Supply chain control: Trade-offs and system requirements

The official published version can be accessed from the link below.A paper describes the underlying forces which drive change in manufacturing enterprises and supply chains. It sets out the complexities in modern capitalism and global economics and illustrates the trade-offs that can be made. IT systems which are required to assist improvements to both customer service and enterprise manufacturing performance are explained, alluding to the special case for the semiconductor industry. Arguments are presented showing how the new tools being developed with the ESPRIT project 20544, X-CITTIC, will satisfy the control needs for a virtual enterprise. This paper describes the underlying forces which drive change in manufacturing enterprises and supply chains. It sets out the complexities in modem capitalism and global economics and illustrates the trade-offs that can be made. IT systems which are required to assist improvements to both customer service and enterprise manufacturing performance are explained alluding to the special case for the semiconductor industry. Finally it shows how the new tools being developed with the ESPRIT project 20544, XCITTIC, will satisfy the control needs for a virtual enterprise

Balancing labor requirements in a manufacturing environment

“This research examines construction environments within manufacturing facilities, specifically semiconductor manufacturing facilities, and develops a new optimization method that is scalable for large construction projects with multiple execution modes and resource constraints. The model is developed to represent real-world conditions in which project activities do not have a fixed, prespecified duration but rather a total amount of work that is directly impacted by the level of resources assigned. To expand on the concept of resource driven project durations, this research aims to mimic manufacturing construction environments by allowing a non-continuous resource allocation to project tasks. This concept allows for resources to shift between projects in order to achieve the optimal result for the project manager. Our model generates a novel multi-objective resource constrained project scheduling problem. Specifically, two objectives are studied; the minimization of the total direct labor cost and the minimization of the resource leveling. This research will utilize multiple techniques to achieve resource leveling and discuss the advantage each one provides to the project team, as well as a comparison of the Pareto Fronts between the given resource leveling and cost minimization objective functions. Finally, a heuristic is developed utilizing partial linear relaxation to scale the optimization model for large scale projects. The computation results from multiple randomly generated case studies show that the new heuristic method is capable of generating high quality solutions at significantly less computational time”--Abstract, page iv

Analyse eines digitalen Zwillings zur zeitkontinuierlichen Batchoptimierung in der Halbleiterfertigung

Motivated by the ongoing growth in demand for microchips, high production costs and the complex interplay of human, machine, material and method (4M), suppliers strive to develop more advanced production planning and control regimes for semiconductor production. Batching decisions often dramatically influence the overall performance of wafer fabs in terms of capacity utilization, due date compliance, cycle time and variability. To optimize such processes, we present an integrated testbed for batch formation optimization. Using a simulation of multiple semiconductor work centers, we explore how to optimize work in progress (WIP) flow with a continuous real-time scheduler and previously published batch formation heuristics. The proposed solver is designed to only optimize capacity-limited operations. By considering real-world operations requirements and semiconductor process specifics such as qualification criteria and re-entrance in our model, we demonstrate how to realize significant throughput gains. We explore and demonstrate the developed digital twin through a powerful BI frontend for historical analysis and real-time shop floor monitoring

Semiconductor Fab Scheduling with Self-Supervised and Reinforcement Learning

Semiconductor manufacturing is a notoriously complex and costly multi-step process involving a long sequence of operations on expensive and quantity-limited equipment. Recent chip shortages and their impacts have highlighted the importance of semiconductors in the global supply chains and how reliant on those our daily lives are. Due to the investment cost, environmental impact, and time scale needed to build new factories, it is difficult to ramp up production when demand spikes. This work introduces a method to successfully learn to schedule a semiconductor manufacturing facility more efficiently using deep reinforcement and self-supervised learning. We propose the first adaptive scheduling approach to handle complex, continuous, stochastic, dynamic, modern semiconductor manufacturing models. Our method outperforms the traditional hierarchical dispatching strategies typically used in semiconductor manufacturing plants, substantially reducing each order's tardiness and time until completion. As a result, our method yields a better allocation of resources in the semiconductor manufacturing process

Recent developments and future trends of industrial agents

The agent technology provides a new way to design and engineer control solutions based on the decentralization of control over distributed structures, addressing the current requirements for modern control systems in industrial domains. This paper presents the current situation of the development and deployment of agent technology, discussing the initiatives and the current trends faced for a wider dissemination and industrial adoption, based on the work that is being carried out by the IEEE IES Technical Committee on Industrial Agents

Intelligent shop scheduling for semiconductor manufacturing

Semiconductor market sales have expanded massively to more than 200 billion dollars annually accompanied by increased pressure on the manufacturers to provide higher quality products at lower cost to remain competitive. Scheduling of semiconductor manufacturing is one of the keys to increasing productivity, however the complexity of manufacturing high capacity semiconductor devices and the cost considerations mean that it is impossible to experiment within the facility. There is an immense need for effective decision support models, characterizing and analyzing the manufacturing process, allowing the effect of changes in the production environment to be predicted in order to increase utilization and enhance system performance. Although many simulation models have been developed within semiconductor manufacturing very little research on the simulation of the photolithography process has been reported even though semiconductor manufacturers have recognized that the scheduling of photolithography is one of the most important and challenging tasks due to complex nature of the process. Traditional scheduling techniques and existing approaches show some benefits for solving small and medium sized, straightforward scheduling problems. However, they have had limited success in solving complex scheduling problems with stochastic elements in an economic timeframe. This thesis presents a new methodology combining advanced solution approaches such as simulation, artificial intelligence, system modeling and Taguchi methods, to schedule a photolithography toolset. A new structured approach was developed to effectively support building the simulation models. A single tool and complete toolset model were developed using this approach and shown to have less than 4% deviation from actual production values. The use of an intelligent scheduling agent for the toolset model shows an average of 15% improvement in simulated throughput time and is currently in use for scheduling the photolithography toolset in a manufacturing plant

Serial-batch scheduling – the special case of laser-cutting machines

The dissertation deals with a problem in the field of short-term production planning, namely the scheduling of laser-cutting machines. The object of decision is the grouping of production orders (batching) and the sequencing of these order groups on one or more machines (scheduling). This problem is also known in the literature as "batch scheduling problem" and belongs to the class of combinatorial optimization problems due to the interdependencies between the batching and the scheduling decisions. The concepts and methods used are mainly from production planning, operations research and machine learning