Manufacturing Execution Breakout SEMICONDUCTOR INDUSTRY VALUE NETWORK

Transcription

1 Manufacturing Execution Breakout SEMICONDUCTOR INDUSTRY VALUE NETWORK

2 Manufacturing Execution Breakout Introductions & Objectives Today Existing Capabilities in ERP New Streamlined for Fabless Manufacturers Adaptive Manufacturing (Intro) Open Discussion Time & Next Steps

3 Manufacturing Execution Breakout Part of a Series of Topics Summer 2007 Supply Chain Round Table Focus on Planning & Collaboration Today Represents Next Round of Discussion Fall 2007 Manufacturing Execution Breakout Focus on Production & Order Execution Spring Benchmarking & Best Practice Roadshow Focus - Supply Chain or Manufacturing Summer 2008 Open for Next Round of Discussions Ideas Include S&OP, Fulfillment, Update on Collaboration Who Would You Like to Hear From?

4 Breakout Objectives Key Topics Focused on Manufacturing Execution Discussion on Standard SAP Execution Focus More on Fabless What Exists Today in SAP ERP (MM, PP)? Make Move Sell Service Streamlined Improvements on Standard New Package to Streamline Based on NVIDIA Model Focus on Specific Pain Points for Fabless Buy Innovate Plan Comply Adaptive Manufacturing Intro What is SAP Adaptive Manufacturing Open Q&A

6 Fabless Supply Chain Model Wafer Fab Sort Die Bank Assembly Test Finish Goods Purchase Order Wafer/Die Drop Ship Receipt Auto Payment Lot Trace Production Order Die Bank 10 Sort Purchase Order Receipt Auto Payment Production Yields Lot Progress WIP Costing Wafer Lot Trace Production Order G C-R33 Device FG 10 Assembly Purchase Order Receipt Auto Payment 20 Test Purchase Order Receipt Auto Payment Production Yields Lot Progress WIP Costing Die Bank Lot Trace Contract Price Amount $ Limit Period of Perf Release Hist PO Release Assy/ Test Price Additional Svs Auto Payment Lot Trace Accounts Pay.

7 FAB Purchase Issue PO to Supplier Decide Move to Diebank FAB Receipt Know Act Assign Binning Cost Variance

8 Assembly Release Production Order and PO Lot Status Genealogy Release Assembly Orders Decide Scheduling Capacity Management Production Receipts Know Act Check BOM Quality Assurance Production Yields, Mfg Area Move (Rosetta net 7B1)

9 MRO non inventory items Create Order or request Invoice / Payment Decide Account coding Catalog selection Receipt Confirmation Know Act Order Placement eworkflow Approval

10 Rework and Retest Lot Status Genealogy Release Rework Orders Decide Scheduling Capacity Management Production Receipts Know Act Check BOM Lot Move Production Yields, Mfg Area Move (Rosetta net 7B1)

11 Process Routing Subcontract Assembly and Test can be defined and tracked for each lot. Multiple subcontract vendors can be defined for each device.

12 Assembly Procurement in Routing Procurement data such as contract and pricing can be specified by routing operations. This will generate a Purchase Order from the release assembly Work Order.

13 Bill of Materials Component Scrap % Component scrap rates can be defined on the BOM, along with co-products.

14 Production Order Operation Yields Work Order operations can track subcontractor yields by operation and lot. Status such as HOLD can be defined for each lot/operation.

15 Work Order WIP Cost Material and Services Assembly and Test services can be captured by Work Order lot. Plan and actual cost

16 Subcontractor Scheduling and Capacity Subcontractor scheduling and capacity planning can be depicted from load and Gantt charts.

17 Statistical Process Control - QA

18 Lot Attribute Set Lot attributes can be freely defined for each device lot. These attributes can be further used in the tracking, quality and inventory allocation processes.

19 Binning to Different Part number/lot split Binning and splits can be transacted with complete trace and genealogy.

20 Lot Genealogy Trace

21 Lot Test and QA Results

22 Lot QA Parameters and lot disposition

23 Trace to Foundry Source

25 Fabless Manufacturing Processes Demand Plan Purchase Requirements for Wafers Purchase Order for Wafers Foundry Demand Management MRP Planned order for Devices Advanced Shipment Notice (ASN) Ship the Dies with Wafer Maps Lot Assignment Master Data Management Lot Genealogy Lot Split & Lot Merge Create Purchase/Production Order Close Purchase Order Cost the Production Order Close the Production Order Order Complete Purchase Order + WIP Feed Periodic WIP Status Warehouse (Rosettanet 7B1) SubCon Ship

26 SAP Fabless Manufacturing Lot Status Genealogy Release Assembly Orders Decide Scheduling Capacity Management Production Receipts Know Act Check BOM Quality Assurance Production Yields, Mfg Area Move (Rosetta net 7B1)

27 SAP Fabless Manufacturing Solution Pre-configured solution for Fabless Manufacturing Solution based on best manufacturing practices perfected by nvidia and other leaders Automated multiple transactions Ease of Use and Dashboard for planning Templates for integration with Contract Manufacturers

28 SAP Fabless Manufacturing Functionality Master Data Maintenance Bill of Material with Time Phased Yields Ability to maintain Test programs with version Ability to maintain multiple substrates Automated Build Processes Automates creation of Production Order and PO for Tracking and Costing Visibility of lots in Die Bank of the CM and allocation to Production Automates issue of components WIP Tracking Integration with Subcontractors using 7B1 Template for tracking (64 fields) Lot Genealogy Product Costing Lot Split & Merge

29 Master Data Maintenance - BOM Geared towards Fabless Manufacturing BOM Mass transaction to create time phase yield BOM Final Test Program and SLT program details can be captured Time phased Yields in calculation of to determine BOM base quantity Options to have different yield percentage and co-product for each week Binning information stored for each co-product Template Workflow for BOM release process Alternate substrate option as an input component Bom_demo.exe

30 Performix xmes Die Allocation & Release Dash board that gives visibility of demand and availability of dies Creates Turnkey, Multi site SNC Purchase Orders/Production Orders Ability to assign Die lots based on batch characteristics Flexibility in routing the co-products (Ship To Locations) Performs Auto GI for Die, Substrate and Memory components Ability to assign alternate substrates Creates Purchase Orders for Subcon service charges Assigns blanket PO for variable service charges Ability to capture special instructions for the multi Subcons

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39 SAP Fabless Manufacturing Solution Work in Process Tracking Provides visibility into in-process inventory in real time B2B feeds from Assembly & Test Operations using 7B1 Production Order and Purchase Order created to track WIP and Cost Integration with SNC for Subcon collaboration Automated Functions (GI..) Enables lot tracking Tracks Yields, On holds, Reworks and Scrap Enables Product Costing Facilitates Vendor payments

40 Contact Mark David SAP America Principal Hi Tech Industry Cell:(415) Brian Krpec Director, Sales and Business Development Performix Inc Tel: (512) Accelerating Manufacturing Excellence

42 SAP Adaptive Manufacturing IDM s Customers Supply Network Collaboration Suppliers Enterprise ERP (SAP) 3) Manufacturing Collaboration Plant Shop Floor Visibility xmii Shop Floor Integration xmii 2) Manufacturing Visibility & Integration Asset Collection & Monitoring Tools (Open Integration) Asset Management and Optimization VIP Manufacturing Execution System (Open Integration) Manufacturing Execution (MES) Partner 1) Manufacturing Execution Assets Processes Products

43 Manufacturing Integration & Intelligence MES Integration and Manufacturing Dashboard Improved CUSTOMER SERVICE by providing real-time visibility into manufacturing and quality status Increase MANUFACTURING EFFECTIVENESS, through proactive notification and tracking of manufacturing KPI s and statistical trends Open Manufacturing Integration Effectively integrate and aggregate shop floor systems Enables ERP and Visualization Connect both internal and external operations KEY CAPABILITIES Manufacturing Visibility Configurable KPI and actionable manufacturing dashboard definition Proactive notification and alerts Drill down and route cause analysis Screen Shot

44 Manufacturing Execution Process Flows For Fabless Semiconductor INNOVATIONS & EFFICIENCIES FOR FABLESS Supply Network Collab Fab Purchase Rework & Test Release Tracking Performix xmes Assembly Release Improved Support of Contract Mfg (Production Order vs. SNC Work Order) Better Collaboration & Condensed Cycle Times Streamlined ERP Processes for Fabless Reduction of Master Data & Setup Status Tracking & Alert Mgmt STANDARD SAP ERP FAB PURCHASE ASSEMBLY RELEASE Rework & Test MRO

45 Manufacturing Execution Process Flows For Manufacturers STANDARD SAP ERP FAB PURCHASE ASSEMBLY RELEASE Rework & Test MRO ADAPTIVE MANUFACTURING xmii Integration, Shop Floor Visibility, Metrics, SPC, Actionable Partner MES Backend MES Focus on Manufacturing Effectiveness, Efficiency, Responsiveness & Cost Enable the Enterprise

47 Next Steps Semiconductor Roadshow Value Benchmarking FABLESS Supply Chain Focus idm/ FAB-LITE Adaptive Manufacturing Best Practices Industry Level Best Practices Approach 1:1 Workshop intended to be business process focus to better understand your roadmap and pain points We do prep focusing content on your company in terms of a benchmarking survey We bring best practices & benchmarking aligned to your specific business Experts to provide an action plan! Alignment, Update, & Recommendation Clarification of Priorities & Pain Points Roadmap Priorities & Alignment Solution Presentation & Update

48 Includes Comprehensive Benchmarking & Recommendation Readout 1 Company-specific report Detailed, confidential report comparing your 2 performance to peers & best practices One-on-one session Experts to align on priorities, challenges, and make recommendations HR Cost per Function HR Cost per Employee ($) $500 $450 $400 Average Q1 $350 Company X $300 $301 $250 $231 $239 $210 $219 $200 $150 $100 $119 $78 $66 $26 $50 $54 $0 $32 $22 $11 $0 $0 Recruitment & Staffing Training & Development Employee Relocation HR Strategy Personnel Data Management Labor Relations Benefits Administration Payroll Administration Strategic Resources Planning Pension Plans Administration Compensation Planning Compensation Administration Benefits Planning Time & Attendance Exit Management P. 23

49 Performix, Inc. Strategic Overview.

50 Agenda Introduction Understand SAP Solution at Champion About Performix Demo Next Steps Confidential & Proprietary 50

51 Performix, Inc A Manufacturing Products and Solutions company Manufacturing Composite Apps for SAP eco system Focus on Pharmaceuticals, Process and Fabless Semiconductor industry verticals Currently deploying solutions for Fortune 100 companies Offices in Houston, Texas with development teams in Pune, India. 51

52 Performix, Inc - Vision To be a leading provider of manufacturing execution products and solutions by extending SAP functionality and leveraging SAP infrastructure Enhance SAP functionality to complete the MES solution Focus on Pharmaceutical, Process and Fabless Semi industry verticals 52

53 Performix xmes Product Suites 53

54 Performix xmes TM for Pharmaceuticals/Process SAP R/3 PP PPI Advanced Planning & Optimization (APO) Demand SNP PPDS Planning Production Planning (PP) Material Management Quality Management SAP xmii Manufacturing Intelligence Manufacturing Integration Master Data Transactions Data Plan Data Performix S95/B2MML Connector Material Track & Trace Weigh & Dispense (W&D) Execution Engine Compliance Electronic Work Instruction (EWI) Electronic Batch Records (EBR) Performix OPC Connector OPC Standards Devices 54

55 Performix xmes Composite App Recipe Production Management Execute SAP Recipe Performance in SAP in SAP Download Plan and Recipe Download Master Data SAP R/3 System SAP Modified Recipe Recipe SAP xmii Transactions History Retrieval Master Data Download Recipe Download Recipe Upload S95/B2MML Execute Recipe Retrieve Execution History from xbatch xmes xrecipe Create/Modify SAP Recipe in xrecipe Store Execution History in EBR S88 DB xbatch 55

56 Performix xmes TM Components Other Plant Systems PP or PPPI Batch History Plan & Recipes xrecipe xmes Browser UI PDA UI Forms UI Workstep Execution Engine Containers Barcode & RFID Readers Material & Resource Details Electronic Work Instructions Allocation Engine Process Control Systems Master Data Material Lot Status xbatch (EBR) Status Monitoring Engine Weigh Scales & Dispensers Label Printers 56

57 Performix xmes : Extending the reach of SAP Leverages SAP Functionality & Infrastructure (xmii) Small footprint and minimal configuration Rapid Deployment and Rollout Leverage SAP existing configuration Leverage of entire SAP Landscape From PLM through Plant Maintenance and Quality Mgmt, PP/PI and APO, for Manufacturing Execution 57

58 Performix xrecipe Templates 58

59 Performix xrecipe 59

60 Performix xrecipe Phase Parameters 60

61 Log-in 61

62 Performix xmes Dynamic Regulatory Reporting Execution Pointer Color Indicates Execution State Selection Pointer Execution Pipeline Execution Pipeline In Graphical Form Showing Connections Supervisor can facilitate the Re-Execution of any Phase Sequence by moving the execution pointer Supervisor Can Insert AdHoc Phases at the selection pointer Supervisor Can Switch Recipes at the selection pointer xbatch Electronic Record Reflects all changes 62

63 Performix xmes Exception Tracking Flag Color Indicates Deviation State Indicates The Parameter Value Is Invalid Icon Indicates That E-Signature Is Required Indicates E-Signature Is Required Due to a Change 63

64 Performix xmes Exception Tracking Flag Color Indicates Deviation State Indicates The Parameter Value Is Invalid Icon Indicates That E-Signature Is Required Indicates E-Signature Is Required Due to a Change 64

65 Phase Linkage Diagram The diagram shows a graphical representation of the entire execution pipeline. It will also show connections to other phases where material gets transferred. 65

66 Execution of a Phase Execution proceeds further as all the work instruction associated with the phase are executed by the operator, orchestrated by xmes. 66

67 Menu Items: Batch Unit 67

68 Menu Items: Running Phase 68

69 Menu Items: Available Lots 69

70 Menu Items: Allocated Lots 70

71 Menu Items: Material Requests 71

72 Performix xmes EBR (xbatch) Order Update Material Update xmes S95 PP-PI Connector xmes Engine Recipes with Operations & Phases Recipe Parameters Report Parameters Batch Events Phase Report Parameters User Actions Deviations Resource Events WIP Material Movement xmii xmes Connector xmes xbatch XMII Visualization xmii Historian Connector Process Historian 72

73 PDA UI- Login 73

74 PDA UI- Campaign Overview 74

75 PDA UI- Batch Units 75

76 PDA UI- Expanded Phases 76

77 PDF UI-1 77

78 PDF UI-2 78

79 PDF UI-3 79

80 Performix xmes Analytics Using SAP xmii 80

81 Contacts Performix Inc Beechnut, Suite# 114 Houston, Texas United States of America Tel: (713) Fax (713) Sham Afzalpurkar, CEO (281) Brian Krpec, Director Business Dev (512)