先進(jìn)生產(chǎn)計(jì)劃及調(diào)度(APS)

在半導(dǎo)體制造業(yè)中面臨的挑戰(zhàn)和機(jī)遇

張濤(英特爾，上海)/鄭力(清華，北京)

12.2003

’03IE&EM

AdvancedPlanning/Scheduling(APS)inSemiconductorManufacturing:

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

1

先進(jìn)生產(chǎn)計(jì)劃及調(diào)度(APS)

在半導(dǎo)體制造業(yè)中面臨的挑戰(zhàn)SupplyChain 供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進(jìn)生產(chǎn)計(jì)劃及調(diào)度AdvancedPlanningSystemCaseStudy先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda提綱2SupplyChain 供應(yīng)鏈AgendSupplyChain供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進(jìn)生產(chǎn)計(jì)劃及調(diào)度AdvancedPlanningSystemCaseStudy先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda提綱3SupplyChainSupplyChaininSemiconductorManufacturing半導(dǎo)體制造企業(yè)的供應(yīng)鏈Material

Supplier原材料供應(yīng)商Retail銷售Capital

Eqpt

Supplier設(shè)備供應(yīng)商Subcontractor分包商OEMProduction生產(chǎn)Distribution派送4SupplyChaininSemiconductorReduceinventories減少庫存Movetobuild-to-order按訂貨制造Reduceplanningcycletime縮短計(jì)劃制訂時(shí)間Improvedeliveryperformance提高計(jì)劃制訂水平FocusontotalSupplyChainManagement(SCM)專注于供應(yīng)鏈整體優(yōu)化Collaborativeplanningandexecution整合計(jì)劃和執(zhí)行SCMTrendinSemiconductorManufacturing半導(dǎo)體制造企業(yè)供應(yīng)鏈管理趨勢5ReduceinventoriesSupplyChain供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進(jìn)生產(chǎn)計(jì)劃及調(diào)度AdvancedPlanningSystemCaseStudy先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda提綱6SupplyChainPurchasingSupplyPlanSchedulingLogisticsPlanningOrderMgmtDemandPlanSupplyDistributionProductionProcessControlManufacturingExecutionSystemInfrastructuresSCMStrategicPlanReal-timeDispatchingVirtualFactoryPlanningSalesFrequencyMonth/QuarterWeek/MonthDay/HourMinuteSCMArchitecture供應(yīng)鏈管理構(gòu)架StrategyPlanExecutionSupplyChainManagement7PurchasingSupplyPlanSchedulinSemiconductorIndustry: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(shí)間，特別是生產(chǎn)計(jì)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(jìn)工業(yè)工程（運(yùn)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(jià)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(jì)算8SemiconductorIndustry:ChalleLackofsupplychainvisibility企業(yè)供應(yīng)鏈透明度低Inefficientproduction/distributionplanningandexecution低效率生產(chǎn)/派送計(jì)劃和執(zhí)行LongresponsivenessTPT客戶響應(yīng)速度慢Lackofflexibility生產(chǎn)計(jì)劃柔性差Lackofoptimization

生產(chǎn)計(jì)劃優(yōu)化程度差Pooron-timedelivery低及時(shí)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9LackofsupplychainvisibilitSolution(Resource:ITRS*)

解決方案（源自ITRS*）Significantimprovementsinfactoryplanning/schedulingarerequired.必須通過先進(jìn)生產(chǎn)計(jì)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(jìn)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(jìn)裝備的利用率，提高工廠的可擴(kuò)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10Solution(Resource:ITRS*)

解決方DataSources(ROO)RoutingProductsBOMResourcesDemandDataStorage(ROR)APSSolverAPSSystemsPlanLong-RangeMid-RangeDaily/WeeklyChangeScheduleDispatchAPSArchitecture

先進(jìn)生產(chǎn)計(jì)劃及調(diào)度之構(gòu)架LP/MIPSimulation/Rule-basedJ2EE/.Net11DataSources(ROO)RoutingProduUnifiedDataModel(UDM)統(tǒng)一數(shù)據(jù)模型FastSolveSpeed快速求解MultipleLevelsofOptimization

多層次優(yōu)化RapidImplementation易于實(shí)施HighReliability高可靠性Customer-OrientedSolution面向用戶的解決方案Strengthof“What-if”Capability強(qiáng)大假設(shè)分析能力AdvantageofAPS

先進(jìn)生產(chǎn)計(jì)劃及調(diào)度之優(yōu)勢12UnifiedDataModel(UDM)SupplyChain供應(yīng)鏈AdvancedPlanning/Scheduling(APS)先進(jìn)生產(chǎn)計(jì)劃及調(diào)度AdvancedPlanningSystemCaseStudy先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)實(shí)例Agenda提綱13SupplyChainAPSPlanningSystem“X”

先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)“X”Assembly&TestManufacturingCapacityPlanningToolusedinmid-rangehorizon(nexthalfyear)芯片封裝生產(chǎn)計(jì)劃決策支持軟件系統(tǒng)ModelingSupplyChainfromAssytoTestwithinventorycontrol決定工廠的設(shè)備投資和庫存水平，是半導(dǎo)體生產(chǎn)控制及管理軟件中最核心的部分OptimizingVirtualFactory/subcontractors’capacitywithonedemandsignal整合優(yōu)化工廠內(nèi)部和外包商的生產(chǎn)能力14APSPlanningSystem“X”

先進(jìn)生產(chǎn)計(jì)IndustryBenchmark

行業(yè)對比CriticalSuccessFactorIndicatorRangeMedianBICAPSPlanningSystem“X”SpeedFrequencyWeekly-QuarterlyQuarterlyWeeklyWeeklyCycletime1–5days1day1day1

hourAccuracyHorizon6months–2years6months6months6monthsEfficiencyToolExcel-

LegacyExcelLegacyAPSResource:

PricewaterhouseCoopers.Surveyedcompaniesinclude:

Intel,TexasInstruments,Motorola,NEC,Fujitsu,NationalSemiconductor,Conexant,andFairchildSemiconductor15IndustryBenchmark

行業(yè)對比CriticaBenefitsof“X”SystemApplication

“X”系統(tǒng)的優(yōu)勢Faster:ShortenCapacityPlanningTPT;Improveresponsiveness更快：生產(chǎn)計(jì)劃周期；客戶響應(yīng)速度Better:OptimizeVirtualFactoryresourceutilization;Minimizematerialinventory更好：提高設(shè)備利用率；減少庫存量Cheaper:Savehugeamountofmanhours更便宜：節(jié)約大量用于制定生產(chǎn)計(jì)劃的人力成本16Benefitsof“X”SystemApplicaSummary

總結(jié)ProductionManagementinsemiconductormanufacturingfacesseriouschallengesnowadays…目前半導(dǎo)體生產(chǎn)管理面臨嚴(yán)重挑戰(zhàn)…ManygreatopportunitiesforAPS!同時(shí)也為APS造就了無數(shù)機(jī)遇！17Summary

總結(jié)ProductionManagemenQ&A

18Q&A18Backup

附件

19Backup

附件19采購供給計(jì)劃生產(chǎn)調(diào)度系統(tǒng)物流計(jì)劃生產(chǎn)計(jì)劃系統(tǒng)訂單管理需求計(jì)劃供給物流生產(chǎn)過程控制系統(tǒng)整合共享信息平臺實(shí)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(shí)時(shí)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(jì)劃頻率虛擬企業(yè)生產(chǎn)管理：月/季度生產(chǎn)計(jì)劃：周/月生產(chǎn)調(diào)度：小時(shí)/天生產(chǎn)實(shí)時(shí)分派：分SCMArchitecture供應(yīng)鏈管理構(gòu)架20采購供給計(jì)劃生產(chǎn)調(diào)度系統(tǒng)物流計(jì)劃生產(chǎn)計(jì)劃系統(tǒng)訂單管理需求計(jì)劃芯片封裝生產(chǎn)計(jì)劃決策支持軟件系統(tǒng)決定工廠的設(shè)備投資和庫存水平人員配置，是半導(dǎo)體生產(chǎn)控制及管理軟件中最核心的部分整合優(yōu)化工廠內(nèi)部和外包商的生產(chǎn)能力提供供應(yīng)鏈管理診斷分析工具先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)介紹21芯片封裝生產(chǎn)計(jì)劃決策支持軟件系統(tǒng)先進(jìn)生產(chǎn)計(jì)劃系統(tǒng)介紹21智域計(jì)劃?的優(yōu)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(jì)劃?的優(yōu)勢包括：更快：生產(chǎn)計(jì)劃周期；客戶響應(yīng)速度更好：提高設(shè)備利用率；減少庫存量；消除人為錯(cuò)誤；增強(qiáng)計(jì)劃靈活性更便宜：節(jié)約大量用于制定生產(chǎn)計(jì)劃的人力成本主要因素范圍平均水平最好