生产计划及调度.pptx

先进生产方案及调度先进生产方案及调度 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亚太，江苏 星航，奉贤刘丛龙星航，奉贤史学东江苏，亚太12.2003 03 IE&EMAdvanced Planning/Scheduling APS in Semiconductor Manufacturing:Challenges and OpportunitiesMike ZHANG Intel,Shanghai/Li ZHENG Tsinghua Univ.,Beijing1qSupply Chain 供给链qAdvanced Planning/Scheduling APS 先进生产方案及调度qAdvanced Planning System Case Study 先进生产方案系统实例Agenda 提纲2qSupply Chain 供给链qAdvanced Planning/Scheduling APS 先进生产方案及调度qAdvanced Planning System Case Study 先进生产方案系统实例Agenda 提纲3Supply Chain in Semiconductor Manufacturing 半导体制造企业的供给链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4qReduce inventories 减少库存qMove to build-to-order 按订货制造qReduce planning cycle time 缩短方案制订时间qImprove delivery performance 提高方案制订水平qFocus on total Supply Chain Management SCM 专注于供给链整体优化qCollaborative planning and execution 整合方案和执行SCM Trend in Semiconductor Manufacturing 半导体制造企业供给链管理趋势5qSupply Chain 供给链qAdvanced Planning/Scheduling APS 先进生产方案及调度qAdvanced Planning System Case Study 先进生产方案系统实例Agenda 提纲6PurchasingSupply PlanSchedulingSchedulingLogisticsPlanningPlanningOrder MgmtDemand PlanSupplyDistributionProductionProcess ControlManufacturing Execution SystemInfrastructuresSCM Strategic PlanReal-time Real-time DispatchingDispatchingVirtual Factory Virtual Factory PlanningPlanningSalesFrequencyFrequencyMonth/QuarterMonth/QuarterWeek/MonthWeek/MonthDay/HourDay/HourMinuteMinuteSCM Architecture 供给链管理构架StrategyStrategyPlanPlanExecutionExecutionSupply Chain ManagementSupply Chain Management7Semiconductor 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响时间，特别是生产方案的制定周期。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 plex 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，效劳尚未本地化qProduction Management:guesswork,manual work 生产管理：主观臆断、手工计算8qLack of supply chain visibility 企业供给链透明度低qInefficient production/distribution planning and execution 低效率生产/派送方案和执行qLong responsiveness TPT 客户响应速度慢qLack of flexibility 生产方案柔性差qLack of optimization 生产方案优化程度差qPoor on-time delivery 低及时交货率qHigh inventory,low turnover 高库存、低周转率q peting 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9Solution Resource:ITRS*解决方案源自解决方案源自ITRS*qSignificant improvements in factory planning/scheduling are required.必须通过先进生产方案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.必须探索和开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10Data Sources(ROO)RoutingRoutingProductsProductsBOMBOMResourcesResourcesDemandDemandData Storage RORAPS SolverAPS SystemsAPS SystemsPlanLong-RangeLong-RangeMid-RangeMid-RangeDaily/Weekly Daily/Weekly ChangeChangeScheduleScheduleDispatchDispatchAPS Architecture先进生产方案及调度之构架先进生产方案及调度之构架LP/MIPSimulation/Rule-basedJ2EE/.Net11qUnified 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先进生产方案及调度之优势先进生产方案及调度之优势12qSupply Chain 供给链qAdvanced Planning/Scheduling APS 先进生产方案及调度qAdvanced Planning System Case Study 先进生产方案系统实例Agenda 提纲13APS Planning System“X 先进生产方案系统先进生产方案系统“XqAssembly&Test Manufacturing Capacity Planning Tool used in mid-range horizon next half year 芯片封装生产方案决策支持软件系统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局部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14Industry Benchmark行业比照Resource:PricewaterhouseCoopersPricewaterhouseCoopers.Surveyed panies include:Intel,Texas Instruments,Motorola,NEC,Intel,Texas Instruments,Motorola,NEC,Fujitsu,National Semiconductor,Conexant,and Fairchild SemiconductorFujitsu,National Semiconductor,Conexant,and Fairchild Semiconductor15Benefits of“X System Application“X系统的优势qFaster:Shorten Capacity Planning TPT;Improve responsiveness 更快：生产方案周期；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 更廉价：节约大量用于制定生产方案的人力成本16Summary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！17Q&A18Backup附件附件19采购采购供给计划供给计划生产调度生产调度生产调度生产调度系统系统系统系统物流物流计划计划生产计划生产计划生产计划生产计划系统系统系统系统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实实实实施施施施战战战战术术术术战战战战略略略略供应链战略规划系统供应链战略规划系统生产实时生产实时生产实时生产实时分派系统分派系统分派系统分派系统虚拟企业生产虚拟企业生产虚拟企业生产虚拟企业生产管理系统管理系统管理系统管理系统销售销售供供供供 应应应应 链链链链 管管管管 理理理理计划频率计划频率计划频率计划频率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 供给链管理构架20q芯片封装生产方案决策支持软件系统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局部q整合优化工厂内部和外包商的生产能力q提供供给链管理诊断分析工具先进生产方案系统介绍先进生产方案系统介绍21智域方案智域方案的优势的优势 *资料源自PricewaterhouseCoopers；参加比照的公司包括：Intel,Texas Instruments,Motorola,NEC,Fujitsu,National Semiconductor,Conexant,and Fairchild Semiconductor智域方案的优势包括：更快：生产方案周期；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；增强方案灵活性更廉价：节约大量用于制定生产方案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方案智域方案表现表现速度：处理速度：处理频率频率每周一次每周一次 每季度一每季度一次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 方案时间尺度方案时间尺度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：分析工具数据表格；软件包数据表格；软件包数据表格数据表格软件包软件包软件包软件包22芯片制造业芯片制造业Fab投资投资23qDemandSales Forecasts&OrdersqBill of Materials BOMqRoutingsProduction RoutingsqProductsRaw Material,WIP,Finished GoodsInventory LevelsqResource AvailabilityAvailable Labor WorkpatternsProduction Capacities,Set-up Rqmts,etc.qBusiness RulesAPS Inputs24qProduction PlanFeasible Plan Based on Constraints and Due DatesqInventory PlanProjected Inventory Levels Throughout Planning HorizonqDetailed ScheduleDetailed Schedule for Workcenters,MES,etc.qVisibility Lots,Machines,Scheduling ConflictsqRapid What if Planning Capability APS Output25演讲完毕，谢谢观看！