控制生產週期時間之產能規劃機制

Abstract

本論文提出AT（Allowance Time）概念，並用此概念來發展一適用於接單的產能規劃系統。 在典型晶圓代工廠的產能規劃系統中，產能分配方式是以工單的純加工時間來佔用機台的產能。工單一旦佔用機台產能後，其在機台上所佔用的產能位置便固定了，而不能任意更動。換句話說，工單在機台上的開始和結束加工的時點在規劃時已經固定了。 而AT（Allowance Time）概念則是以一大於工單純加工時間的時間範圍來決定工單在機台上可以佔用產能的範圍，讓工單在產能分配時，可以在此一範圍內任意佔用機台的產能，也就是說，工單佔用機台產能的位置並沒有固定。所以，工單在機台上所佔用的產能位置能夠微調，能讓更多的工單分配到機台上加工，達到更高的機台利用率。 根據AT概念，本論文發展一控制生產週期時間的產能規劃原型系統。同時據此產能規劃機制，建立一適用於接單的快速接單機制。

In this thesis, a novel concept known as AT (Allowance Time) is proposed for developing an effective capacity planning system for the justification of order acceptance. In a typical capacity planning system used in IC foundry, traditional ways to allocate resource to a particular job is by allocating a fixed time interval equal to the processing time of the job. That is, the starting time and ending time of utilizing the resource by the particular job has been fixed when the job has been planned. The AT concept proposes that the resource time allocated to a particular job should be larger than its processing time so the job can 'float' in the capsulated time interval even when it has been planned. That is, the resource time can be slightly reallocated so that more jobs can be assigned to the resources and achieve higher utilization of resources. According to the concept of AT, we have developed a cycle time based capacity planning prototype system. Based on the capacity planning mechanism, a quick response mechanism for order acceptance justification has also been established. 1.1 研究背景與動機................................................................1 1.2 研究目的............................................................................2 1.3 研究範圍與限制................................................................2 1.4 研究方法與步驟................................................................3 第二章 文獻探討...................................................................................4 2.1 相關文獻的整理與分析....................................................4 2.1.1 排程方法回顧.........................................................4 2.1.2 產能規劃相關文獻.................................................5 2.2 A公司P軟體規劃方式、功能及優缺點解析...................10 2.2.1 P軟體之架構...........................................................10 2.2.2 P軟體之規劃流程...................................................14 2.2.3 以P軟體做規劃的優缺點.......................................16 2.3 B公司F軟體規劃方式、功能及優缺點解析....................20 2.3.1 F軟體之架構...........................................................20 2.3.2 F軟體之規劃流程...................................................20 2.3.3 以F軟體做規劃的優缺點.......................................26 第三章 AT產能規劃機制之構建..........................................................28 3.1 AT構想...............................................................................28 3.2 AT產能規劃機制之架構...................................................34 3.3 AT產能規劃機制之規劃流程...........................................35 3.3.1 Balance.....................................................................38 3.3.2 無限產能排單..........................................................38 3.3.3 產能填置..................................................................39 3.3.4 有限產能排單..........................................................46 3.3.5 『PULL』的概念和執行方式.................................46 3.3.6 AT產能規劃機制排程方式.....................................47 3.3.7 考慮多機台（Multi-Resources）的產能規劃機制.54 第四章 快速接單機制之構建...............................................................57 4.1 快速接單機制使用表格的建立........................................57 第五章 實例驗證...................................................................................63 5.1 與P軟體、F軟體的測試驗證............................................63 5.1.1 基本環境說明..........................................................63 5.1.2 相關資料說明..........................................................63 5.1.3 規劃結果分析..........................................................64 5.2 實際案例的執行................................................................67 第六章 結論與未來研究方向...............................................................72 6.1 結論....................................................................................72 6.2 未來研究方向與建議........................................................72 參考文獻.................................................................................................74 附錄1 P軟體排程演算法........................................................................76 附錄2 P軟體 Slack time的分配方式探討...............................................79 附錄3 P軟體在有multi-resources的情況下的規劃方式探討................86 附錄4 P軟體在有batch-resources的情況下的規劃方式探討...............88 附錄5 關於P軟體的Sequencing方式探討.............................................90 附錄6 F軟體在有multi-resources時的規劃方式探討.................92 附錄7 F軟體在有batch-resources時的規劃方式探討.................95 附錄8 F軟體的Sequencing方式探討...................................98 附錄9 產品製程資料..............................................................................99 附錄10 機台資料....................................................................................101