System and method for manufacturing planning and control

• US 20050137732A1
• Filed: 12/18/2003
• Published: 06/23/2005
• Est. Priority Date: 12/18/2003
• Status: Active Grant

• Current Assignee: Taiwan Semiconductor Manufacturing Company Limited
• Original Assignee: Taiwan Semiconductor Manufacturing Company Limited
• Inventors: Huang, Wei-Chuan, Chao, Jen-Lin, Hsu, Chen-Wei, Chang, Chin-Yung, Lo, Chiang-Chou, Wen, Cheng-Hsi
• Granted Patent: US 7,130,707 B2
• Time in Patent Office: Days
• US Class Current: 700/100
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32086 Integrate process planning and job shop scheduling
• CPC Class Codes: G06Q 10/00 Administration; Management
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A customer-orientated manufacturing planning and controlling system. An order management module is programmed to receive an order for a product and reserve a capacity for the order based on a capacity model that considers a plurality of capacity vectors in a production system. A plan engine generates a fixed production schedule for the order based on the capacity model. A priority management engine provides a priority for the order. A production schedule monitor and evaluation module determines whether the order in process conforms to the fixed production schedule by statistical process control (SPC) and whether to adjust the fixed production schedule and to adjust the priority based on a dynamic achievement model of historical fixed production schedules, based on historical production information in a production database storing production information of the production system.

Claims

1. A computer implemented system for manufacturing planning in a production system, comprising:

a capacity model, considering a plurality of capacity vectors in the production system;

an order management module to receive an order for a product and reserve a capacity for the order based on the capacity model;

a plan engine to generate a fixed production schedule for the order based on the capacity model; and

a production schedule monitor and evaluation module to determine whether the order in process conforms to the fixed production schedule and whether to adjust the fixed production schedule when the order in process deviates from the fixed production schedule.

2. The system as claimed in claim 1, wherein the production system is an integrated circuit (IC) foundry.

3. The system as claimed in claim 2, wherein the plan engine generates a new fixed production schedule for the order in process according to a deviation when receiving an adjustment determination from the production schedule monitor and evaluation module.

4. The system as claimed in claim 2, wherein the order of the product is divided into a plurality of lots for production.

5. The system as claimed in claim 4, further comprising a dynamic achievement model of historical fixed production schedules for the production schedule monitor and evaluation module to refer and determine the fixed production schedule adjustment accordingly.

6. The system as claimed in claim 5, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate.

7. The system as claimed in claim 6, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

8. The system as claimed in claim 7, wherein manufacturing capability limits deviation.

9. The system as claimed in claim 8, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.

10. A computer implemented system for IC manufacturing planning in an IC foundry, comprising:

a production database storing production information of the IC foundry;

a capacity model considering a plurality of capacity vectors in the IC foundry;

an order management module to receive an order for a product and reserve a capacity for the order based on the capacity model;

a plan engine to generate a fixed production schedule for the order based on the capacity model;

a dynamic achievement model of historical fixed production schedules based on historical production information in the production database; and

a production schedule monitor and evaluation module to determine whether the order in process conforms to the fixed production schedule and whether to adjust the fixed production schedule based on the dynamic achievement model when the order in process deviates from the fixed production schedule.

11. The system as claimed in claim 10, wherein the plan engine generates a new fixed production schedule for the order in process according to a deviation when receiving an adjustment determination from the production schedule monitor and evaluation module.

12. The system as claimed in claim 10, wherein the order of the product is divided into a plurality of lots for production.

13. The system as claimed in claim 10, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate.

14. The system as claimed in claim 13, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

15. The system as claimed in claim 14, wherein the manufacturing capability limits deviation.

16. The system as claimed in claim 15, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.

17. A system of a production schedule adjustment for IC production, comprising:

a production database storing production information in an IC foundry;

a plan engine to generate a fixed production schedule for an order produced in the IC foundry;

a dynamic achievement model of historical fixed production schedules based on historical production information in the production database; and

a production schedule monitor and evaluation module to determine whether the order in process conforms to the fixed production schedule and whether to adjust the fixed production schedule based on the dynamic achievement model.

18. The system as claimed in claim 17, wherein the order is divided into a plurality of lots.

19. The system as claimed in claim 18, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate.

20. The system as claimed in claim 19, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

21. The system as claimed in claim 20, wherein the manufacturing capability limits deviation.

22. The system as claimed in claim 21, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.

23. A method of manufacturing planning and control in an IC foundry, comprising the steps of:

receiving an order of an IC product;

reserving a capacity and generating a fixed production schedule for the order; and

manufacturing the order according to the fixed production schedule.

24. The method as claimed in claim 23, wherein the capacity is reserved based on a capacity model of the IC foundry.

25. The method as claimed in claim 23, wherein the order is divided into a plurality of lots.

26. The method as claimed in claim 23, further comprising the step of:

determining whether the order in process conforms to the fixed production schedule; and

determining whether to adjust the fixed production schedule based on a dynamic achievement model of historical fixed production schedules.

27. The method as claimed in claim 26, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate.

28. The method as claimed in claim 27, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

29. The method as claimed in claim 28, wherein the manufacturing capability limits deviation.

30. The method as claimed in claim 29, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.

31. A storage medium for storing a computer program providing a method of manufacturing planning and control in an IC foundry, using a computer to perform the steps of:

receiving an order of an IC product;

reserving a capacity and generating a fixed production schedule for the order;

determining whether the order in process conforms to the fixed production schedule; and

determining whether to adjust the fixed production schedule referring to a dynamic achievement model of historical fixed production schedules.

32. The storage medium as claimed in claim 31, wherein the order is divided into a plurality of lots with the fixed production schedule.

33. The storage medium as claimed in claim 31, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate.

34. The storage medium as claimed in claim 33, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

35. The storage medium as claimed in claim 34, wherein the manufacturing capability limits deviation.

36. The storage medium as claimed in claim 35, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.

37. A computer implemented system for manufacturing planning and control in a production system, comprising:

a capacity model, considering a plurality of capacity vectors in the production system;

an order management module to receive an order for a product and reserve a capacity for the order based on the capacity model;

a plan engine to generate a fixed production schedule for the order based on the capacity model with a plurality of input parameters;

a priority management module to assign a priority to the order in process; and

a production schedule monitor and evaluation module to determine whether the order in process conforms to the fixed production schedule by statistical process control (SPC) and whether to adjust the fixed production schedule and to adjust the priority when the order in process deviates from the fixed production schedule.

38. The system as claimed in claim 37, wherein the production system is an integrated circuit (IC) foundry.

39. The system as claimed in claim 38, wherein the production schedule monitor and evaluation module comprises a statistical process control (SPC) model considering a plurality of SPC vectors to determine whether the order in process conforms to the fixed production schedule.

40. The system as claimed in claim 38, wherein the plan engine generates a new fixed production schedule for the order in process according to a deviation when receiving an adjustment determination from the production schedule monitor and evaluation module.

41. The system as claimed in claim 38, wherein the order of the product is divided into a plurality of lots for production.

42. The system as claimed in claim 41, further comprising a dynamic achievement model of historical fixed production schedules for the production schedule monitor and evaluation module to refer and determine the fixed production schedule adjustment accordingly.

43. The system as claimed in claim 42, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate.

44. The system as claimed in claim 43, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

45. The system as claimed in claim 44, wherein manufacturing capability limits deviation.

46. The system as claimed in claim 45, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.

47. A computer implemented system for matching plan and execution in an IC foundry, comprising:

a production database storing production information of the IC foundry;

a capacity model considering a plurality of capacity vectors in the IC foundry;

an order management module to receive an order for a product and reserve a capacity for the order based on the capacity model;

a plan engine to generate a fixed production schedule for the order based on the capacity model;

a dynamic achievement model of historical fixed production schedules based on historical production information in the production database;

a priority management module to assign a priority to the order in process; and

a production schedule monitor and evaluation module to determine whether the order in process conforms to the fixed production schedule by statistical process control (SPC) and whether to adjust the fixed production schedule based on the dynamic achievement model and to adjust the priority when the order in process deviates from the fixed production schedule.

48. The system as claimed in claim 47, wherein the plan engine generates a new fixed production schedule for the order in process according to a deviation when receiving an adjustment determination from the production schedule monitor and evaluation module.

49. The system as claimed in claim 47, wherein the order of the product is divided into a plurality of lots for production.

50. The system as claimed in claim 47, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate.

51. The system as claimed in claim 50, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

52. The system as claimed in claim 51, wherein the manufacturing capability limits deviation.

53. The system as claimed in claim 52, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.

54. The system as claimed in claim 47, wherein the statistic tool is a SPC model.

55. A method of execution matching in an IC foundry, comprising the steps of:

receiving an order of an IC product;

reserving a capacity and generating a fixed production schedule for the order;

providing a priority for the order;

manufacturing the order with the priority according to the fixed production schedule;

determining whether the order in process conforms to the fixed production schedule with statistical process control (SPC);

determining whether to adjust the priority for the order in process with statistical process control; and

determining whether to adjust the fixed production schedule based on a dynamic achievement model of historical fixed production schedules.

56. The method as claimed in claim 55, wherein the capacity is reserved based on a capacity model of the IC foundry.

57. The method as claimed in claim 55, wherein the order is divided into a plurality of lots.

58. The method as claimed in claim 55, wherein the dynamic achievement model of historical fixed production schedules comprises a relationship between fixed production schedule achievement rate and fixed production schedule adjustment rate with an SPC tool.

59. The method as claimed in claim 58, wherein the dynamic achievement model further comprises a relationship between the fixed production schedule achievement rate and manufacturing capability.

60. The method as claimed in claim 59, wherein the manufacturing capability limits deviation.

61. The method as claimed in claim 60, wherein the dynamic achievement model further provides an optimal working area based on the relationships to evaluate whether to adjust the fixed production schedule.