Taiwan Semiconductor Manufacturing Comp. Ltd.

Yi-Chin Hsu

Sheng-Rong Huang

Kuo-Chen Lin

Wen-Lin Chen

Wei-Kuo Yen

Yao-Tung Liu

Ming-Hsiu Hsieh

Cheng-Che Chen

Wen-Feng Wu

Chih-Yi Hsu

Yi-Hsin Chan

Fu-Kang Lai

Wei-Heng Tai

Yi-Cherng Wang

Chiu-Ju Chen

An automated supply management system for dynamically fulfilling a customer requested order having an order fulfillment system for fulfilling a plurality of customer requests in accordance with a plurality of processing capacity restraints defined for a plurality of pieces of manufacturing equipment disposed within a manufacturing facility; an allocation planning system for receiving a plurality of capacity modeling data from the order fulfillment system, an order management system for communicating a plurality of consumption data and a customer requested due date to the order fulfillment system, wherein the order management system requests the customer requested due date and receives a calendar date of production available to promise from the order fulfillment system; and a manufacturing planning system for receiving an order fulfillment matrix from the order fulfillment system.

Automated supply management method for dynamically fulfilling a customer requested order

A method and system is provided for dynamically coordinating one or more product orders with product parts progressing through a manufacturing process flow. After identifying a first order for generating one or more lots of parts for manufacturing a first product, wherein the first order identifies a predetermined base feature, one or more customer specific features, one or more order specific features, and the quantity of the first product, A smart code is assigned to the first order and the lots of parts, wherein the smart code identifies an association between the first order and the lots of parts. An analysis is then performed, based on the smart codes assigned thereto, to see whether one or more available lots of parts of a second order in production are ready to be converted to produce the first product. The smart code of the available lots is changed to the smart code of the first order if the available lots of the second order are chosen to be further processed for fulfilling the first order.

Method and system for efficiently coordinating orders with product materials progressing through a manufacturing flow

To allocate products for machines on a manufacturing line, provide a standard test time. Minimize total test time with respect to production scheduling. Form a supply demand matrix table for products and machines for product allocation. Find the grid location with minimum testing time. Provide maximum time allocation from a machine at the corresponding position on the matrix table. Determine the grid location with the next minimum testing time. Loop back to provide a maximum allocation of remaining time from the corresponding machine and repeat looping back until no demand is left. Find need for an optimum testing process by testing whether only one machine can test the product and no quantity is allocated to a machine. If YES branch to calculate utilization per machine. If NO, decide whether N &plus;N &equals;NV . If YES perform optimum testing. If NO, branch to calculate machine utilization per machine.

Method for minimizing total test time for testing factories

The invention provides an index of line balance method for maintaining optimum queued quantities of products at a manufacturing step and over an entire manufacturing line. The method begins by: first, assigning a daily standard move of product (Std Move) which should be produced in a manufacturing line. Second, the standard WIP StdWIP is calculated for each manufacturing stage i by multiplying the theoretical cycle time C/T of each stage by the daily standard move StdMove; (i.e., StdWIP=CT*StdMove). Third, the difference Di between the current WIP CWi and standard WIP StdWIP at every stage i. (Di=Cwi-Swi, ) is calculated. Fourth, the cumulative difference CDi between current WIP Cwi and standard WIP StdWIP of every stage i from stage i to stage n is calculated. ##EQU1## Fifth, the index of line balance BIi is calculated by dividing the sum of all positive CDi from stage i to stage n by the absolute value of the sum of all negative CDi from stage i to stage n. Next, the index of line balance BIi for each stage i is plotted as a line chart for each stage i. Lastly, additional production resources (e.g., tools) are allocated to the stages that have an index of line balance BIi greater than 1.2 and production resources are reduced to the stages that have an index of line balance BIi less than 0.80. The method reduces WIP, cycle time and costs by better allocating manufacturing resources.

Method to improve WIP balance in a manufacturing line

A method and system are provided for operating a data processing system including a data base computer system and a resource allocation computer for control of resource allocation in a manufacturing plant with a manufacturing line comprising a plurality of stages with manufacturing machines, the resource allocation computer including data storage means. The method includes several steps including: deriving data from the data storage means and computing the targets for each of the stages; obtaining machine capacity data from the data storage means and employing the machine capacity data for allocating machine capacity proportionally and adjusting targets; adding limits to stages of penetration and adjusting targets; determining residual capacity and allocating the residual capacity of the manufacturing machines; and checking the convergence of targets and machine allocation until convergence is achieved.

Daily target generation and machine allocation with priority

This is a dynamic dispatching method for delivery performance by a factory. SLACK=(Due.sub.-- Date-Now)-(Forecast.sub.-- FAB.sub.-- Out.sub.-- Time); where Due.sub.-- Date=Scheduled due date from Master Production Schedule. The OTD (On Time Delivery) dynamic dispatching method focuses on the due date and the target cycle time under the environment of integrated circuit manufacturing. SLACK policy controls the long term due date and the OTD policy reflects the short term stage queue time. Through fuzzy theory, SLACK and OTD policies are combined as a dispatching controller to control the lot priority of the entire production line. The work piece, with either a long stage queue time, or with an urgent due date is pushed through the overall production line instead of jamming the front end of the process. A demand pull system satisfies the due date and the quantity of monthly demand.

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Hsin-Chu, Taiwan

Yi-Chin Hsu