Simulation and optimization techniques applied in semiconductor assembly and test operations

The importance of back-end operations in semiconductor manufacturing has been growing steadily in the face of higher customer expectations and stronger competition in the industry. In order to achieve low cycle times, high throughput, and high utilization while improving due-date performance, more effective tools are needed to support machine setup and lot dispatching decisions. In previous work, the problem of maximizing the weighted throughput of lots undergoing assembly and test (AT), while ensuring that critical lots are given priority, was investigated and a greedy randomized adaptive search procedure (GRASP) developed to find solutions. Optimization techniques have long been used for scheduling manufacturing operations on a daily basis. Solutions provide a prescription for machine setups and job processing over a finite the planning horizon. In contrast, simulation provides more detail but in a normative sense. It tells you how the system will evolve in real time for a given demand, a given set of resources and rules for using them. A simulation model can also accommodate changeovers, initial setups and multi-pass requirements easily. The first part of the research is to show how the results of an optimization model can be integrated with the decisions made within a simulation model. The problem addressed is defined in terms of four hierarchical objectives: minimize the weighted sum of key device shortages, maximize weighted throughput, minimize the number of machines used, and minimize makespan for a given set of lots in queue, and a set of resources that includes machines and tooling. The facility can be viewed as a reentrant flow shop. The basic simulation was written in AutoSched AP (ASAP) and then enhanced with the help of customization features available in the software. Several new dispatch rules were developed. Rule_First_setup is able to initialize the simulation with the setups obtained with the GRASP. Rule_All_setups enables a machine to select the setup provided by the optimization solution whenever a decision is about to be made on which setup to choose subsequent to the initial setup. Rule_Hotlot was also proposed to prioritize the processing of the hot lots that contain key devices. The objective of the second part of the research is to design and implement heuristics within the simulation model to schedule back-end operations in a semiconductor AT facility. Rule_Setupnum lets the machines determine which key device to process according to a machine setup frequency table constructed from the GRASP solution. GRASP_asap embeds a more robust selection features of GRASP in the ASAP model through customization. This allows ASAP to explore a larger portion of the feasible region at each decision point by randomizing machine setups using adaptive probability distributions that are a function of solution quality. Rule_Greedy, which is a simplification of GRASP_asap, always picks the setup for a particular machine that gives the greatest marginal improvement in the objective function among all candidates. The purpose of the third part of the research is to statistically validate the relative effectiveness of our top six dispatch rules by comparing their performance on 30 real and randomly generated data sets. Using both GRASP and our ASAP discrete event simulation model, we have (1) identified the general order of dispatch rule performance, (2) investigated the impact of having setups installed on machines at time zero on rule performance, (3) determined the conditions under which restricting the maximum number of changeover affects the rule performance, and (4) studied the factors that might simultaneously affect rule performance with the help of a common random numbers experimental design. In the analysis, the first two objectives, weighted key device shortages and weighted throughput, are used to measure outcomes.Operations Research and Industrial Engineerin

Real-time multi-domain optimization controller for multi-motor electric vehicles using automotive-suitable methods and heterogeneous embedded platforms

Los capítulos 2,3 y 7 están sujetos a confidencialidad por el autor. 145 p.In this Thesis, an elaborate control solution combining Machine Learning and Soft Computing techniques has been developed, targeting a chal lenging vehicle dynamics application aiming to optimize the torque distribution across the wheels with four independent electric motors.The technological context that has motivated this research brings together potential -and challenges- from multiple dom ains: new automotive powertrain topologies with increased degrees of freedom and controllability, which can be approached with innovative Machine Learning algorithm concepts, being implementable by exploiting the computational capacity of modern heterogeneous embedded platforms and automated toolchains. The complex relations among these three domains that enable the potential for great enhancements, do contrast with the fourth domain in this context: challenging constraints brought by industrial aspects and safe ty regulations. The innovative control architecture that has been conce ived combines Neural Networks as Virtual Sensor for unmeasurable forces , with a multi-objective optimization function driven by Fuzzy Logic , which defines priorities basing on the real -time driving situation. The fundamental principle is to enhance vehicle dynamics by implementing a Torque Vectoring controller that prevents wheel slip using the inputs provided by the Neural Network. Complementary optimization objectives are effici ency, thermal stress and smoothness. Safety -critical concerns are addressed through architectural and functional measures.Two main phases can be identified across the activities and milestones achieved in this work. In a first phase, a baseline Torque Vectoring controller was implemented on an embedded platform and -benefiting from a seamless transition using Hardware-in -the -Loop - it was integrated into a real Motor -in -Wheel vehicle for race track tests. Having validated the concept, framework, methodology and models, a second simulation-based phase proceeds to develop the more sophisticated controller, targeting a more capable vehicle, leading to the final solution of this work. Besides, this concept was further evolved to support a joint research work which lead to outstanding FPGA and GPU based embedded implementations of Neural Networks. Ultimately, the different building blocks that compose this work have shown results that have met or exceeded the expectations, both on technical and conceptual level. The highly non-linear multi-variable (and multi-objective) control problem was tackled. Neural Network estimations are accurate, performance metrics in general -and vehicle dynamics and efficiency in particular- are clearly improved, Fuzzy Logic and optimization behave as expected, and efficient embedded implementation is shown to be viable. Consequently, the proposed control concept -and the surrounding solutions and enablers- have proven their qualities in what respects to functionality, performance, implementability and industry suitability.The most relevant contributions to be highlighted are firstly each of the algorithms and functions that are implemented in the controller solutions and , ultimately, the whole control concept itself with the architectural approaches it involves. Besides multiple enablers which are exploitable for future work have been provided, as well as an illustrative insight into the intricacies of a vivid technological context, showcasing how they can be harmonized. Furthermore, multiple international activities in both academic and professional contexts -which have provided enrichment as well as acknowledgement, for this work-, have led to several publications, two high-impact journal papers and collateral work products of diverse nature

Operational research IO 2021—analytics for a better world. XXI Congress of APDIO, Figueira da Foz, Portugal, November 7–8, 2021

This book provides the current status of research on the application of OR methods to solve emerging and relevant operations management problems. Each chapter is a selected contribution of the IO2021 - XXI Congress of APDIO, the Portuguese Association of Operational Research, held in Figueira da Foz from 7 to 8 November 2021. Under the theme of analytics for a better world, the book presents interesting results and applications of OR cutting-edge methods and techniques to various real-world problems. Of particular importance are works applying nonlinear, multi-objective optimization, hybrid heuristics, multicriteria decision analysis, data envelopment analysis, simulation, clustering techniques and decision support systems, in different areas such as supply chain management, production planning and scheduling, logistics, energy, telecommunications, finance and health. All chapters were carefully reviewed by the members of the scientific program committee.info:eu-repo/semantics/publishedVersio