Manufacturing Execution Breakout - SAPfm.sap.com/pdf/10306/Mfg Breakout Semico IVN.pdf · Fall 2007...

Manufacturing Execution Breakout

SEMICONDUCTOR INDUSTRY VALUE NETWORK

Introductions & ObjectivesToday –Existing Capabilities in ERP


New – Streamlined for Fabless

Open Discussion Time & Next StepsManufacturers – Adaptive Manufacturing (Intro)


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

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


Scheduling

Rework and Retest


DecideDecide


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

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


Scheduling

SAP Fabless Manufacturing


DecideDecide


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

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

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

HR Cost per Employee ($)

HR Cost per Function

$231

$301

$210

$119

$66

$0

$239

$54$32

$219

$22 $11$0

$26

$78

$0

$50

$100

$150

$200

$250

$300

$350

$400

$450

$500

Recruitm

ent & Staff

ing

Training

& Develop

mentEmplo

yee Reloc

ation

HR Strateg

y

Personn

el Data

Managem

entLabor

Relation

sBene

fits Adm

inistra

tionPayr

oll Adm

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ion

Strateg

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urces

Plannin

g

Pension

Plans A

dminis

tration

Compen

sation

Plannin

g

Compen

sation

Adminis

tration

Benefits

P lannin

gTime &

Attendan

ceExit

Managem

ent

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)

http://www.sap.com/index.epx


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

[email protected]

(281)610-4164

Brian Krpec, Director Business Dev

[email protected]

(512)709-4704

www.performixinc.com

ContactsContacts

Manufacturing Execution Breakout - SAPfm.sap.com/pdf/10306/Mfg Breakout Semico IVN.pdf · Fall 2007...

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Transcript of Manufacturing Execution Breakout - SAPfm.sap.com/pdf/10306/Mfg Breakout Semico IVN.pdf · Fall 2007...