先进生产计划与调度

*,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,1,1,Click to edit Master title style,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,),12.2003,03 IE&EM,Advanced Planning/Scheduling(APS)in Semiconductor Manufacturing:Challenges and Opportunities,Mike ZHANG(Intel,Shanghai)/Li ZHENG(Tsinghua Univ.,Beijing),1,Supply Chain,供应链,Advanced Planning/Scheduling(APS),先进生产计划及调度,Advanced Planning System Case Study,先进生产计划系统实例,Agenda,提纲,2,Supply Chain,供应链,Advanced Planning/Scheduling(APS),先进生产计划及调度,Advanced Planning System Case Study,先进生产计划系统实例,Agenda,提纲,3,Supply 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,分包商,OEM,Production,生产,Distribution,派送,4,Reduce inventories,减少库存,Move to build-to-order,按订货制造,Reduce planning cycle time,缩短计划制订时间,Improve delivery performance,提高计划制订水平,Focus on total Supply Chain Management(SCM),专注于供应链整体优化,Collaborative planning and execution,整合计划和执行,SCM Trend in Semiconductor Manufacturing,半导体制造企业供应链管理趋势,5,Supply Chain,供应链,Advanced Planning/Scheduling(APS),先进生产计划及调度,Advanced Planning System Case Study,先进生产计划系统实例,Agenda,提纲,6,Purchasing,Supply Plan,Scheduling,Logistics,Planning,Order Mgmt,Demand Plan,Supply,Distribution,Production,Process Control,Manufacturing Execution System,Infrastructures,SCM Strategic Plan,Real-time Dispatching,Virtual Factory Planning,Sales,Frequency,Month/Quarter,Week/Month,Day/Hour,Minute,SCM Architecture,供应链管理构架,Strategy,Plan,Execution,Supply Chain Management,7,Semiconductor Industry:Challenges,产业现状：挑战,Marketing 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。,The 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。,Semiconductor manufacturing is among the most complex 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。,Many 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：,No 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,Production Management:guesswork,manual work,生产管理：主观臆断、手工计算,8,Lack of supply chain visibility,企业供应链透明度低,Inefficient production/distribution planning and execution,低效率生产,/,派送计划和执行,Long responsiveness TPT,客户响应速度慢,Lack of flexibility,生产计划柔性差,Lack of optimization,生产计划优化程度差,Poor on-time delivery,低及时交货率,High inventory,low turnover,高库存、低周转率,Competing management objectives,相互矛盾的生产管理目标,Production Management:Current Status,生产管理现状,9,Solution(Resource:ITRS*),解决方案（源自,ITRS,*,）,Significant 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,Improvements 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,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,10,Data Sources(ROO),Routing,Products,BOM,Resources,Demand,DataStorage(ROR),APSSolver,APSSystems,Plan,Long-Range,Mid-Range,Daily/WeeklyChange,Schedule,Dispatch,APSArchitecture,先进生产,计,计划及调,度,度之构架,LP/MIP,Simulation/Rule-based,J2EE/.Net,11,UnifiedDataModel(UDM),统一数据,模,模型,FastSolve Speed,快速求解,MultipleLevelsof Optimization,多层次优,化,化,Rapid Implementation,易于实施,HighReliability,高可靠性,Custo,mer-OrientedSolution,面向用户,的,的解决方,案,案,Strengthof,“,“What-if,”,”Capability,强大假设,分,分析能力,Advantage ofAPS,先进生产,计,计划及调,度,度之优势,12,Supply Chain,供应链,AdvancedPlanning/Scheduling(APS),先进生产,计,计划及调,度,度,AdvancedPlanning SystemCase Study,先进生产,计,计划系统,实,实例,Agenda,提纲,13,APSPlanningSystem,“,“X”,先进生产,计,计划系统,“X”,Assembly&TestManufacturing Capacity PlanningToolused inmid-range horizon(nexthalf year),芯片封装,生,生产计划,决,决策支持,软,软件系统,ModelingSupplyChain from Assyto Testwithinventory control,决定工厂,的,的设备投,资,资和库存,水,水平，是,半,半导体生,产,产控制及,管,管理软件,中,中最核心,的,的部分,Optimizing Virtual Factory/subcontractorscapacity with one demand signal,整合优化,工,工厂内部,和,和外包商,的,的生产能,力,力,14,IndustryBenchmark,行业对比,Critical Success Factor,Indicator,Range,Median,BIC,APS Planning System“X”,Speed,Frequency,Weekly-Quarterly,Quarterly,Week,ly,Week,ly,Cycle time,1 5 days,1 day,1 day,1 hour,Accuracy,Horizon,6 months 2 years,6 months,6 months,6 months,Efficiency,Tool,Excel-,Legacy,Excel,Legacy,APS,Resource:,PricewaterhouseCoopers,.,Surveyedcompanies include:,Intel,TexasInstruments,Motorola,NEC,Fujitsu,National Semiconductor,Conexant,andFairchild Semiconductor,15,Benefitsof,“,“X”System Application,“,“X”,系统的优,势,势,Faster:ShortenCapacityPlanning TPT;Improve responsiveness,更快：生,产,产计划周,期,期；客户,响,响应速度,Better:OptimizeVirtualFactoryresource utilization;Minimizematerialinventory,更好：提,高,高设备利,用,用率；减,少,少库存量,Cheaper:Save huge amount ofmanhours,更便宜：,节,节约大量,用,用于制定,生,生产计划,的,的人力成,本,本,16,Summary,总结,Production Management insemiconductor manufacturingfaces serious challenges nowadays,目前半导,体,体生产管,理,理面临严,重,重挑战,Manygreat opportunitiesforAPS!,同时也为,APS,造就了无,数,数机遇！,17,Q&A,18,Backup,附件,19,采购,供给计划