manufacturing execution breakout - sapfm.sap.com/pdf/10306/mfg breakout semico ivn.pdf · fall 2007...
TRANSCRIPT
Manufacturing Execution Breakout
SEMICONDUCTOR INDUSTRY VALUE NETWORK
Introductions & ObjectivesToday –Existing Capabilities in ERP
Manufacturing Execution Breakout
New – Streamlined for Fabless
Open Discussion Time & Next StepsManufacturers – Adaptive Manufacturing (Intro)
Manufacturing Execution Breakout
Part of a Series of Topics Summer 2007 Supply Chain Round TableFocus on Planning & Collaboration
Today Represents Next Round of DiscussionFall 2007 Manufacturing Execution BreakoutFocus on Production & Order Execution
Spring Benchmarking & Best Practice RoadshowFocus - Supply Chain or Manufacturing
Summer 2008Open for Next Round of DiscussionsIdeas – Include S&OP, Fulfillment, Update on CollaborationWho Would You Like to Hear From?
Breakout Objectives
Discussion on Standard SAP ExecutionFocus More on FablessWhat Exists Today in SAP ERP (MM, PP)?
Streamlined Improvements on Standard New Package to Streamline Based on NVIDIA ModelFocus on Specific Pain Points for Fabless
Adaptive Manufacturing Intro− What is SAP Adaptive Manufacturing− Open Q&A
Key Topics Focused on Manufacturing Execution
Make
Move
Buy
Plan
Sell
Innovate
Service
Comply
Introductions & ObjectivesToday –Existing Capabilities in ERP
Manufacturing Execution Breakout
New – Streamlined for Fabless
Open Discussion Time & Next StepsManufacturers – Adaptive Manufacturing (Intro)
Fabless Supply Chain Model
Wafer Fab Sort Die Bank Assembly
Finish GoodsTest
Production Order
Die Bank•10 Sort
•Purchase Order•Receipt•Auto Payment
•Production Yields•Lot Progress•WIP Costing•Wafer Lot Trace
Production OrderG87-1339C-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
Purchase OrderWafer/Die•Drop Ship•Receipt•Auto Payment•Lot Trace
Contract•Price•Amount $ Limit•Period of Perf•Release Hist
PO Release•Assy/ Test Price•Additional Svs•Auto Payment•Lot Trace•Accounts Pay.
Assign Binning
Issue PO to Supplier
Move to Diebank FAB Receipt
FAB Purchase
KnowKnow ActAct
DecideDecide
Cost Variance
Capacity Management
Release Assembly Orders
Check BOM
Lot Status Genealogy
Scheduling
Assembly Release – Production Order and PO
Production ReceiptsKnowKnow ActAct
DecideDecide
Production Yields, Mfg Area Move (Rosetta net 7B1)
Quality Assurance
Order Placement
Catalog selection
Receipt Confirmation
Account coding
Create Order or request
MRO – non inventory items
eWorkflow Approval
KnowKnow ActAct
DecideDecideInvoice / Payment
Capacity Management
Release Rework Orders
Check BOM
Lot Status Genealogy
Scheduling
Rework and Retest
Production ReceiptsKnowKnow ActAct
DecideDecide
Production Yields, Mfg Area Move (Rosetta net 7B1)
Lot Move
Process Routing
Subcontract Assembly and Test can be defined and tracked for each lot. Multiple subcontract vendors can be defined for each device.
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.
Bill of Materials – Component Scrap %
Component scrap rates can be defined on the BOM, along with co-products.
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.
Work Order WIP Cost – Material and Services
Assembly and Test services can be captured by Work Order lot. Plan and actual cost
Subcontractor Scheduling and Capacity
Subcontractor scheduling and capacity planning can be depicted from load and Gantt charts.
Statistical Process Control - QA
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.
Binning to Different Part number/lot split
Binning and splits can be transacted with complete trace and genealogy.
Lot Genealogy Trace
Lot Test and QA Results
Lot QA Parameters and lot disposition
Trace to Foundry Source
Introductions & ObjectivesToday –Existing Capabilities in ERP
Manufacturing Execution Breakout
New – Streamlined for Fabless
Open Discussion Time & Next StepsManufacturers – Adaptive Manufacturing (Intro)
Fabless Manufacturing Processes
PeriodicWIP Status
Demand
ManagementMRP
Foundry
SubCon
Warehouse
Order Complete
Demand Plan
Purchase Requirements for Wafers
Purchase Order for Wafers
Advanced Shipment Notice (ASN)Planned order
for Devices
Lot Assignment
Create Purchase/Production Order
Close Purchase Order
Cost the Production Order
Close the
Production Order
(Rosettanet 7B1)
Ship the Dies with Wafer Maps
Ship
Purchase Order + WIP Feed
• Master Data Management
• Lot Genealogy
• Lot Split & Lot Merge
Capacity Management
Release Assembly Orders
Check BOM
Lot Status Genealogy
Scheduling
SAP Fabless Manufacturing
Production ReceiptsKnowKnow ActAct
DecideDecide
Production Yields, Mfg Area Move (Rosetta net 7B1)
Quality Assurance
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
SAP Fabless Manufacturing – Functionality
Master Data MaintenanceBill of Material with Time Phased YieldsAbility to maintain Test programs with versionAbility to maintain multiple substrates
Automated Build ProcessesAutomates creation of Production Order and PO for Tracking and Costing Visibility of lots in Die Bank of the CM and allocation to ProductionAutomates issue of components
WIP TrackingIntegration with Subcontractors using 7B1 Template for tracking (64 fields)
Lot GenealogyProduct CostingLot Split & Merge
Geared towards Fabless Manufacturing BOM Mass transaction to create time phase yield BOMFinal Test Program and SLT program details can be capturedTime phased Yields in calculation of to determine BOM base quantity Options to have different yield percentage and co-product for each weekBinning information stored for each co-productTemplate Workflow for BOM release process Alternate substrate option as an input component
Master Data Maintenance - BOM
Bom_demo.exe
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
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
Contact
Mark DavidSAP America
PrincipalHi Tech Industry
Cell:(415)216-7414Email: [email protected]
Brian KrpecDirector, Sales and Business Development
Performix IncTel: (512)732-9889
[email protected] Manufacturing Excellence
Introductions & ObjectivesToday –Existing Capabilities in ERP
Manufacturing Execution Breakout
New – Streamlined for Fabless
Open Discussion Time & Next StepsManufacturers – Adaptive Manufacturing (Intro)
SAP Adaptive Manufacturing – IDM’s
Enterprise ERP (SAP)
Shop Floor
Plant
Asset Collection &Monitoring Tools (Open Integration)
Manufacturing Execution System (Open Integration)
Supply Network Collaboration
Asset Management and Optimization
VIP
VisibilityxMII
Manufacturing Execution(MES)
Partner
Assets Processes Products
Shop Floor Integration xMII
1) Manufacturing Execution
2) Manufacturing Visibility & Integration
3) Manufacturing Collaboration
CustomersSuppliers
Manufacturing Integration & IntelligenceMES Integration and Manufacturing Dashboard
Manufacturing Visibility
Configurable KPI and actionable manufacturing dashboard definition
Proactive notification and alerts
Drill down and route cause analysis
Open Manufacturing IntegrationEffectively integrate and aggregate shop floor systems
Enables ERP and Visualization
Connect both internal and external operations
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
KEY CAPABILITIES
Screen Shot
Manufacturing Execution Process Flows For Fabless Semiconductor
FAB PURCHASE ASSEMBLY
RELEASEMRORework
& Test
INNOVATIONS & EFFICIENCIES FOR FABLESS
SupplyNetwork Collab
PerformixxMES
• 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
Fab PurchaseRework & Test
Release Tracking
Assembly Release
STANDARD SAP ERP
Manufacturing Execution Process Flows For Manufacturers
FAB PURCHASE ASSEMBLY
RELEASEMRORework
& Test
ADAPTIVE MANUFACTURINGxMII Partner
MES• Focus on Manufacturing Effectiveness, Efficiency, Responsiveness & Cost• Enable the EnterpriseIntegration, Shop Floor
Visibility, Metrics, SPC,Actionable
Backend MES
STANDARD SAP ERP
Introductions & ObjectivesToday –Existing Capabilities in ERP
Manufacturing Execution Breakout
New – Streamlined for Fabless
Open Discussion Time & Next StepsManufacturers – Adaptive Manufacturing (Intro)
Benchmarking
Next Steps - 2008 Semiconductor Roadshow
Alignment, Update, & Recommendation1:1 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!
• FABLESS – Supply Chain Focus• iDM/ FAB-LITE – Adaptive
Manufacturing
Approach
Value
Best Practices • Industry Level Best Practices
• Clarification of Priorities & Pain Points
• Roadmap Priorities & Alignment• Solution Presentation & Update
P. 23
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HR Cost per Function
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$210
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$66
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$54$32
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Recruitm
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Training
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HR Strateg
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Personn
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Managem
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Relation
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Plannin
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Plannin
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Adminis
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Benefits
P lannin
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Attendan
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Average Q1
Company X
Includes Comprehensive Benchmarking & Recommendation Readout
Company-specific reportDetailed, confidential report comparing your performance to peers & best practices
1 2 One-on-one sessionExperts to align on priorities, challenges, and make recommendations
.
Performix, Inc.Strategic Overview
50Confidential & Proprietary
AgendaAgenda
IntroductionUnderstand SAP Solution at Champion About Performix DemoNext Steps
51
Performix, IncPerformix, 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.
52
Performix, Inc - VisionPerformix, 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
53
Performix xMES™ Product SuitesPerformix xMES™ Product Suites
54
Execution Engine
SAP R/3
Devices
Advanced Planning & Optimization (APO)
PP PPI
Electronic Work
Instruction (EWI)
MaterialManagement
Material Track & Trace
Weigh & Dispense
(W&D)
SAP xMII
Manufacturing Integration
Manufacturing Intelligence
Production Planning (PP)
PPDS
Performix xMESTM for Pharmaceuticals/Process
Master Data
SNPDemand Planning
Transactions DataPlan Data
Quality Management
OPC Standards
Performix S95/B2MML Connector
Performix OPC Connector
Compliance
ElectronicBatch
Records(EBR)
55
Execute SAP RecipeExecute SAP RecipeProduction
Performance in SAPProduction
Performance in SAP
SAP R/3 SystemSAP R/3 System
SAP xMII TransactionsSAP xMII Transactions
History RetrievalHistory
RetrievalRecipe
DownloadRecipe
DownloadMaster Data
Download
Master Data
DownloadRecipe UploadRecipe Upload
xMESxMES xRecipexRecipe
xBatchxBatchS88 DB S88 DB
Create/Modify SAP Recipe in xRecipe
SAP RecipeModified Recipe
Recipe Managementin SAP
Recipe Managementin SAP
Download Master Data
Download Plan and Recipe
Execute Recipe
Store Execution History in EBR
Retrieve Execution History from
xBatch
Performix xMES Composite App
S95/B2MML
56
Performix xMESTM ComponentsPerformix xMESTM Components
Workstep Execution
Engine
xRecipe
Allocation Engine
PP or
PPPI
Other Plant Systems
Process Control Systems
Master
Data
Containers
Material Lot Status
Browser UI
Material & Resource Details
Plan & Recipes
Status Monitoring
Engine
Batch History
PDA UI
Weigh Scales
& Dispensers
Label Printers
Forms UI
Barcode & RFID
Readers
xBatch (EBR)
Electronic Work
Instructions
xMES
57
Performix xMES™ : Extending the reach of SAPPerformix 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
58
Performix xRecipe TemplatesPerformix xRecipe Templates
59
Performix xRecipePerformix xRecipe
60
Performix xRecipe Phase ParametersPerformix xRecipe Phase Parameters
61
Log-inLog-in
62
Performix xMES Dynamic Regulatory ReportingPerformix xMES Dynamic Regulatory Reporting
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
ExecutionPipeline Execution Pipeline
In Graphical FormShowing Connections
ExecutionPointer
SelectionPointer
Color IndicatesExecution State
63
Performix xMES Exception TrackingPerformix xMES Exception Tracking
Icon IndicatesThat E-Signature
Is Required
Flag Color Indicates
Deviation State
IndicatesE-Signature Is Required Due to a Change
Indicates The Parameter
Value Is Invalid
64
Performix xMES Exception TrackingPerformix xMES Exception Tracking
Icon IndicatesThat E-Signature
Is Required
Flag Color Indicates
Deviation State
IndicatesE-Signature Is Required Due to a Change
Indicates The Parameter
Value Is Invalid
65
Phase Linkage DiagramPhase 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.
66
Execution of a PhaseExecution of a Phase
Execution proceeds further as all the work instruction associated with the phase are executed
by the operator, orchestrated by xMES.
67
Menu Items: Batch UnitMenu Items: Batch Unit
68
Menu Items: Running PhaseMenu Items: Running Phase
69
Menu Items: Available LotsMenu Items: Available Lots
70
Menu Items: Allocated LotsMenu Items: Allocated Lots
71
Menu Items: Material RequestsMenu Items: Material Requests
72
Performix xMES EBR (xBatch)Performix xMES EBR (xBatch)
XMIIVisualization
xMII xMESConnector
xMESxBatch
xMESEngine
Batch EventsPhase Report ParametersUser ActionsDeviationsResource EventsWIP Material Movement
xMESS95 PP-PIConnector
Recipes withOperations & PhasesRecipe ParametersReport Parameters
Order UpdateMaterial Update
xMII HistorianConnector
ProcessHistorian
73
PDA UI- LoginPDA UI- Login
74
PDA UI- Campaign OverviewPDA UI- Campaign Overview
75
PDA UI- Batch UnitsPDA UI- Batch Units
76
PDA UI- Expanded PhasesPDA UI- Expanded Phases
77
PDF UI-1PDF UI-1
78
PDF UI-2PDF UI-2
79
PDF UI-3PDF UI-3
80
Performix xMES Analytics Using SAP xMIIPerformix xMES Analytics Using SAP xMII
81
Performix Inc.9720 Beechnut, Suite# 114
Houston, Texas 77036
United States of America Tel: (713)995-8118
Fax (713)995-8150
Sham Afzalpurkar, CEO
(281)610-4164
Brian Krpec, Director Business Dev
(512)709-4704
www.performixinc.com
ContactsContacts