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Delivering Rapid Results

Delivering Rapid Results

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Delivering Rapid Results

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  1. Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Software Solutions for Manufacturing Operations -Rapid Implementation -Rapid Returns -Rapid Change Manufacturing Capacity Simulation, Scheduling, and Production Planning

  2. Products • Capacity Simulation • Utilize stochastic, discrete event simulation to determine the capacity of a facility. • Investigate product mix, machine setups, policies, staffing and their effect on cycle times, WIP, and throughput • Work Flow Scheduling • Starting with the current state of the factory, provide detailed schedules with which to control material movement over the next 1 to 48 hours • Production Planning • Starting with current factory or enterprise state, analyze the capability to meet demands over period of interest • Utilize backward scheduling of backlog, safety stock, and forecasted demands to determine anticipated ship dates, required start dates • Mapping finished goods and WIP to orders and identify shortages and constraints

  3. The Simulation Model Alternatives • Programming the Simulation “From Scratch” • General High Level Language [PASCAL, FORTRAN, C] or Simulation Language [SIMAN,SLAM-II] • Control over Program Logic • ManSim Simulation Software • No programming • Menu-driven, user friendly • Little training required • Easy to maintain • Designed specifically for semiconductor/high tech industry

  4. Why Simulate? • Most effective way to develop strategies for reducing cycle time, increasing output, and meeting on-time delivery • Cheaper and faster than monitoring history • Excellent learning tool • What is my capacity and where are the factory bottlenecks? • What will happen with a different product mix? • What will happen to lead-times when we change production facilities? • How can I plan output and equipment needs during a ramp? • Only planning methodology capable of providing feasible capacity loadings and work flow schedules in complex manufacturing environments

  5. Variability Makes Analysis More Difficult Examples of Stochastic Variables: • Equipment Failures • Scrap / Rework • Absenteeism • Test Times • Engineering Lots • Cycle Times • Material Shortages • Repair Times • Operator Assists • Yield Loss • Hardware Availability • Binning & Product Substitution Degree Of Difficulty When Analyzing A Problem Quantity of Stochastic Variables and their Interdependencies/ Interrelationships

  6. Model Types and the Ability to Analyze Dynamic Systems Model Type Opinion Models Spreadsheet Models Simulation Models Ability To Analyze Stochastic/Dynamic Systems Low Medium High

  7. Static Models vs. Simulation • Static Models overstate capacity and understate cycle time which can lead to shortages of equipment, high inventories and late shipments • Static models are inadequate to model the coordinated use of multiple resources • Simulation models calculate • Capacity • WIP • Cycle Time All of which take into account the interaction between lots, machines and people.

  8. What is a Discrete Event? • A Discrete Eventis an instantaneous action that occurs at a unique point in time. The occurrences of these events may cause the status of one or more resources to change. Such events are: • part arrivals • end of machine cycle • equipment failures • preventive maintenance (PM) • equipment repairs, etc. • operator available • A discrete event simulator is constantly generating and processing events.

  9. Every Time An Event Occurs . . . 1. The status of one or more resources is updated.2. The total time the above updated resources remained in the previous state is calculated & stored.3. One or more events are scheduled to happen in the future. Event Processing

  10. Operator Inputs: Recipe & Skills • Products in Q • Selection Rule Load Unload Process 1 2 • Type 1 • Min • UPH • Type 2 • Min. • Min. • Min. or 3 4 • Minutes • Type N • Min. 5 6 Work Station Simulation Clock: Event 3 Event 2 Event 4 Event 1 Simulation Logic: Update Select Prod 3 Reports Based on Priority Add Add Add Add 5 min. 5 min. 45 min. 5 min. Start Next 5 Products in Q Product • Average Times for Each Step and Q (Cycle Time) • Total of 1 Unit/Hour Throughput (Actual Capacity) • Q Size (Size of Overall Capacity Constraint) • Time to Completion or Time to Start (Schedule) • Utilization of Equipment and Operator (% Busy, Idle, Down) • Number of Products in Process (WIP) How Discrete Event Simulation Works How ManSim, TestSim Works (Multiply Times X Work Stations for a Factory Simulation) Next Work Station Outputs:

  11. ManSim – InputsFactory Data Model Definitions WORK AREAS • Number of operators by shift • Operator skill levels • Number of maintenance personnel by shift • Maintenance skill levels • Personnel Breaks • Operator Costs • Maintenance Costs WORK STATIONS • Workstation type: Batch, Serial, Part Sequential, Cluster, Tester, Handler/Prober, Burn-in oven, General purpose, Subcontractor • Assigned work areas • Rules Equipment Loading Setup • Max Queue Size/ JIT • Time required to load equipment • Time required to unload equipment • Preventive maintenance schedules • Load tools • Consumables PRODUCTS • Process used • Constant or variable lot size • Starts Constant rate Starts by planning period Demand by planning period Lot starts file Starts by day and time • Product type • Maximum allowable lots in factory • Priority class • Due date calculation factor • Initial WIP by process step • Process time by step • Hardware requirement by step PROCESS • Sequence of steps • Step definitions: Workstation Processing time Rework Percent Rework steps Yield loss Lot Scraps • Define equipment for step • Equipment Groups • Sub processes • Alternate Processing EQUIPMENT SPECIFIC DEFINITIONS • Mean time between failures • Mean time to repair • Load size in lots or parts • Process capacity in parts per hour • Capacity by product • Setup time for specification change • Initial equipment status condition • Engineering shutdowns

  12. ManSim – InputsFactory Operations Control - Rules PRODUCT RELEASE RULES • Product released uniformly into factory • Poisson distribution • User Lot Starts file • Maximum allowable lots in factory PRODUCTION CALENDAR • Days worked per week • Shifts worked by day • Hours worked per shift • Planning Periods EQUIPMENT LOADING RULE • Full load required • Attempt full load • Partial loads allowed • Batch multiple products EQUIPMENT SETUP RULES • Setup match required for both product type and specification code • Allow changeover if setup match not found • Setup match not required – process highest priority lot • Product type setup match required • Product type setup match if possible • Specification type setup match required • Specification setup match if possible DISPATCH RULESQUEUE PRIORITIZATIONS • First in first out • Shortest imminent processing • Shortest remaining processing • Least number of lots in next queue • Random • Earliest due date • Critical ratio • Slack • Time needed next workstation

  13. ManSim – InputsFactory Operations Control - Variation STOCHASTIC CAPABILITIES • MTBF/MTTR • MTBA/MTTA (A is Operator Assist) • PARTS PER HOUR • PROCESS TIME • PROCESS DELAY • YIELD • REWORK (% LOTS, %PARTS/LOT) • SCRAP • PM DURATION • LOT SIZE • SETUP TIME (BY TYPE) • SETUP TIME (BY PRODUCT SPEC) • EQUIPMENT PERCENT UP • TRANSPORT TIMES • PERSONNEL ABSENCE STOCHASTIC CAPABILITIES • EQUIPMENT PARAMETERS BY PRODUCT PARTS PER HOUR SETUP MTBA/MTTA • PRODUCT REVENUE/PART COST/PART % HOT LOTS VARIATION DURING SIMULATION TIME PERIODS • YIELD • REWORK • SCRAP • PARTS PER HOUR • PROCESS TIME

  14. ManSim – Outputs OPERATIONS • Average daily moves in lots and parts • Average WIP in lots and parts • Maximum WIP in lots and parts • WIP at end of each production period PRODUCTS • Throughput in parts per week • Calendar and production cycle times • Cycle time range/standard deviation • Throughput and cycle time by period • Parts out by planning period • WIP at end of planning periods • Average daily moves in lots and parts • Average WIP in lots and parts • Maximum WIP in lots and parts PROCESS • Cycle time by recipe step • Queue/delay times • Cumulative yield WORKSTATIONS • Throughput in parts per week • Throughput and utilization by period • Average load size • Average queue size • Maximum queue size • Throughput and utilization by product by period EQUIPMENT • Percentage of time busy • Percentage of time in setup • Percentage of time idle • Percentage of time down

  15. ManSim – Outputs PARAMETRIC CHARTS • WIP vs. time • Operation vs. time MAINTENANCE PERSONNELDETAILS BY SHIFT • Percent utilization • Average number of personnel available • Minimum number of personnel available • Average size of repair queue • Maximum size of repair queue • Average size of PM queue • Maximum size of PM queue OPERATOR DETAILS BY SHIFT • Percent utilization • Average number of operators available • Minimum number of operators available • Detail for skilled operators SCHEDULING DISPATCH LIST • Equipment allocation • Lot processing shift schedule • Operator schedule EVENT LOG • Lot histories • Equipment histories

  16. Planner – Outputs Product Substitution • Substituted Products to fulfill orders • Source of substituted products • Quantity claimed Unfilled Orders • Order and Customer ID • Type of product(s) ordered • Due date of orders • Shorts quantity Order Status Report • Order ID, Quantity, and due date • Type of product(s) ordered • Customers ID • Source of materials to satisfy orders • Required quantity versus claimed quantity • Date that order is fulfilled Late Orders List • Order ID, Quantity, and due date • Type of product(s) ordered • Source of materials to satisfy orders • Late Order quantity • Date that order is fulfilled Available To Promise • Type and quantity of product(s) available • Quantity of finished good • Quantity of initial inventory • Type and quantity of back orders • Throughput and Demand for every period

  17. Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Delivering Rapid Results Software Solutions for Manufacturing Operations -Rapid Implementation -Rapid Returns -Rapid Change Manufacturing Capacity Simulation, Scheduling, and Production Planning