorManufacturing:

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

1SupplyChain 供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進生產(chǎn)計劃及調(diào)度AdvancedPlanningSystemCaseStudy先進生產(chǎn)計劃系統(tǒng)實例Agenda提綱2SupplyChain供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進生產(chǎn)計劃及調(diào)度AdvancedPlanningSystemCaseStudy先進生產(chǎn)計劃系統(tǒng)實例Agenda提綱3SupplyChaininSemiconductorManufacturing半導(dǎo)體制造企業(yè)的供應(yīng)鏈MaterialSupplier原材料供應(yīng)商Retail銷售CapitalEqptSupplier設(shè)備供應(yīng)商Subcontractor分包商OEMProduction生產(chǎn)Distribution派送4Reduceinventories減少庫存Movetobuild-to-order按訂貨制造Reduceplanningcycletime縮短計劃制訂時間Improvedeliveryperformance提高計劃制訂水平FocusontotalSupplyChainManagement(SCM)專注于供應(yīng)鏈整體優(yōu)化Collaborativeplanningandexecution整合計劃和執(zhí)行SCMTrendinSemiconductorManufacturing半導(dǎo)體制造企業(yè)供應(yīng)鏈管理趨勢5SupplyChain供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進生產(chǎn)計劃及調(diào)度AdvancedPlanningSystemCaseStudy先進生產(chǎn)計劃系統(tǒng)實例Agenda提綱6PurchasingSupplyPlanSchedulingLogisticsPlanningOrderMgmtDemandPlanSupplyDistributionProductionProcessControlManufacturingExecutionSystemInfrastructuresSCMStrategicPlanReal-timeDispatchingVirtualFactoryPlanningSalesFrequencyMonth/QuarterWeek/MonthDay/HourMinuteSCMArchitecture供應(yīng)鏈管理構(gòu)架StrategyPlanExecutionSupplyChainManagement7SemiconductorIndustry:Challenges

產(chǎn)業(yè)現(xiàn)狀：挑戰(zhàn)Marketingenvironmentchangesdramatically.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)時間，特別是生產(chǎn)計劃的制定周期。Thecostofequipmentsisveryhigh.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。Semiconductormanufacturingisamongthemostcomplexproductionproblemsencounteredtoday.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。ManyenterpriseslackexpertiseinIE/ORtoapplyAPS.優(yōu)秀的生產(chǎn)管理系統(tǒng)需要先進工業(yè)工程（運籌）學(xué)成果支持。InChina中國國情：

NodomesticAPSprovider無國內(nèi)APS提供者。國外APS提供者產(chǎn)品價格高，服務(wù)尚未本地化ProductionManagement:guesswork,manualwork生產(chǎn)管理：主觀臆斷、手工計算8Lackofsupplychainvisibility企業(yè)供應(yīng)鏈透明度低Inefficientproduction/distributionplanningandexecution低效率生產(chǎn)/派送計劃和執(zhí)行LongresponsivenessTPT客戶響應(yīng)速度慢Lackofflexibility生產(chǎn)計劃柔性差Lackofoptimization

生產(chǎn)計劃優(yōu)化程度差Pooron-timedelivery低及時交貨率Highinventory,lowturnover高庫存、低周轉(zhuǎn)率Competingmanagementobjectives相互矛盾的生產(chǎn)管理目標(biāo)ProductionManagement:CurrentStatus

生產(chǎn)管理現(xiàn)狀9Solution(Resource:ITRS*)

解決方案（源自ITRS*）Significantimprovementsinfactoryplanning/schedulingarerequired.必須通過先進生產(chǎn)計劃和調(diào)度系統(tǒng)來提高半導(dǎo)體制造的生產(chǎn)率Improvementsinfactoryforecastingandflexiblefactoryinformation/controlsystemsthatcanchangewithbusinessconditionsmustbedevelopedandimplemented.

必須改進工廠的需求預(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…schedulinganddispatching…mustbedevelopedtoimproveequipmentOEEandextendibility.

必須探索和發(fā)展生產(chǎn)調(diào)度和分派技術(shù)，以改進裝備的利用率，提高工廠的可擴展性*InternationalTechnologyRoadmapofSemiconductor國際半導(dǎo)體技術(shù)路線圖--半導(dǎo)體技術(shù)權(quán)威資料10DataSources(ROO)RoutingProductsBOMResourcesDemandDataStorage(ROR)APSSolverAPSSystemsPlanLong-RangeMid-RangeDaily/WeeklyChangeScheduleDispatchAPSArchitecture先進生產(chǎn)計計劃及調(diào)度度之構(gòu)架LP/MIPSimulation/Rule-basedJ2EE/.Net11UnifiedDataModel(UDM)統(tǒng)一數(shù)據(jù)模模型FastSolveSpeed快速求解MultipleLevelsofOptimization多層次優(yōu)化化RapidImplementation易于實施HighReliability高可靠性Customer-OrientedSolution面向用戶的的解決方案案Strengthof““What-if””Capability強大假設(shè)分分析能力AdvantageofAPS先進生產(chǎn)計計劃及調(diào)度度之優(yōu)勢12SupplyChain供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進生產(chǎn)計計劃及調(diào)度度AdvancedPlanningSystemCaseStudy先進生產(chǎn)計計劃系統(tǒng)實實例Agenda提綱13APSPlanningSystem““X”先進生產(chǎn)計計劃系統(tǒng)“X”Assembly&TestManufacturingCapacityPlanningToolusedinmid-rangehorizon(nexthalfyear)芯片封裝生生產(chǎn)計劃決決策支持軟軟件系統(tǒng)ModelingSupplyChainfromAssytoTestwithinventorycontrol決定工廠的的設(shè)備投資資和庫存水水平，是半半導(dǎo)體生產(chǎn)產(chǎn)控制及管管理軟件中中最核心的的部分OptimizingVirtualFactory/subcontractors’capacitywithonedemandsignal整合優(yōu)化工工廠內(nèi)部和和外包商的的生產(chǎn)能力力14IndustryBenchmark行業(yè)業(yè)對對比比CriticalSuccessFactorIndicatorRangeMedianBICAPSPlanningSystem“X”SpeedFrequencyWeekly-QuarterlyQuarterlyWeeklyWeeklyCycletime1–5

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hourAccuracyHorizon6months–2years6months6months6monthsEfficiencyToolExcel-LegacyExcelLegacyAPSResource:PricewaterhouseCoopers.Surveyedcompaniesinclude:Intel,TexasInstruments,Motorola,NEC,Fujitsu,NationalSemiconductor,Conexant,andFairchildSemiconductor15Benefitsof““X””SystemApplication““X””系統(tǒng)統(tǒng)的的優(yōu)優(yōu)勢勢Faster:ShortenCapacityPlanningTPT;Improveresponsiveness更快快：：生生產(chǎn)產(chǎn)計計劃劃周周期期；；客客戶戶響響應(yīng)應(yīng)速速度度Better:OptimizeVirtualFactoryresourceutilization;Minimizematerialinventory更好好：：提提高高設(shè)設(shè)備備利利用用率率；；減減少少庫庫存存量量Cheaper:Savehugeamountofmanhours更便便宜宜：：節(jié)節(jié)約約大大量量用用于于制制定定生生產(chǎn)產(chǎn)計計劃劃的的人人力力成成本本16Summary總結(jié)結(jié)ProductionManagementinsemiconductormanufacturingfacesseriouschallengesnowadays……目前前半半導(dǎo)導(dǎo)體體生生產(chǎn)產(chǎn)管管理理面面臨臨嚴(yán)嚴(yán)重重挑挑戰(zhàn)戰(zhàn)…ManygreatopportunitiesforAPS!同時時也也為為APS造就就了了無無數(shù)數(shù)機機遇遇??！17Q&A18Backup附件件19采購供給計劃生產(chǎn)調(diào)度系統(tǒng)物流計劃生產(chǎn)計劃系統(tǒng)訂單管理需求計劃供給物流生產(chǎn)過程控制系統(tǒng)整合共享信息平臺實施戰(zhàn)術(shù)戰(zhàn)略供應(yīng)鏈戰(zhàn)略規(guī)劃系統(tǒng)生產(chǎn)實時分派系統(tǒng)虛擬企業(yè)生產(chǎn)管理系統(tǒng)銷售供應(yīng)鏈管理計劃頻率虛擬企業(yè)生產(chǎn)管理：月/季度生產(chǎn)計劃：周/月生產(chǎn)調(diào)度：小時/天生產(chǎn)實時分派：分SCMArchitecture供應(yīng)應(yīng)鏈鏈管管理理構(gòu)構(gòu)架架20芯片片封封裝裝生產(chǎn)產(chǎn)計計劃劃決策策支支持持軟軟件件系系統(tǒng)統(tǒng)決定定工工廠廠的的設(shè)設(shè)備備投投資資和和庫庫存存水水平平人人員員配配置置，，是是半導(dǎo)體生產(chǎn)控控制及管理軟軟件中最核心心的部分整合優(yōu)化工廠廠內(nèi)部和外包包商的生產(chǎn)能能力提供供應(yīng)鏈管管理診斷分析析工具先進生產(chǎn)計劃劃系統(tǒng)介紹21智域計劃?的優(yōu)勢*資料源自自PricewaterhouseCoopers；參加對比的的公司包括：：Intel,TexasInstruments,Motorola,NEC,Fujitsu,NationalSemiconductor,Conexant,andFairchildSemiconductor智域計劃?的優(yōu)勢包括：更快：生產(chǎn)計計劃周期；客客戶響應(yīng)速度度更好：提高設(shè)設(shè)備利用率；；減少庫存量量；消除人為為錯誤；增強強計劃靈活性性更便宜：節(jié)約約大量用于