SAP Manufacturing Days - Marcel Cayers ASML

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SAP Manufacturing Days 2013

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SAP Manufacturing Days - Marcel Cayers ASML

  1. 1. Marcel Caeyers IT Solution Team Manager - Manufacturing September 2013 / SAP Manufacturing Days / Den Bosch Shop Floor Control The Road to Integrated Manufacturing
  2. 2. • Introducing ASML A cornerstone of the chip industry • Impact on Operations A lean program to streamline production processes • Program: Shop Floor Control The IT enabler for achieving business value • Questions Agenda Public Slide 2 April 2013
  3. 3. Introducing ASML A cornerstone of the chip industry
  4. 4. ASML - A cornerstone of the chip industry Public Slide 4 April 2013
  5. 5. ASML employees in US:1,617 Source: VLSI Research/ASML Q4 2012 Over 55 sales and service offices located worldwide ASML employees in Europe: 5,068 ASML employees in Asia: 1,812 Sales to Europe 27% sales to US 69% sales to ASIA 4% Public Slide 5 ASML: World’s largest semiconductor equipment vendor April 2013
  6. 6. Moore’s Law holds steady for more than 40 years • Double the computing power per chip • At equivalent power consumption • For half the price • Every 1.5 to 2 years 1970 1975 1980 1985 1990 1995 2000 2005 2010 Public Slide 6 101 102 103 104 105 106 107 108 109 1010 100 TransistorsperDie Memory Microprocessor This graphic of Moore’s law shows how his prediction of transistor shrink has been realized over 40 years. Source: Intel April 2013
  7. 7. Overlay down to 2 nanometers 1 nm = 4 silicon atoms The technical challenges Stacking layers: what does that mean… April 2013 Public Slide 7
  8. 8. m/sec2 0 10 20 40 7030 50 60 80 90 100 110 120 130 140 150 The technical challenges Acceleration: a comparison... A stone drops at 9.8 m/sec2 A dragster accelerates at 33 m/sec2 A jet fighter in a catapult at 44 m/sec2 An attack missile at 50 to 120 m/sec2 A TWINSCAN NXT reticle stage at 150 m/sec2 April 2013 Public Slide 8
  9. 9. …resulting in the systems that conquered the market 1984: PAS 2000 Resolution: >1m Overlay: 250 nm 1989: PAS 5000 Resolution: <500 nm overlay: 100 nm 1990’s: PAS 5500 steppers/ scanners Resolution: 400 to 90 nm overlay: 100 to 12 nm 2000’s: Twinscan Resolution: 100 to 38 nm overlay: 20 to 4 nm In 30 years: From 1,200 nm to less than 20 nm resolution From <0.5M€ per system to >60M€ 2010’s: NXE EUV systems Resolution: 32 to <20 nm overlay: 2 nm Public Slide 9 April 2013
  10. 10. Impact on Operations A lean program to streamline production processes
  11. 11. Or do you want to become the best factory?Does your factory look like this? Public Slide 11 What makes the difference? April 2013
  12. 12. ASML Manufacturing process Public Slide 12 WH SuppliersBuild OperationsDelivery Operations • +/- 350 Suppliers • Added Value >90% • 60 Partners (80%) • +/- 10.000 People • 9 Modules /system •18000 m2 • 2000 Buy in Items /system • +/- 300 goods receipts /day • 6-12 months Training / Engineer • 2 shifts per day /wk, 1 shift per day /weekend • 7x24 Test Area • 3-8 Systems / week Suppliers Build Operations Delivery Operations April 2013
  13. 13. ASML Manufacturing process Public Slide 13 WH What makes manufacturing @ ASML special? Suppliers Build Operations Delivery Operations April 2013 Dynamic Master Data - high number of Engineering Changes (100 p/wk) Rework, Recovery, Repair - continuously due to searching the limits of technology Master Production Sequences - contain all possible technical dependencies Operators - highly educated
  14. 14. Flow: 8 key changes April 2013 Public Slide 14
  15. 15. Slide 15 | FLOW - High level impact April 2013 Public Slide 15 The "blueprint" is introduced Takts Regular rebalanced to improve cycletime and delivery Kits are adjusted on basis of the Takts After approval: the changes are implemented Support and issue resolution are improved Improved Transparency Takted way of working is introduced
  16. 16. Program: Shop Floor Control The IT enabler for achieving business value
  17. 17. Shop Floor Control program @ASML April 2013 Public Slide 17 Work Instructions Dynamic customized per machine configuration Introducing SAP ME - Fair work packages per operator per shift - Blueprinting & Sequencing tooling - Real-time monitoring / progress tracking Production Orders - Customized per customers order Detailed integral planning of materials, skills, people, cabins, etc. Alert Management Real-time logging & progress tracking of disturbances in production Management Reporting Based on a single source of truth MES – Machine Interfacing Fully automated system qualification  Increased delivery & planning reliability  Reduced customer reaction time  Reduced stock & obsolescence  Improved planning efficiency  Transparency of operations
  18. 18. Shop Floor Control functions mapped on ISA95 April 2013 Public Slide 18 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 ProductionOperatorDashboard(GUI) SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence
  19. 19. April 2013 Public Slide 19 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence Work Preparation – Create and Release Routing in ECC
  20. 20. Work Preparation - Create sub-routings in GRE April 2013 Public Slide 20 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence
  21. 21. Work preparation: Routing  Sub-routing  Work package per operator July 2012 Public Slide 21 1 2 3 8 9 4 5 6 7 10 20 30 Main routing in SAP-ECC Sub-routing in Graphical Routing Editor Optimized Work Package in SAP-ME 1 4 5 8 9 2 3 6 7 Operator A Operator B
  22. 22. April 2013 Public Slide 22 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence Work Preparation - Create optimal sequence per operator
  23. 23. April 2013 Public Slide 23 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence Work Preparation – Release routing to SAP ME, report to SAP ECC
  24. 24. April 2013 Public Slide 24 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence Manufacturing Execution: Create Production Order in ECC
  25. 25. Manufacturing Execution: Release Order to SAP ME April 2013 Public Slide 25 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence
  26. 26. April 2013 Public Slide 26 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence Manufacturing Execution: Schedule Routing Steps in time
  27. 27. April 2013 Public Slide 27 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence Manufacturing Execution: Start 1st Routing Step in the Production Operator Dashboard
  28. 28. April 2013 Public Slide 28
  29. 29. April 2013 Public Slide 29 Machine - Level 1 & 2 MES - Level 3 ERP - Level 4 SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning ProductionOperatorDashboard(GUI) SAP MII Quintiq Operational Planning Siemens TCE Indicenter / Coach Test Scripts SAPBusinessObjects(Reports/Dashboards) SAP Manufacturing Execution SAP ECC Graphical Routing Editor Quintiq Shift Planning Quintiq Operational Planning Siemens TCE RSuite / Coach Test Scripts SAP MII - Manufacturing Integration & Intelligence Manufacturing Execution: POD accesses dashboards, reports, work instructions, etc.
  30. 30. Public Slide 30 April 2013
  31. 31. Public Slide 31 April 2013
  32. 32. Shop Floor Control impact on FLOW improvement • Graphical Routing Editor to define blueprint • Calculate optimal sequence (in 2 min. instead of 5 days) • Fair Work Packages per operator, per shift • Dynamic sequencing • Real-time progress tracking (even available for operator during shift) • Monitoring and reporting • Escalate disturbance notifications • Assure production progress • Trigger the just-in-time delivery of kit carts • Dynamic Work instructions • Operator assignments • Execute Work Packages in takts • Disturbance resolution process April 2013 Public Slide 32
  33. 33. What’s next ? This week : Start of Work preparation in PRD Next week : Final UAT Sept. 30 : Start Roll-out to 1st workcenters Till end Q1 : Roll-out in ASML Netherlands To be planned / follow-up projects: - Potential enhancements after pilot in EUV factory; - MES – Machine interfacing; - World-Wide roll-out:  USA - Wilton  USA - San Diego  Taiwan - Linkou - Next step for disturbance resolution (QIM ??) - Workplace efficiency – Use of Mobile / iPad July 2012 Public Slide 33
  34. 34. Questions

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