Method, program storage device, and apparatus for optimizing and analyzing efficiency of equipment

• US 6,618,642 B2
• Filed: 12/13/2000
• Issued: 09/09/2003
• Est. Priority Date: 12/18/1999
• Status: Active Grant

• Current Assignee: Samsung Electronics Co. Ltd.
• Original Assignee: Samsung Electronics Co. Ltd.
• Inventors: Kim, Sung-tae, Hyun, In-ho, Maeng, Ju-Seok
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Swindell, Walter R.
• Application Number:
  US09/734,857
• Publication Number:
  US 20010005799A1
• Time in Patent Office: 1,000 Days
• Field of Search: 700/1, 700/28, 700/90-173, 483/4-6, 703/1, 703/28
• US Class Current: 700/173
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/31411 Down time, loss time estimation, calculation
• CPC Class Codes: G05B 2219/32015 Optimize, process management, optimize production line
• CPC Class Codes: G05B 2219/32366 Line performance evaluation
• CPC Class Codes: G05B 2219/32385 What is simulated, manufacturing process and compare results with real process
• CPC Class Codes: G05B 2219/45031 Manufacturing semiconductor wafers
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method, apparatus and program storage device for analyzing and optimizing equipment efficiency are disclosed. In an illustrative embodiment equipment running time is subdivided into a valuable operating time component and a plurality of performance loss time components. Ideal equipment reference information reflecting dynamic manufacturing parameters is simulated, and an operational performance loss is analyzed in detail. From the analysis of the operational performance loss, priority in input of resources is determined. Advantageously, parameters of a dynamically changing manufacturing environment are incorporated in the analysis and optimization of general equipment efficiency. Moreover, performance loss is more accurately analyzed compared to conventional methods. As such, the performance operating rate is more effectively utilized in reducing performance loss.

Claims

1. A method for analyzing and optimizing an equipment efficiency, the method comprising:

(a) subdividing an equipment running time of a provided equipment into a valuable operating item and at least two performance loss items and modeling the equipment running time;

(b) calculating performance loss times, among the modeled performance loss items to provide basic data, the performance loss times corresponding to items independent of dynamic variables, the dynamic variables having values that change according to the operational environment of the equipment;

(c) simulating operation of the equipment using the values corresponding to the dynamic variables and the basic data and calculating target values for the performance of the equipment;

(d) measuring an actual equipment running time of the equipment and calculating surveyed values for the performance of the equipment, the surveyed values corresponding to the target values; and

(e) comparing the surveyed values with the corresponding target values to obtain gaps, and determining priority in input of resources.

2. The method of claim 1, wherein the target value for the performance of the equipment is a performance operating rate.

3. The method of claim 2, wherein the target values for the performance of the equipment include ratios of performance loss times to the equipment running time, the performance loss times corresponding to the modeled performance loss items.

4. An apparatus for analyzing an equipment efficiency, comprising:

a basic data database which stores performance loss times as basic data, the performance loss times corresponding to items independent of dynamic variables, the dynamic variables having values that change according to the operational environment of a provided equipment among a plurality of performance loss items modeled with respect to the provided equipment;

an equipment simulator which receives values corresponding to the dynamic variables input by a user and the basic data from the basic data database, the equipment simulator capable of simulating the operation of the equipment, and calculating target values for the performance of the equipment;

a surveyed value calculator which calculates surveyed values for the performance of the equipment from the measured actual equipment running time data of the equipment, the surveyed values corresponding to the target values for the performance of the equipment; and

an evaluation output unit which calculates and outputting the gaps between the target values input from the equipment simulator and the corresponding surveyed values input from the surveyed value calculator.

5. The apparatus of claim 4, wherein the target value calculated by the equipment simulator is a performance operating rate.

6. The apparatus of claim 4, wherein the target values calculated by the equipment simulator include ratios of performance loss times to the equipment running time, the performance loss times corresponding to the modeled performance loss items.

7. A method for analyzing and optimizing equipment efficiency, the method comprising:

subdividing equipment running time into a valuable operating component and at least two performance loss components;

simulating ideal equipment reference information reflecting dynamic manufacturing parameters;

analyzing an operational performance loss; and

determining a priority of input of resources therefrom.

8. The method as recited in claim 7, further comprising calculating performance loss times corresponding to items independent of dynamic variables among modeled performance loss items to provide basic data, the dynamic variables having values that change according to an operating environment of the equipment.

9. The method as recited in claim 8, further comprising simulating operation of the equipment using values corresponding to the dynamic variables and the basic data and calculating target values for performance of the equipment.

10. The method as recited in claim 9, further comprising measuring an actual equipment running time of the equipment and calculating surveyed values for the performance of the equipment, the surveyed values corresponding to the target values.

11. The method as recited in claim 10, further comprising comparing the surveyed values with the corresponding target values to obtain gaps, and determining priority in input of resources.

12. The method as recited in claim 10, wherein the target value for the performance of the equipment is a performance operating rate.

13. The method as recited in claim 10, wherein the target values for the performance of the equipment include ratios of performance loss times to the equipment running time, the performance loss times corresponding to the modeled performance loss items.

14. A program storage device readable by a machine, said program storage device tangibly embodying a program of instructions executable by the machine to perform a process for analyzing and optimizing an equipment efficiency, wherein the process includes:

(a) subdividing an equipment running time of a provided equipment into a valuable operating item and at least two performance loss items and modeling the equipment running time;

(b) calculating performance loss times, among the modeled performance loss items to provide basic data, the performance loss times corresponding to items independent of dynamic variables, the dynamic variables having values that change according to the operational environment of the equipment;

(c) simulating operation of the equipment using the values corresponding to the dynamic variables and the basic data and calculating target values for the performance of the equipment;

(d) measuring an actual equipment running time of the equipment and calculating surveyed values for the performance of the equipment, the surveyed values corresponding to the target values; and

(e) comparing the surveyed values with the corresponding target values to obtain gaps, and determining priority in input of resources.

15. The program storage device of claim 14, wherein the target value for the performance of the equipment is a performance operating rate.

16. The program storage device of claim 14, wherein the target values for the performance of the equipment include ratios of performance loss times to the equipment running time, the performance loss times corresponding to the modeled performance loss items.

17. A program storage device readable by a machine, said program storage device tangibly embodying a program of instructions executable by the machine to perform a process for analyzing and optimizing an equipment efficiency, wherein the process includes:

subdividing equipment running time into a valuable operating component and at least two performance loss components;

simulating ideal equipment reference information reflecting dynamic manufacturing parameters;

analyzing an operational performance loss; and

determining a priority of input of resources therefrom.

18. The program storage device as recited in claim 17, wherein the process further includes calculating performance loss times corresponding to items independent of dynamic variables among modeled performance loss items to provide basic data, the dynamic variables having values that change according to an operating environment of the equipment.

19. The program storage device as recited in claim 18, wherein the process further includes simulating operation of the equipment using values corresponding to the dynamic variables and the basic data and calculating target values for performance of the equipment.

20. The program storage device as recited in claim 19, wherein the process further includes measuring an actual equipment running time of the equipment and calculating surveyed values for the performance of the equipment, the surveyed values corresponding to the target values.

21. The program storage device as recited in claim 20, further comprising comparing the surveyed values with the corresponding target values to obtain gaps, and determining priority in input of resources.

22. The program storage device as recited in claim 20, wherein the target value for the performance of the equipment is a performance operating rate.

23. The program storage device as recited in claim 20, wherein the target values for the performance of the equipment include ratios of performance loss times to the equipment running time, the performance loss times corresponding to the modeled performance loss items.