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IE的機會與挑戰 : 以IC晶圓製造業為例


   黃崑智 (Kun-Chih Huang)

          部經理
         產能企劃部
         工業工程處


                          K...
TSMC & Overseas Subsidiaries
                                                               TSMC
                   TSMC E...
Fab-1 ( 6”)


                         HSIP                   ITRI
                                                       ...
Value Chain of Semiconductor Industry
                                       設備供應商



                      IDM 廠商        ...
Semiconductor Industry in Taiwan

IC設計      光罩製作       晶圓製造       IC封裝          測試                   出貨

•   聯發科   •   台灣光...
IC Manufacturing Flow
Material                                                                   Assembly
Supplier        ...
Fab Cross Section - 3 Level Fab
                                                                                      Exha...
Fab Layout - Typical



Bay    Bay    Bay     Bay     Bay   Bay



             Inter-Bay AMHS




Bay    Bay    Bay     B...
300mm Fab Model - Fully AMHS




  Source: International SEMATACH


                                   KCH December 26, 2002
The features of Semiconductor Industry
                     資本密集

                     技術密集

                     產品生命週...
IE Job Opportunity in Wafer Fab
 工業工程

 生產企劃 (生管)

 製造管理

 資材管理 (採購與物管)

 人力資源管理             處 處 有 IE ...
 風險管理

 品...
The Challenge of IE in Wafer Fab
                      Internationalization




Complicated                               ...
Job Function of IE Organization
 Capacity Planning (time study, bottleneck management, simulation, OEE)

 Cost Managemen...
Example


Capacity Planning and Simulation Application




                                      KCH December 26, 2002
Capacity Planning in the MPC system

 Resource Planning                       Production Planning                       De...
Capacity Planning: 4W1H

         .Design a brand new Fab; or
 WHY     .Optimize a running Fab to make sure the
          ...
First Step




Time Measurement / Time Study

                                KCH December 26, 2002
Rough-Cut capacity planning
         system framework
     MPS
(monthly base)



                                         ...
Capacity Requirement Planning
          system framework
        MPS                                  Cycle time index
   ...
Planner, Scheduler and Simulator


    PLANNER                     SCHEDULER
                      Work
                  ...
History of Simulation Application in TSMC
   04/’91~06/’91             NCTU (SLAMII, PHOTO)

   07/’91~12/’91   Software...
Barriers of Simulation Application

 People:

 Managers/Supervisors are not familiar with
  simulation concept/methodolo...
The Future

生產管理
  &                    品質管理
供應鏈管理



              I.E.
       Integrating Expert

Information
Technology...
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IE-008 Ie的機會與挑戰 以Ic晶圓製造業為例

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IE-008 Ie的機會與挑戰 以Ic晶圓製造業為例

  1. 1. IE的機會與挑戰 : 以IC晶圓製造業為例 黃崑智 (Kun-Chih Huang) 部經理 產能企劃部 工業工程處 KCH December 26, 2002
  2. 2. TSMC & Overseas Subsidiaries TSMC TSMC Europe TSMC Japan Fab1 TSMC USA WaferTech TSMC Fab8,12 VIS TSMC Fab2,3,5,7 TSMC Fab6,14 SSMC KCH December 26, 2002
  3. 3. Fab-1 ( 6”) HSIP ITRI Fab-8 ( 8〞) Fab-12 WSMC VIS TASMC Fab3/4 Fab-2 (6”) SSMC (Singapore) Fab-12 (12”) Fab-3 (8”) VIS (8”) Fab-5 (8”) WaferTech (Camas, WA, USA) Fab6 Fab14 TSIP Fab-14 ( 12”) Fab-6 ( 8”) Fab-7 ( 8”) (Under Construction) KCH December 26, 2002
  4. 4. Value Chain of Semiconductor Industry 設備供應商 IDM 廠商 系 統 應 晶 IC EDA 與 光 & 用 系 圓 封 測 統 設 設計服務廠商 罩 代 裝 試 OEM 市 計 供 廠 廠 工 廠 廠 場 廠 應 商 IP供應商 廠 商 商 商 商 商 商 產品架 核心IP 製造、組 系統層 製作 晶圓製 封裝 測試 構與規 取得與 設計整合 裝與運籌 次整合 光罩 造技術 技術 技術 格制定 發展 管理 化 導 晶 學 線 圓 品 架 供 供 供 應 應 應 Source: 半導體趨勢圖示(電子時報) 商 商 商 KCH December 26, 2002
  5. 5. Semiconductor Industry in Taiwan IC設計 光罩製作 晶圓製造 IC封裝 測試 出貨 • 聯發科 • 台灣光罩 • 台積電 • 日月光 • 福雷 • 威盛 • 新台 • 聯電 • 矽品 • 聯測 • 矽統 • 台積電 • 華邦 • 華泰 • 南茂 • 揚智 • 中華杜邦 • 旺宏 • 凌生 • 大眾 • 矽成 • ... • 世界先進 • 鑫成 • 矽豐 • 宇慶 • 力晶 • ... • ... • 凌揚 • 茂矽 • 義隆 • 南亞科技 • 瑞昱 • 矽統 • 台晶 • 鈺創 晶圓供應 • ... • 中德 • 信越 • 小松 KCH December 26, 2002
  6. 6. IC Manufacturing Flow Material Assembly Supplier Wafer Fabrication Testing Customer Raw Wafer Chemicals Laser Mark Special gas Oxidation Photo resist Diffusion Reticle Reticle Design Metal Sputter Develop Etch Ion Implant Wafer Accept Test Un-probed Wafer Probed Wafer Probing IC Assembly Untested Package Final Test Tested Package KCH December 26, 2002
  7. 7. Fab Cross Section - 3 Level Fab Exhaust Stacks Stair Level 3 Case Clean Subfab Level 2 Utility Level 1 Subfab Make-Up Air Gas Cabinets Process Vacuum Line Process Supply Submains Scrubber Air Return Shafts Main Process Supply systems Source : M+W KCH December 26, 2002
  8. 8. Fab Layout - Typical Bay Bay Bay Bay Bay Bay Inter-Bay AMHS Bay Bay Bay Bay Bay Bay Intra-Bay AMHS KCH December 26, 2002
  9. 9. 300mm Fab Model - Fully AMHS Source: International SEMATACH KCH December 26, 2002
  10. 10. The features of Semiconductor Industry  資本密集  技術密集  產品生命週期短 摩爾定律:  價格競爭激烈 IC上可容納的電晶體數目, IC上可容納的電晶體數目, 約每隔18個月便會增加一倍 約每隔18個月便會增加一倍  市場應用領域廣 ,性能也將提升一倍。  市場變動快且風險高  研究發展需求多  國際化競爭程度高 KCH December 26, 2002
  11. 11. IE Job Opportunity in Wafer Fab  工業工程  生產企劃 (生管)  製造管理  資材管理 (採購與物管)  人力資源管理 處 處 有 IE ...  風險管理  品質管理  MIS & CIM管理  專案管理  ... KCH December 26, 2002
  12. 12. The Challenge of IE in Wafer Fab Internationalization Complicated Complicated Process Manufacturing Technology Operations Highly Educated Knowledge Workers KCH December 26, 2002
  13. 13. Job Function of IE Organization  Capacity Planning (time study, bottleneck management, simulation, OEE)  Cost Management (standard cost preparation, cost reduction program)  Capital Investment Evaluation (Payback, Break-even, COO, CAPEX)  Layout Management & EQ move-in management  Headcount Evaluation (Operations IDL & DL)  Benchmarking  Change Master (BPR, ERP, SCM, CI, CIM, E-commerce)  New Fab Planning (site survey, site master plan, building plan, layout plan)  Project Management (Schedule and Budget Control) KCH December 26, 2002
  14. 14. Example Capacity Planning and Simulation Application KCH December 26, 2002
  15. 15. Capacity Planning in the MPC system Resource Planning Production Planning Demand Management Rough-cut capacity Master Production planning Scheduling (MPS) Capacity Requirement Material Requirement Planning (CRP) Planning (MRP) Finite Loading Input/Output Shop Floor Control Vendor Follow up Analysis (SFC) System Source: Manufacturing Planning and Control Systems edited by Thomas E. Vollmann, William L. Berry and D. Clay Whybark KCH December 26, 2002
  16. 16. Capacity Planning: 4W1H .Design a brand new Fab; or WHY .Optimize a running Fab to make sure the production be completed at the right time Resource plan, Rough-cut capacity plan, WHAT Capacity requirement plan, finite loading WHEN Weekly, Monthly, Quarterly, Yearly WHO IE, PC, MFG, Consultant .Static models by spread sheet technique HOW .Dynamic models by simulation technique KCH December 26, 2002
  17. 17. First Step Time Measurement / Time Study KCH December 26, 2002
  18. 18. Rough-Cut capacity planning system framework MPS (monthly base) process flow (by step) Yield data process time by step CRP Module EQ resource (q'ty, uptime, eff.) Capacity Requirement (EQ utilization) KCH December 26, 2002
  19. 19. Capacity Requirement Planning system framework MPS Cycle time index (weekly base) Scheduled lots current WIP (by steps group) process flow process flow (by steps group) MRP (by step) module Yield data process time by step CRP Module EQ resource Wafer Start schedule (q'ty, uptime, eff.) Capacity Requirement (EQ utilization) KCH December 26, 2002
  20. 20. Planner, Scheduler and Simulator PLANNER SCHEDULER Work Release Order Planning Work Dispatching Factory Modeling Factory What If Status SIMULATOR Scenario Analysis KCH December 26, 2002
  21. 21. History of Simulation Application in TSMC  04/’91~06/’91 NCTU (SLAMII, PHOTO)  07/’91~12/’91 Software Survey (ManSim, Archilles, Promodel, Qplus)  07/’92~10/’92 Software procurement (ManSim 3.1.1)  10/’92~11/’92 Verification (Software acceptance test)  12/’92~03/’93 Fab2A modeling & Validation  04/’93~06/’93 Fab2A 1st case study (Hot run ratio analysis)  08/’93~11/’93 Fab2A 2nd case study (WIP vs Cycle Time analysis)  03/’94~12/’94 MES system interface development & Fab Managers Training  01/’’95 Fab2A 3rd case study (Bottleneck utilization vs C/T)  03/’95 Software upgrade from ManSim 3.1.1 to ManSim 3.5  04/’95~ IMPES concept proposal and MS/X On Time Survey KCH December 26, 2002
  22. 22. Barriers of Simulation Application  People:  Managers/Supervisors are not familiar with simulation concept/methodology. Therefore, they don't feel confident of simulation result.  Full-Time vs. Part-Time assignment  Tooling:  The pre-defined shop floor control rule can not cover all of the Fab's rule.  Lack a good interface between Simulator and MES.  The result of Stand alone application is not easy proved. KCH December 26, 2002
  23. 23. The Future 生產管理 & 品質管理 供應鏈管理 I.E. Integrating Expert Information Technology 組織與流程管理 KCH December 26, 2002

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