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題名：雙子星晶圓廠之生產支援決策模式
作者：盧俊偉
作者(外文)：Lu, Chun-Wei
校院名稱：中華大學
系所名稱：科技管理博士學位學程
指導教授：杜瑩美
學位類別：博士
出版日期：2013
主題關鍵詞：自動化搬運系統產能決策；產能支援；績效評估模式；AMHS capacity policy decision；Capacity backup；Performance estimation model
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近年來在半導體產業機台設置費逐漸升高以及產品毛利率逐漸下滑的趨勢下，管理者對於未來的新建廠房之概念也漸漸有所轉變，從原先的單一廠房概念逐漸轉型為雙子星廠之建廠模式。所謂雙子星晶圓廠通常位於同一地理位置且產能技術上之配置通常存在著一定的差異性，因此為了提高整體之績效表現以及符合市場之需求變化，廠區之間可以透過自動化搬運系統達到產能互相支援之行為，以解決暫時性產能不足或是機台負荷不平衡等問題。有鑒於此，本研究主要是針對雙子星晶圓廠環境提出一套有效之生產管控決策模式，以解決面對上述之相關問題時能有一系統性之決策參考依據。
本研究將從生產系統績效角度提出有相關之生產支援決策之模式架構。首先，針對自動化搬運系統之產能進行規劃，以了解欲進行生產支援時各廠區應保有多少自動化搬運系統產能。另一方面，關於產能支援決策則是包含產能支援時間點與支援效益觀點等方向進行探討與研究，制定良好的產能支援流程邏輯以協助管理者進行管控。接著針對雙子星晶圓廠在生產支援情況下，建構其相關之績效預估模式，運用先前提出之管控機制，藉由修正傳統等候模型等方式著手發展出較準確之預估模式。
最後透過數值範例、統計分析與模擬系統之配合，針對各模式進行相關之驗證與實驗探討，其結果顯示各模式皆能有效達到相關之表現，如以最少車輛數達到生產系統較佳之產出量與產品生產週期時間，透過產能支援管控模式使得工件生產週期時間與瓶頸工作站前WIP皆有所改善，以及在產能支援之生產績效預估上亦有不錯的準確度。
藉由上述三大方面之考量，發展建立一套有效的雙子星生產支援決策模式，最終協助管理者得以使雙子星晶圓廠之生產效能與績效能夠得到充分的利用，提高公司於市場上之利潤與競爭力。
Semiconductor manufacturing is one of the most complicated industries in the world. In order to reduce some facility costs and increase production flexibility, twin-fab concept has been established over the past decade, which means two neighboring fabs can be connected to each other by automatic material handling system (AMHS). Through the design of twin-fab, the manufacturing performance of two fabs, such as total throughput and products’ cycle times, can be improved and enhanced effectively by different capacity backup policies. However, if lacking of completed production planning and control models, the benefit of twin-fab will be decreased significantly.
In this study, a completed production planning and control model for capacity backup of twin fabs is developed. There are three modules included in the proposed model, AMHS capacity determination module, capacity backup module and performance estimation module. The AMHS capacity determination module helps to set up the suitable AMHS capacity for each fab of twin fabs under the purpose of maintaining the originally designed optimal production throughput or cycle time of products. Therefore, a GI/G/m queuing model based on FCFS (First-come-first-serve) dispatching rule of AMHS is applied to determine the required number of vehicles. Regarding to the capacity backup module, the control policy of capacity support is established and two control thresholds are developed. The concept of protective capacity and GI/G/m queuing model were utilized to design these two control thresholds. Moreover, the performance evaluation model is proposed to estimate the whole production performance of twin fabs under backup policy. The queuing theory and Little’s Law are applied to the estimation model.
Finally, the numerical experiment, statistical analysis and simulation system are used to validate the proposed model. The result showed that each module can achieve the research targets. The better cycle times and throughput can be reached by using less AMHS capacity. The WIP (work in process) of the bottleneck for twin fabs can be improved by the capacity backup module. The production performance under capacity backup policy can be estimated accurately.
Based on the production planning and control model, the machines blocking and starving phenomena will be avoided and it will result in reducing the cycle time of products and increasing the total throughput of twin fabs.
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