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1、1 1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(英特尔，上海) / 郑力(清华，北京)03 IE&EMAdvanced Planning / Scheduling (APS) in Semiconductor Manufacturing: Challenges and OpportunitiesMike ZHANG (Intel, Shanghai) / Li ZHENG (Tsinghua Univ., Beijing)12 2qSupply Chain 供应链qAdvanced Planning/Scheduling (APS) 先进生产计划及调度qAdvance
2、d Planning System Case Study 先进生产计划系统实例Agenda 提纲23 3qSupply Chain 供应链qAdvanced Planning/Scheduling (APS) 先进生产计划及调度qAdvanced Planning System Case Study 先进生产计划系统实例Agenda 提纲34 4Supply Chain in Semiconductor Manufacturing 半导体制造企业的供应链Material Supplier原材料供应商Retail销售Capital Eqpt Supplier设备供应商Subcontractor分
3、包商OEMProduction生产Distribution派送45 5qReduce inventories 减少库存qMove to build-to-order 按订货制造qReduce planning cycle time 缩短计划制订时间qImprove delivery performance 提高计划制订水平qFocus on total Supply Chain Management (SCM) 专注于供应链整体优化qCollaborative planning and execution 整合计划和执行SCM Trend in Semiconductor Manufactur
4、ing 半导体制造企业供应链管理趋势56 6qSupply Chain 供应链qAdvanced Planning/Scheduling (APS) 先进生产计划及调度qAdvanced Planning System Case Study 先进生产计划系统实例Agenda 提纲67 7PurchasingSupply PlanSchedulingSchedulingLogisticsPlanningPlanningOrder MgmtDemand PlanSupplyDistributionProductionProcess ControlManufacturing Execution Sy
5、stemInfrastructuresSCM Strategic PlanReal-time Real-time DispatchingDispatchingVirtual Factory Virtual Factory PlanningPlanningSalesFrequencyFrequencyMonth/QuarterMonth/QuarterWeek/MonthWeek/MonthDay/HourDay/HourMinuteMinuteSCM Architecture 供应链管理构架StrategyStrategyPlanPlanExecutionExecutionSupply Cha
6、in ManagementSupply Chain Management78 8Semiconductor Industry: Challenges 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应时间，特别是生产计划的制定周期。 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 complex producti
7、on 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，服务尚未本地化qProduction Management: guesswork, manual work 生产管理：主观臆断、手工计算89 9qLack of supply cha
8、in visibility 企业供应链透明度低qInefficient production/distribution planning and execution 低效率生产/派送计划和执行qLong responsiveness TPT 客户响应速度慢qLack of flexibility 生产计划柔性差qLack of optimization 生产计划优化程度差qPoor on-time delivery 低及时交货率qHigh inventory, low turnover 高库存、低周转率qCompeting management objectives 相互矛盾的生产管理目标Pr
9、oduction Management: Current Status 生产管理现状91010Solution (Resource: ITRS*)解决方案（源自ITRS*）qSignificant improvements in factory planning/scheduling are required. 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qImprovements in factory forecasting and flexible factory information/control systems that can change with business
10、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* International Technology Roadmap of Semiconductor 国际半导体技术路线图 - 半导体技术权威资料1011
11、11Data Sources (ROO)RoutingRoutingProductsProductsBOMBOMResourcesResourcesDemandDemandData Storage (ROR)APS SolverAPS SystemsAPS SystemsPlanLong-RangeLong-RangeMid-RangeMid-RangeDaily/Weekly Daily/Weekly ChangeChangeScheduleScheduleDispatchDispatchAPS Architecture先进生产计划及调度之构架LP/MIPSimulation/ Rule-b
12、asedJ2EE/ .Net111212qUnified 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先进生产计划及调度之优势121313qSupply Chain 供应链qAdvanced
13、Planning/Scheduling (APS) 先进生产计划及调度qAdvanced Planning System Case Study 先进生产计划系统实例Agenda 提纲131414APS Planning System “X” 先进生产计划系统“X”qAssembly & Test Manufacturing Capacity Planning Tool used in mid-range horizon (next half year) 芯片封装生产计划决策支持软件系统qModeling Supply Chain from Assy to Test with inventory
14、 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部分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141515Industry Benchmark行业对比Critical Success FactorIndicatorRangeMedianBICAPS Planning System “X”SpeedFrequencyWeekly - QuarterlyQuarterlyWeeklyWeeklyCycle time1
15、5 days1 day1 day1 hourAccuracyHorizon6 months 2 years6 months6 months6 monthsEfficiencyToolExcel - LegacyExcelLegacyAPSResource: PricewaterhouseCoopersPricewaterhouseCoopers. Surveyed companies include: IntelIntel, , Texas InstrumentsTexas Instruments, , MotorolaMotorola, , NECNEC, , FujitsuFujitsu,
16、 , National SemiconductorNational Semiconductor, , ConexantConexant, and , and Fairchild SemiconductorFairchild Semiconductor151616Benefits of “X” System Application “X”系统的优势qFaster: Shorten Capacity Planning TPT; Improve responsiveness 更快：生产计划周期；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 更便宜：节约大量用于制定生产计划的人力成本161717Summary总结qProduction Management in semiconductor manufacturing faces serious cha
