先進生產計劃及調度(APS)

在半導體制造業中面臨的挑戰和機遇

IE&EM

AdvancedPlanning/Scheduling(APS)inSemiconductorManufacturing:

ChallengesandOpportunities1SupplyChain 供應鏈AdvancedPlanning/Scheduling(APS)先進生產計劃及調度AdvancedPlanningSystemCaseStudy先進生產計劃系統實例Agenda提綱2SupplyChain供應鏈AdvancedPlanning/Scheduling(APS)先進生產計劃及調度AdvancedPlanningSystemCaseStudy先進生產計劃系統實例Agenda提綱3SupplyChaininSemiconductorManufacturing半導體制造企業的供應鏈Material

Supplier原材料供應商Retail銷售Capital

Eqpt

Supplier設備供應商Subcontractor分包商OEMProduction生產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)專注于供應鏈整體優化Collaborativeplanningandexecution整合計劃和執行SCMTrendinSemiconductorManufacturing半導體制造企業供應鏈管理趨勢5SupplyChain供應鏈AdvancedPlanning/Scheduling(APS)先進生產計劃及調度AdvancedPlanningSystemCaseStudy先進生產計劃系統實例Agenda提綱6PurchasingSupplyPlanSchedulingLogisticsPlanningOrderMgmtDemandPlanSupplyDistributionProductionProcessControlManufacturingExecutionSystemInfrastructuresSCMStrategicPlanReal-timeDispatchingVirtualFactoryPlanningSalesFrequencyMonth/QuarterWeek/MonthDay/HourMinuteSCMArchitecture供應鏈管理構架StrategyPlanExecutionSupplyChainManagement7SemiconductorIndustry:Challenges

產業現狀：挑戰Marketingenvironmentchangesdramatically.半導體產業市場變化劇烈。企業必須縮短市場反應時間，特別是生產計劃的制定周期。Thecostofequipmentsisveryhigh.半導體裝備成本極高。主要設備使用率的提高，能為公司節省巨額開支。Semiconductormanufacturingisamongthemostcomplexproductionproblemsencounteredtoday.半導體制造的復雜性和專業性，使其生產管理成為最具挑戰的課題。ManyenterpriseslackexpertiseinIE/ORtoapplyAPS.優秀的生產管理系統需要先進工業工程（運籌）學成果支持。InChina中國國情：

NodomesticAPSprovider無國內APS提供者。國外APS提供者產品價格高，服務尚未本地化ProductionManagement:guesswork,manualwork生產管理：主觀臆斷、手工計算8Lackofsupplychainvisibility企業供應鏈透明度低Inefficientproduction/distributionplanningandexecution低效率生產/派送計劃和執行LongresponsivenessTPT客戶響應速度慢Lackofflexibility生產計劃柔性差Lackofoptimization

生產計劃優化程度差Pooron-timedelivery低及時交貨率Highinventory,lowturnover高庫存、低周轉率Competingmanagementobjectives相互矛盾的生產管理目標ProductionManagement:CurrentStatus

生產管理現狀9Solution(Resource:ITRS*)

解決方案（源自ITRS*）Significantimprovementsinfactoryplanning/schedulingarerequired.必須通過先進生產計劃和調度系統來提高半導體制造的生產率Improvementsinfactoryforecastingandflexiblefactoryinformation/controlsystemsthatcanchangewithbusinessconditionsmustbedevelopedandimplemented.

必須改進工廠的需求預測，建立柔性的工廠信息和管理軟件系統，使得工廠產能可以隨著市場環境的改變而改變…schedulinganddispatching…mustbedevelopedtoimproveequipmentOEEandextendibility.

必須探索和發展生產調度和分派技術，以改進裝備的利用率，提高工廠的可擴展性*InternationalTechnologyRoadmapofSemiconductor國際半導體技術路線圖--半導體技術權威資料10DataSources(ROO)RoutingProductsBOMResourcesDemandDataStorage(ROR)APSSolverAPSSystemsPlanLong-RangeMid-RangeDaily/WeeklyChangeScheduleDispatchAPSArchitecture

先進生產計劃及調度之構架LP/MIPSimulation/Rule-basedJ2EE/.Net11UnifiedDataModel(UDM)統一數據模型FastSolveSpeed快速求解MultipleLevelsofOptimization

多層次優化RapidImplementation易于實施HighReliability高可靠性Customer-OrientedSolution面向用戶的解決方案Strengthof“What-if”Capability強大假設分析能力AdvantageofAPS

先進生產計劃及調度之優勢12SupplyChain供應鏈AdvancedPlanning/Scheduling(APS)先進生產計劃及調度AdvancedPlanningSystemCaseStudy先進生產計劃系統實例Agenda提綱13APSPlanningSystem“X”

先進生產計劃系統“X”Assembly&TestManufacturingCapacityPlanningToolusedinmid-rangehorizon(nexthalfyear)芯片封裝生產計劃決策支持軟件系統ModelingSupplyChainfromAssytoTestwithinventorycontrol決定工廠的設備投資和庫存水平，是半導體生產控制及管理軟件中最核心的部分OptimizingVirtualFactory/subcontractors’capacitywithonedemandsignal整合優化工廠內部和外包商的生產能力14IndustryBenchmark

行業對比CriticalSuccessFactorIndicatorRangeMedianBICAPSPlanningSystem“X”SpeedFrequencyWeekly-QuarterlyQuarterlyWeeklyWeeklyCycletime1–5days1day1day1

hourAccuracyHorizon6months–2years6months6months6monthsEfficiencyToolExcel-

LegacyExcelLegacyAPSResource:

PricewaterhouseCoopers.Surveyedcompaniesinclude:

Intel,TexasInstruments,Motorola,NEC,Fujitsu,NationalSemiconductor,Conexant,andFairchildSemiconductor15Benefitsof“X”SystemApplication

“X”系統的優勢Faster:ShortenCapacityPlanningTPT;Improveresponsiveness更快：生產計劃周期；客戶響應速度Better:OptimizeVirtualFactoryresourceutilization;Minimizematerialinventory更好：提高設備利用率；減少庫存量Cheaper:Savehugeamountofmanhours更便宜：節約大量用于制定生產計劃的人力成本16Summary

總結ProductionManagementinsemiconductormanufacturingfacesseriouschallengesnowadays…目前半導體生產管理面臨嚴重挑戰…ManygreatopportunitiesforAPS!同時也為APS造就了無數機遇！17Q&A

18Backup

附件

19采購供給計劃生產調度系統物流計劃生產計劃系統訂單管理需求計劃供給物流生產過程控制系統整合共享信息平臺實施戰術戰略供應鏈戰略規劃系統生產實時分派系統虛擬企業生產管理系統銷售供應鏈管理計劃頻率虛擬企業生產管理：月/季度生產計劃：周/月生產調度：小時/天生產實時分派：分SCMArchitecture供應鏈管理構架20芯片封裝生產計劃決策支持軟件系統決定工廠的設備投資和庫存水平人員配置，是半導體生產控制及管理軟件中最核心的部分整合優化工廠內部和外包商的生產能力提供供應鏈管理診斷分析工具先進生產計劃系統介紹21智域計劃?的優勢*資料源自PricewaterhouseCoopers；參加對比的公司包括：Intel,TexasInstruments,Motorola,NEC,Fujitsu,NationalSemiconductor,Conexant,andFairchildSemiconductor智域計劃?的優勢包括：更快：生產計劃周期；客戶響應速度更好：提高設備利用率；減少庫存量；消除人為錯誤；增強計劃靈活性更便宜：節約大量用于制定生產計劃的人力成本主要因素范圍平均水平最好水平智域計劃?表現速度：處理頻率每周一次–每季度一次每周一次每周一次每周一次速度：處理時間一天–五天一天一天一小時計劃時間尺度6個月–18個月6個月6個月6個月效率：分析工具數據表格；軟件包數據表格軟件包軟件包22芯片制造業(Fab)投資23DemandSalesForecasts&OrdersBillofMaterials(BOM)RoutingsProductionRoutingsProductsRawMaterial,WIP,FinishedGoodsInventoryLevelsResourceAvailabilityAvailableLaborWorkpatternsProductionCapacities,Set-upRqmts,etc.BusinessRulesAPSInputs24ProductionPlanFeasiblePlanBasedonConstraintsandDueDatesInventoryPlanProjectedInventoryLevelsThroughoutPlanningHorizonDetailedScheduleDetailedScheduleforWorkcenters,MES,etc.VisibilityLots,Machines,SchedulingConflictsRapid‘Whatif’PlanningCapability

APSOutput259、春去春又回，新桃換舊符。在那桃花盛開的地方，在這醉人芬芳的季節，愿你生活像春天一樣陽光，心情像桃花一樣美麗，日子像桃子一樣甜蜜