Use of simulation to generate predictions pertaining to a manufacturing facility

• US 20090119077A1
• Filed: 11/06/2007
• Published: 05/07/2009
• Est. Priority Date: 11/06/2007
• Status: Abandoned Application

• Current Assignee: Applied Materials Incorporated
• Original Assignee: Applied Materials Incorporated
• Inventors: Norman, David Everton, Stafford, Richard
• Application Number:
  US11/983,120
• Publication Number:
  US 20090119077A1
• Time in Patent Office: Days
• US Class Current: 703/6
• CPC Class Codes: G05B 13/026 using a predictor
• CPC Class Codes: G05B 17/02 electric

Abstract

In one embodiment, a method for using simulation to predict the future of a manufacturing facility includes obtaining data pertaining to the current state of the manufacturing facility, and building a simulation model based on the obtained data. The method may further include identifying a time horizon defining a point of time in the future, performing a simulation run for the time horizon using the simulation model to predict the state of the manufacturing facility at the future point of time, and storing the resulting predictions in a database.

Claims

1. A computerized method comprising:

obtaining data pertaining to a current state of at least a portion of a manufacturing facility;

building a simulation model based on the data pertaining to the current state of at least a portion of the manufacturing facility;

identifying a time horizon defining a point of time in the future;

performing a simulation run for the time horizon using the simulation model to predict a state of at least a portion of the manufacturing facility at the future point of time; and

storing resulting predictions in a database

2. The method of claim 1 wherein the data pertaining to the current state of at least a portion of the manufacturing facility is obtained from at least one of a manufacturing execution system (MES), a maintenance management system (MMS), a material control system (MCS), an equipment control system (ECS), a computerized integrated manufacturing system (CIM), or an inventory control system (ICS).

3. The method of claim 1 wherein the data pertaining to the current state of at least a portion of the manufacturing facility comprises a current state of equipment in at least a portion of the manufacturing facility and a current processing step of a product in at least a portion of the manufacturing facility.

4. The method of claim 1 wherein obtaining the data pertaining to the current state of at least a portion of the manufacturing facility comprises:

submitting queries to one or more source system to obtain data needed for the simulation model; and

receiving query results from the source systems.

5. The method of claim 1 further comprising:

obtaining static data describing static characteristics of at least a portion of the manufacturing facility; and

adding the static data to the simulation model.

6. The method of claim 1 wherein the static characteristics of at least a portion of the manufacturing facility comprise information about the behavior of equipment, operators or tools in at least a portion of the manufacturing facility.

7. The method of claim 1 wherein performing the simulation run comprises:

recording transitions of a product during the simulation run; and

recording transitions of equipment, operators or tools during the simulation run.

8. The method of claim 7 wherein:

the recorded transitions of the product identify each step the product goes through during the simulation run; and

the recorded transitions of the equipment, operators or tools identify each state the equipment, operators or tools go through during the simulation run.

9. The method of claim 4 further comprising:

receiving simulation properties from a user, the prediction properties identifying at least one of the time horizon, the one or more source systems, query parameters, or entities being predicted.

10. A computer-readable medium having executable instructions to cause a computer system to perform a method comprising:

obtaining data pertaining to a current state of at least a portion of a manufacturing facility;

building a simulation model based on the data pertaining to the current state of at least a portion of the manufacturing facility;

identifying a time horizon defining a point of time in the future;

performing a simulation run for the time horizon using the simulation model to predict a state of at least a portion of the manufacturing facility at the future point of time; and

storing resulting predictions in a database.

11. The computer-readable medium of claim 10 wherein the data pertaining to the current state of at least a portion of the manufacturing facility is obtained from at least one of a manufacturing execution system (MES), a maintenance management system (MMS), a material control system (MCS), an equipment control system (ECS), a computer integrated manufacturing system (CIM), or an inventory control system (ICS).

12. The computer-readable medium of claim 10 wherein the data pertaining to the current state of at least a portion of the manufacturing facility is dynamic data comprising a current state of equipment, operators or tools in at least a portion of the manufacturing facility and a current processing step of a product in at least a portion of the manufacturing facility.

13. The computer-readable medium of claim 10 wherein obtaining the data pertaining to the current state of at least a portion of the manufacturing facility comprises:

submitting queries to one or more source system to obtain data needed for the simulation model; and

receiving query results from the source systems.

14. The computer-readable medium of claim 10 wherein the method further comprises:

obtaining static data describing static characteristics of at least a portion of the manufacturing facility; and

adding the static data to the simulation model.

15. The computer-readable medium of claim 10 wherein performing the simulation run comprises:

recording transitions of a product during the simulation run; and

recording transitions of equipment, operators or tools during the simulation run.

16. The computer-readable medium of claim 15 wherein:

the recorded transitions of the product identify each step the product goes through during the simulation run; and

the recorded transitions of the equipment, operators or tools identify each state the equipment, operators or tools go through during the simulation run.

17. An apparatus comprising:

a simulation model builder to obtain data pertaining to a current state of at least a portion of a manufacturing facility, and to build a simulation model based on the data pertaining to the current state of at least a portion of the manufacturing facility; and

a simulation engine, coupled to the simulation model builder, to identify a time horizon defining a point of time in the future, and to perform a simulation run for the time horizon using the simulation model to predict a state of at least a portion of the manufacturing facility at the future point of time; and

a prediction database, coupled to the simulation engine, to store predictions resulting from the simulation run.

18. The apparatus of claim 17 wherein the data pertaining to the current state of at least a portion of the manufacturing facility is obtained from at least one of a manufacturing execution system (MES), a maintenance management system (MMS), a material control system (MCS), an equipment control system (ECS), a computer integrated manufacturing system (CIM), or an inventory control system (ICS).

19. The apparatus of claim 17 wherein the data pertaining to the current state of at least a portion of the manufacturing facility comprises a current state of equipment, operators or tools in at least a portion of the manufacturing facility and a current processing step of a product in at least a portion of the manufacturing facility.

20. The apparatus of claim 17 wherein the simulation model builder is to obtain the data pertaining to the current state of at least a portion of the manufacturing facility by

submitting queries to one or more source system to obtain data needed for the simulation model, and

receiving query results from the source systems.

21. The apparatus of claim 17 wherein the simulation model builder is further to obtain static data describing static characteristics of at least a portion of the manufacturing facility, and to add the static data to the simulation model.

22. The apparatus of claim 17 wherein the simulation engine is to record transitions of a product during the simulation run, and to record transitions of equipment, operators or tools during the simulation run, wherein the recorded transitions of the product identify each step the product goes through during the simulation run, and the recorded transitions of the equipment, operators or tools identify each state the equipment, operators or tools go through during the simulation run.