Forecast test-out of probed fabrication by using dispatching simulation method

• US 6,876,894 B1
• Filed: 11/05/2003
• Issued: 04/05/2005
• Est. Priority Date: 11/05/2003
• Status: Expired due to Fees

• Current Assignee: Taiwan Semiconductor Manufacturing Company Limited
• Original Assignee: Taiwan Semiconductor Manufacturing Company Limited
• Inventors: Chang, Joseph, Chiu, Vincent, Chen, Nai-Chiang, Chen, Chung-Shen, Lin, Ta-Chin
• Primary Examiner(s): Bahta, Kidest
• Application Number:
  US10/701,960
• Time in Patent Office: 517 Days
• Field of Search: 700/97, 700/99, 700100-108, 700/117, 700/121, 700/33, 705 8- 10, 705/26
• US Class Current: 700/100
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 30/0621 Item configuration or customization

Abstract

A method and apparatus for simulating the functioning of various configurations of fabrication and test equipment within a manufacturing line creates a schedule for dispatching of the production lots to the manufacturing line. Based on the product mix forecast, the product volume forecast, the predicted sales schedule, the sales confidence, the actual sales order descriptions, and the product delivery schedule, a potential product dispatch schedule is established that enables a product to be fabricated within the manufacturing line. An equipment dispatch schedule for equipment employed in fabrication and testing of the product to be fabricated is defined according to the product dispatch schedule. The potential product dispatch schedule is then simulated based on the process and test equipment model. Upon completion of the simulation, the potential product dispatch schedule is assessed for optimization.

Claims

1. A method for scheduling fabrication and testing of product within a manufacturing line comprising the steps of:

a) creating a process equipment model for equipment and processes within said manufacturing line;

b) generating a potential product dispatch schedule for the product to be fabricated within said manufacturing line;

c) defining an equipment dispatch schedule for equipment employed in fabrication and testing of said product to be fabricated according to said product dispatch schedule;

d) simulating said potential product dispatch schedule;

e) determining if said potential product dispatch schedule is optimized;

f) if said product dispatch schedule is not optimized, generating another potential product dispatch schedule for said product and performing steps b) through e); and

g) if said product dispatch schedule is optimized, dispatching said products for fabrication and test according to said schedule;

wherein the process equipment model is described as a Petri-Net model to express the function of the process equipment during fabrication and test of said product.

2. The method of claim 1 wherein said process equipment model includes equipment set-up, equipment break-down, and equipment repair.

3. The method of claim 1 wherein the process equipment model includes a probability factor for unanticipated interruption for fabrication and test of high priority product.

4. The method of claim 1 further comprising the steps of:

determining if said equipment dispatch schedule is to be changed; and

if said equipment dispatch schedule is to be changed, modifying said equipment dispatch schedule and performing steps d) through g).

5. An apparatus for scheduling fabrication and testing of product within a manufacturing line comprising:

a) means for creating a process equipment model for equipment and processes within said manufacturing line;

b) means for generating a potential product dispatch schedule for product to be fabricated within said manufacturing line;

c) means for defining an equipment dispatch schedule for equipment employed in fabrication and testing of said product to be fabricated according to said product dispatch schedule;

d) means for simulating said potential product dispatch schedule;

e) means for determining if said potential product dispatch schedule is optimized;

f) means for generating another potential product dispatch schedule for said product and activating the means of b) through e), if said product dispatch schedule is not optimized; and

g) means for dispatching said products for fabrication and test according to said schedule, if said product dispatch schedule is optimized;

wherein the process equipment model is described as a Petri-Net model to express the function of the process equipment during fabrication and test of said product.

6. The apparatus of claim 5 wherein the process equipment model includes a probability factor for unanticipated interruption for fabrication and test of high priority product.

7. The apparatus of claim 5 wherein said process equipment model includes equipment set-up, equipment break-down, and equipment repair.

8. The apparatus of claim 5 further comprising:

means for determining if said equipment dispatch schedule is to be changed; and

means for modifying said equipment dispatch schedule and activating the means of d) through g), if said equipment dispatch schedule is to be changed.

9. A manufacturing and test scheduling system for scheduling and dispatch of the fabrication of product and of verification of function of said product comprising:

a product requirement and allocation generator which receives product forecast information, product order information, product process equipment information to generate a product lot scheduling;

a manufacturing equipment model generator which receives a product capability and capacity schedule and the product process equipment information to generate a simulation model for fabrication and testing of said product; and

a manufacturing simulator which receives an equipment dispatch algorithm and is in communication with said manufacturing equipment model generator to receive said simulation model and in communication with said product requirement and allocation generator to receive a candidate product lot scheduling to simulate and simulation model using said candidate product lot scheduling to determine if said product lot scheduling and said equipment dispatch algorithm are optimized, whereby;

if said product lot scheduling is not optimized, informing said product requirement and allocation generator to modify said product lot scheduling,

if said product lot scheduling is optimized, initiating dispatching said product for fabrication and testing; and

if said equipment dispatch algorithm is not optimized, modifying said equipment dispatch algorithm and re-simulating said simulation model to determine if said product lot scheduling and said equipment dispatch algorithm are optimized.

10. The manufacturing and testing scheduling system of claim 9 wherein said simulation model for fabrication and testing of said product includes equipment set-up, equipment break-down, and equipment repair.

11. The manufacturing and testing scheduling system of claim 9 wherein the simulation model for fabrication and testing of said product includes a probability factor for unanticipated interruption for fabrication and test of high priority product.

12. The manufacturing and testing scheduling system of claim 9 wherein the simulation model for fabrication and testing of said product is described as a Petri-Net model to express the function of the process equipment during fabrication and test of said product.

13. A manufacturing system for the fabrication and testing of product comprising:

manufacturing and test scheduling system for scheduling and dispatch of the fabrication of product and of verification of function of said product comprising;

a product requirement and allocation generator which receives product forecast information, product order information, product process equipment information to generate a product lot scheduling;

a manufacturing equipment model generator which receives a product capability and capacity schedule and the product process equipment information to generate a simulation model for fabrication and testing of said product; and

a manufacturing simulator which receives an equipment dispatch algorithm and is in communication with said manufacturing equipment model generator to receive said simulation model and in communication with said product requirement and allocation generator to receive a candidate product lot scheduling to simulate and simulation model using said candidate product lot scheduling to determine if said product lot scheduling and said equipment dispatch algorithm are optimized, whereby;

if said product lot scheduling is not optimized, informing said product requirement and allocation generator to modify said product lot scheduling,

if said product lot scheduling is optimized, initiating dispatching said product for fabrication and testing; and

if said equipment dispatch algorithm is not optimized, modifying said equipment dispatch algorithm and re-simulating said simulation model to determine if said product lot scheduling and said equipment dispatch algorithm are optimized.

14. The manufacturing system of claim 13 wherein said simulation model for fabrication and testing of said product includes equipment set-up, equipment break-down, and equipment repair.

15. The manufacturing system of claim 13 wherein the simulation model for fabrication and testing of said product includes a probability factor for unanticipated interruption for fabrication and test of high priority product.

16. The manufacturing system of claim 13 wherein the simulation model for fabrication and testing of said product is described as a Petri-Net model to express the function of the process equipment during fabrication and test of said product.

17. A medium for retaining a computer program for scheduling fabrication and testing of product within a manufacturing line, said computer program executed on a computer system performs the program process comprising the steps of:

a) creating a process equipment model for equipment and processes within said manufacturing line;

b) generating a potential product dispatch schedule for product to be fabricated within said manufacturing line;

c) defining an equipment dispatch schedule for equipment employed in fabrication and testing of said product to be fabricated according to said product dispatch schedule;

d) simulating said potential product dispatch schedule;

e) determining if said potential product dispatch schedule is optimized;

f) if said product dispatch schedule is not optimized, generating another potential product dispatch schedule for said product and performing steps b) through e); and

g) if said product dispatch schedule is optimized, dispatching said products for fabrication and test according to said schedule;

wherein the process equipment model is described as a Petri-Net model to express the function of the process equipment during fabrication and test of said product.

18. The medium for retaining a computer program of claim 17 wherein said process equipment model includes equipment set-up, equipment break-down, and equipment repair.

19. The medium for retaining a computer program of claim 17 wherein the process equipment model includes a probability factor for unanticipated interruption for fabrication and test of high priority product.

20. The medium for retaining a computer program of claim 17 wherein the program further comprises the steps of:

determining if said equipment dispatch schedule is to be changed; and

if said equipment dispatch schedule is to be changed, modifying said equipment dispatch schedule and performing steps d) through g).