晶圓製造廠訂單抵換訂價機制之構建

Abstract

由於資訊的不透明，常會造成企業銷貨預測與市場實際需求有所差異。如何妥善因應顧客因策略更動而提出之插換單需求，快速評估生產面與成本面變動，制定合適的抵換方案及換單價格，將是企業追求服務品質提升，維持系統最終獲利所必需考量的一項重要因子。 針對上述問題，本文以系統化的觀點，提出晶圓製造廠訂單抵換的定價機制，期使晶圓製造業者在面臨顧客提出的插換單要求時，能依據廠內之生產特性及產能，進行最合理的調度，同時在滿足顧客需求與維持系統穩定的前提下，設定合適的插入工單的抵換價格，以獲取利潤。 本文基於限制理論的管理概念，以關鍵資源為監控重點，分為三大模組進行定價相關的規劃作業： 1.「產能定價模組」－首先透過系統轉換成本之分攤，配合各規劃工單的製程結構及產能耗用狀況，推估工單於定價關鍵資源的基本產能成本。接著，應用動態瓶頸法，依照工單的緊迫度因子與等級優勢加價因子，推算工單因等級別而縮減等候時間所應付出的補償成本。最後，累加各項成本並以成本加價法來設定工單的基本產能價格。 2.「抵換價格訂定模組」－當面臨插換單需求時，首先應用郭氏[24]之「訂單抵換機制」分析、比較關鍵資源產能供需的方式，獲取初步的候選工單。接著，考量工單等級別、瓶頸機種產能供需區間、候選工單可釋放時點、產品族之異同、候選工單的基本價格與已耗用產能成本等因子，篩選出最適的抵換方案。最後，根據抵換作業將所造成的產能及成本之變動，制定插入工單所應負擔之抵換價格。 3.「抵換評估模組」－依據抵換方案進行重排程及異動結果之績效評估。 模擬結果顯示，應用本文的訂單抵換定價機制，不僅能將等級別對於等候時間的影響反應至工單基本價格中，也可以快速搜尋出合適的抵換方案，進而設定插單的抵換價格。對於生產系統整體而言，所選取之抵換方案對生產績效及淨利之保障，有相當的成效，亦實現實質的抵換獲利。

Because of information uncertainty, there is often a variance between sales forecast and real market demand. How to respond to the need of order exchange from customers, to analyze the impact to production and cost, and to design an appropriate order exchange plan and order exchange price, have become an important task for enterprises in pursuing higher service quality and ultimate profit maximization. To solve the above problems, this thesis will base on a systematic viewpoint to propose a pricing mechanism for order exchange in wafer fabrication. When a wafer manufacturer faces an order exchange demand from a customer, it can base on the production characteristics and capacity of the fab to proceed an appropriate adjustment. By both satisfying customer demand and maintaining system stabilization, the mechanism will help determine an order exchange price of inserting order so that a higher profit can be achieved. This thesis will base on the management concept of theory of constraint (TOC) and use critical resources as our monitoring emphasis. Three modules are introduced for the pricing mechanism: 1. Capacity pricing module – Based on the allocation of system conversion cost, process of each planned order and the capacity usage, it estimated first the unit capacity usage cost of each critical resource. Next, bottleneck dynamics method will be applied to calculate the compensation cost of reducing queueing time because of higher priority based on an order’s urgency factor and value-added factor of higher priority. Then, all cost factors will be summarized to get the capacitated cost of each priority order. Based on markup method, the basic capacity price for each order can be determined. 2. Order exchange pricing module – When facing an order exchange need, a preliminary order nominee list will be obtained based on the analysis of order exchange mechanism proposed by Kuo[24] and the capacity loading comparison of critical resources. Next, factors such as priority levels of orders, capacity supply and demand of bottleneck machines, releasing time of nominee orders, difference among product families, basic price of nominee order, and exhausted capacity cost, will be considered to find the most appropriate order exchange plan. Then, based on the change of capacity and cost due to order exchange activity, an exchange price of inserting order will be determined. 3. Order exchange evaluation module – Based on the order exchange plan, a rescheduling will be proceeded, and performance evaluation is conducted. The simulation results showed that pricing mechanism for order exchange not only can reflect the impact of priority level to queueing time into the basic order price, it can also search an appropriate order exchange option quickly and determine the order exchange price. For the production system, the overall performance and net income can be protected by the order exchange plan, and the profit of order exchange can be realized.