CN105488579A - Production line balance based production capacity planning and optimization system and method - Google Patents
Production line balance based production capacity planning and optimization system and method Download PDFInfo
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention provides a production line balance based production capacity planning and optimization system and method. The system comprises an input module used for collecting machine production data and integrating the data, a calculation module used for calculating, simulating, optimizing and evaluating integrated data to obtain a production process and machine production capacity optimization scheme, and an output module used for outputting the optimization scheme. According to the production capacity planning and optimization system and method, associated production processes and production capacity as well as relative machine loads in a same unit are output by the system; corresponding relationships between all production processes and available machines are made into a data table by the system, and the data table can be linked to an existing production system and maintained; a shared frequency of the machines measured according to the production processes and a production process quantity shared according to the machines are calculated and analyzed, so that a most original and most important data basis is provided for production line balance planning and dynamic prediction; and meanwhile, a matched complete algorithm is provided subsequently and can be made into a system, thereby bringing convenience for optimization.
Description
Technical field
The present invention relates to semiconductor applications, particularly, the present invention relates to a kind of based on the capacity planning of line balancing and the system and method for optimization.
Background technology
The complicacy of semiconductor production is the diversity of product, the frequency of product mix change, and the product processing procedure production capacity expansion cycle is long, board and processing procedure corresponding relation are staggered in length and breadth etc., often there is entire plant production capacity and certain series products capacity planning deficiency, cause later stage production line production capacity uneven, board utilization factor difference is large, the problem that MPS and product mix change cannot be tackled in time, simultaneously for dynamic yields forecasting and the board production allocation deficiency of short-term, also board utilization factor difference can be caused to become large, cause capacity loss, have influence on production line whole machine balancing the most at last, the performance of the output linearity and maximum production capacity.
In order to solve the problem, existing usual way is: be responsible for by each district of manufacturing department subordinate and corresponding engineering department special messenger, for the heap goods processing procedure occurred in the recent period and the low board of utilization factor, the direction that Discuss and analyse board production capacity is launched and concrete scheme, and charge to board production capacity expansion planning electrical form, implement the later stage accordingly and launch plan.Afterwards, follow the tracks of production capacity launch progress by manufacturing department, reflection relevant issues, engineering department implements to launch action.Described method has suitable passivity, is substantially can make the property contained measure targetedly when problem has occurred or be about to occur.
Due to empirical judgement and estimation just based on the production capacity present situation of particular process or a small amount of product mix, lack quantitative analysis board being shared to degree by processing procedure, and the balance optimization to production capacity integrated planning, again run into same processing procedure heap goods, product line imbalance problem through the later stage of being everlasting.Described Normal practice lacks globality, perspective, quantification property, can not produce line and changes the production capacity brought and to be uneven weighing apparatus problem by Prediction and interference fast and effectively.
Therefore need to be improved further, to eliminate the problems referred to above current described method.
Summary of the invention
In summary of the invention part, introduce the concept of a series of reduced form, this will further describe in embodiment part.Summary of the invention part of the present invention does not also mean that the key feature and essential features that will attempt to limit technical scheme required for protection, does not more mean that the protection domain attempting to determine technical scheme required for protection.
The present invention, in order to overcome current existing problems, provides a kind of based on the capacity planning of line balancing and the system of optimization, comprising:
Load module, for collecting board production data and integrating described data;
Computing module, for being undertaken calculating, simulate, optimize and assessing by integrating the data obtained, to obtain the scheme that processing procedure-board production capacity is optimized;
Output module, for exporting the scheme of described optimization.
Alternatively, described load module comprises:
Data input cell, for collecting board production data;
Data Integration unit, for integrating described board production data, to obtain the data being applicable to described computing module.
Alternatively, described board production data comprises the production procedure of the current corresponding matrix system at goods, the in the recent period plan of rolling off the production line, each product processing procedure and available board, the classification of each board group and board list, board processing procedure unit-hour output and each product.
Alternatively, described computing module comprises:
Model creating unit, for setting up production model by integrating the data obtained;
Digital simulation unit, for carrying out simulated production to described production model;
Algorithm optimization unit, for being optimized described model;
Process assessment unit, for assessing the simulated production of described model, to obtain the scheme that processing procedure-board production capacity is optimized.
Alternatively, described output module comprises:
Optimum results unit, for exporting the scheme of described optimization;
Balancing programme unit, for finely tuning the scheme of described optimization.
Present invention also offers a kind of based on the capacity planning of line balancing and the method for optimization, comprising:
Step (a): collect board production data, and described data are integrated, to obtain the data being applicable to linear programming;
Step (b): the described data according to obtaining in step (a) carry out calculating, simulate, optimize and assessing, to obtain the scheme that processing procedure-board production capacity is optimized;
Step (c): export the scheme that the processing procedure-board production capacity obtained in step (b) is launched to optimize.
Alternatively, described step (a) comprises following sub-step:
Step (a-1): collect board production data;
Step (a-2): integrate described board production data, to obtain the data being applicable to described computing module.
Alternatively, described board production data comprises the production procedure of the current corresponding matrix system at goods, the in the recent period plan of rolling off the production line, each product processing procedure and available board, the classification of each board group and board list, board processing procedure unit-hour output and each product.
Alternatively, described step (b) comprises following sub-step:
Step (b-1): set up production model according to integrating the data obtained;
Step (b-2): simulated production is carried out to described model;
Step (b-3): described model is optimized;
Step (b-4): for assessing the simulated production of described model, to obtain the scheme that processing procedure-board production capacity is optimized.
Alternatively, the method setting up production model in described step (b-1) comprises:
Step (b-1-1): integrate in selecting step (a) the product processing procedure production capacity that obtains compared to demand production capacity 1/90% load breach array, with the common factor of board relative load in group compared to processing procedure corresponding to the difference array of average, part that processing procedure production capacity breach the best part is minimum with board relative load and board, set up programming evaluation equation;
Step (b-1-2): according to described solving equation, obtains the parameter of satisfactory optimization processing procedure-board capacity planning scheme.
Alternatively, the constraint condition in described step (b-1) is that processing procedure production capacity is not less than 1/90% of Production requirement, and board relative load is not less than 80% of average load.
Alternatively, described step (b-3) optimal anchor direction is that the board relative load coefficient of variation is less than 20%, and the coefficient of variation of processing procedure production capacity is less than 20%.
Alternatively, described step (c) comprises following sub-step:
Step (c-1): the scheme exporting described optimization;
Step (c-2): the scheme of described optimization is adjusted.
What system of the present invention exported is association processing procedure production capacity and the interior board relative load of same group, the corresponding relation of all processing procedures and available board is made into tables of data by described system, and existing production system and maintenance can be linked to, computational analysis goes out the board shared frequency weighed according to processing procedure, and according to the processing procedure quantity that board is shared, thus provide the most original most important data basic for streamline balance planning and performance prediction.Follow-up supporting a whole set of algorithm, can be made into system, for optimal design offers convenience simultaneously.
Accompanying drawing explanation
Following accompanying drawing of the present invention in this as a part of the present invention for understanding the present invention.Shown in the drawings of embodiments of the invention and description thereof, be used for explaining device of the present invention and principle.In the accompanying drawings,
Fig. 1-2 the present invention is based on the structural representation of the capacity planning of line balancing and the system of optimization;
Fig. 3 is for selecting board before and after system of the present invention to run and coefficient of variation contrast schematic diagram;
Fig. 4 is for selecting website operation trend contrast schematic diagram before and after system of the present invention.
Embodiment
In the following description, a large amount of concrete details is given to provide more thorough understanding of the invention.But, it is obvious to the skilled person that the present invention can be implemented without the need to these details one or more.In other example, in order to avoid obscuring with the present invention, technical characteristics more well known in the art are not described.
Should be understood that, the present invention can implement in different forms, and should not be interpreted as the embodiment that is confined to propose here.On the contrary, provide these embodiments will expose thoroughly with complete, and scope of the present invention is fully passed to those skilled in the art.In the accompanying drawings, in order to clear, the size in Ceng He district and relative size may be exaggerated.Same reference numerals represents identical element from start to finish.
The object of term is only to describe specific embodiment and not as restriction of the present invention as used herein.When this uses, " one ", " one " and " described/to be somebody's turn to do " of singulative is also intended to comprise plural form, unless context is known point out other mode.It is also to be understood that term " composition " and/or " comprising ", when using in this specification, determine the existence of described feature, integer, step, operation, element and/or parts, but do not get rid of one or more other feature, integer, step, operation, element, the existence of parts and/or group or interpolation.When this uses, term "and/or" comprises any of relevant Listed Items and all combinations.
In order to thoroughly understand the present invention, detailed step and detailed structure will be proposed in following description, to explain technical scheme of the present invention.Preferred embodiment of the present invention is described in detail as follows, but except these are described in detail, the present invention can also have other embodiments.
Embodiment 1
The present invention is in order to solve problems of the prior art, provide a kind of based on the capacity planning of line balancing and the system of optimization, by analyzing the existing supporting situation of board processing procedure production capacity completed, in conjunction with in the recent period in goods situation and following MPS and product mix situation, application linear programming, with reference to theory of control, graph theory critical path, Network Maximal-flow, drawer principle etc., calculate current according to all product mixes, the association processing procedure production capacity difference of portioned product combination and these three aspects of specific products, and measurable go out the adequacy of recent throughput requirements and future production demand and the goods in process inventory on the horizon (comingwip) according to each board, thus to make with present situation be the overall throughput equilibrium programming of starting point and specific products and combination production capacity equilibrium programming.
Described program results will be conducive to improving production line whole machine balancing, board utilization factor, improve the production cycle, strengthen linearization output.The output of this system is the processing procedure production capacity based on full factory product, the production capacity expansion optimized design scheme with board relative load optimization in group.
Particularly, as shown in Figure 1, described system comprises:
Load module, for collecting board production data and integrating described data;
Computing module, for calculating integrating the data obtained, to obtain the scheme that processing procedure-board production capacity is optimized;
Output module, for exporting the scheme of described optimization.
Wherein, described load module comprises data input cell and Data Integration unit.
Data input cell in described load module is for completing the collection of data, and as shown in Figure 2, described data comprise:
Described board production data comprises the production procedure of the current corresponding matrix system at goods, the in the recent period plan of rolling off the production line, each product processing procedure and available board, the classification of each board group and board list, board processing procedure unit-hour output and each product.
Wherein, described current at goods and real-time at goods, comprise in real time in number and the distribution of goods.
The described plan of rolling off the production line in the recent period comprises the plan of rolling off the production line of following first quarter moon or longer time.
Described board processing procedure unit-hour output comprises the production capacity hourly of particular process or the board demarcated by Industrial Engineering department.
The collection to board production related data can not only be realized at described load module, to integrate described data further in described Data Integration unit simultaneously, described integration is to process described data, to obtain the data being applicable to computing module.
Described computing module comprises: model creating unit, digital simulation unit, algorithm optimization unit and process assessment unit.
Wherein, described model creating unit, for setting up production model by integrating the data obtained, in this unit, choose integration and obtain data, such as product processing procedure production capacity compared to demand production capacity 1/90% load breach array, with the common factor of board relative load in group compared to processing procedure corresponding to the difference array of average, part that processing procedure production capacity breach the best part is minimum with board relative load and board, set up programming evaluation equation; According to described solving equation, obtain the parameter of satisfactory optimization processing procedure-board capacity planning scheme, by the solution obtained by described solving equation, set up production models.
Wherein, the constraint condition of described solving equation is that processing procedure production capacity is not less than 1/90% of Production requirement, and board relative load is not less than 80% of average load.
Described digital simulation unit, for carrying out simulated production to described model.
Algorithm optimization unit, for being optimized described model, its optimal anchor direction is: the board relative load coefficient of variation is less than 20%, and the coefficient of variation of processing procedure production capacity is less than 20%.
The coefficient of variation algorithm of relative load is:
Wherein, the goods in process inventory on the horizon of average each board in this board group of each concrete board of Xi=goods in process inventory on the horizon ÷.
Processing procedure production capacity coefficient of variation algorithm is:
Wherein, described X
ifor the list of product website technique production capacity, described Y
ifor product website technique board quantity.
Described process assessment unit, for assessing the simulated production of described model, to obtain the scheme that processing procedure-board production capacity is optimized.
Described output module comprises: optimum results unit, for exporting the scheme of described optimization;
Balancing programme unit, adjusts the scheme of described optimization.
What system of the present invention exported is association processing procedure production capacity and the interior board relative load of same group, the corresponding relation of all processing procedures and available board is made into tables of data by described system, and existing production system and maintenance can be linked to, computational analysis goes out the board shared frequency weighed according to processing procedure, and according to the processing procedure quantity that board is shared, thus provide the most original most important data basic for streamline balance planning and performance prediction.Follow-up supporting a whole set of algorithm, can be made into system, for optimal design offers convenience simultaneously.
Embodiment 2
The present invention is in order to solve problems of the prior art, provide a kind of based on the capacity planning of line balancing and the method for optimization, described method is by analyzing the existing supporting situation of board processing procedure production capacity completed, in conjunction with in the recent period in goods situation and following MPS and product mix situation, application linear programming, with reference to theory of control, graph theory critical path, Network Maximal-flow, drawer principle etc., calculate current according to all product mixes, the association processing procedure production capacity difference of portioned product combination and these three aspects of specific products, and measurable go out the adequacy of recent throughput requirements and future production demand and the goods in process inventory on the horizon (comingwip) according to each board, thus to make with present situation be the overall throughput equilibrium programming of starting point and specific products and combination production capacity equilibrium programming.Described program results will be conducive to improving production line whole machine balancing, board utilization factor, improve the production cycle, strengthen linearization output.The output of this system is the processing procedure production capacity based on full factory product, the production capacity expansion optimized design scheme with board relative load optimization in group.
Particularly, described method comprises:
Step (a): collect board production data, and described data are integrated, to obtain the data being applicable to linear programming;
Step (b): the integral data according to obtaining in step (a) calculates, to obtain the scheme that processing procedure-board production capacity is optimized;
Step (c): export the scheme that the processing procedure-board production capacity obtained in step (b) is launched to optimize.
Wherein, described step (a) comprises following sub-step:
Step (a-1): collect board production data;
Step (a-2): integrate described board production data, to obtain the data being applicable to described computing module.
Further, as shown in Figure 2, described collection board production data comprises:
Described board production data comprises the production procedure of the current corresponding matrix system at goods, the in the recent period plan of rolling off the production line, each product processing procedure and available board, the classification of each board group and board list, board processing procedure unit-hour output and each product.
Wherein, described current at goods and real-time at goods, comprise in real time in number and the distribution of goods.
The described plan of rolling off the production line in the recent period comprises the plan of rolling off the production line of following first quarter moon or longer time.
Described board processing procedure unit-hour output comprises the production capacity hourly of particular process or the board demarcated by Industrial Engineering department.
Integrate described data further in described step (a-2), described integration is to process described data, to obtain the data being applicable to computing module.
Described step (b) comprises following sub-step: step (b-1): set up production model according to integrating the data obtained;
Step (b-2): simulated production is carried out to described model;
Step (b-3): described model is optimized;
Step (b-4): for assessing the simulated production of described model, to obtain the scheme that processing procedure-board production capacity is optimized.
Wherein, for setting up production model by integrating the data obtained in described step (b-1), in this step, choose integration and obtain data, such as product processing procedure production capacity compared to demand production capacity 1/90% load breach array, with the common factor of board relative load in group compared to processing procedure corresponding to the difference array of average, part that processing procedure production capacity breach the best part is minimum with board relative load and board, set up programming evaluation equation; According to described solving equation, obtain the parameter of satisfactory optimization processing procedure-board capacity planning scheme, by the solution obtained by described solving equation, set up production models.
Wherein, the constraint condition of described solving equation is that processing procedure production capacity is not less than 1/90% of Production requirement, and board relative load is not less than 80% of average load.
In described (b-3), its optimal anchor direction is: the board relative load coefficient of variation is less than 20%, and the coefficient of variation of processing procedure production capacity is less than 20%.
The coefficient of variation algorithm of relative load is:
Wherein, the goods in process inventory on the horizon of average each board in this board group of each concrete board of Xi=goods in process inventory on the horizon ÷.
Processing procedure production capacity coefficient of variation algorithm is:
Wherein, described X
ifor the list of product website technique production capacity, described Y
ifor product website technique board quantity.
Described process assessment unit, for assessing the simulated production of described model, to obtain the scheme that processing procedure-board production capacity is optimized.
In an embodiment, as shown in Figure 2, in described step (b), calculate Real-time process-output list according to the production capacity per hour of the particular process of being demarcated by Industrial Engineering department or board, available board-product-technique website-technique contrasting data.
According to calculating following technique-production capacity list in 14 days at goods and following 14 days plans of rolling off the production line, Real-time process-output list and the coefficient of variation in real time.
Following production schedule technique-production capacity list is calculated according to MPS, Real-time process-output list and the coefficient of variation.
The load obtaining board load and the coefficient of variation according to following 14 days roll off the production line, obtain the production schedule according to machine utilization and the coefficient of variation, obtain board according to MPS, obtain the list of processing procedure production capacity breach, the list of machine utilization breach simultaneously, carry out the foundation of model according to the described data calculated.
Described step (c) comprises following sub-step:
Step (c-1): the scheme exporting described optimization;
Step (c-2): the scheme of described optimization is adjusted.
The corresponding relation of all processing procedures and available board is made into tables of data by the method for the invention, and existing production system and maintenance can be linked to, computational analysis goes out the board shared frequency weighed according to processing procedure, and according to the processing procedure quantity that board is shared, thus provide the most original most important data basic for streamline balance planning and performance prediction.Follow-up supporting a whole set of algorithm, can be made into system, for optimal design offers convenience simultaneously.
Embodiment 3
System of the present invention and described method all have good effect, as shown in Figure 3, be wherein gold-tinted DUV board at the board relative load comparison diagram in April and September, wherein, September is the load selecting system of the present invention or method, because described board load is higher, generally all can more than 100%, wherein the load of every platform is widely different, cause board that a lot of load is low can production period few, occur that entirety has higher load, local utilization ratio is low, but after system described in the application of the invention or method, the operation of each board brings up to 1422 from 1329, the coefficient of variation is down to 22.1% by 33.6%, improve 7% 34% respectively.
In addition, in another embodiment, as shown in Figure 4, the website operation trend form of website gold-tinted of attaching most importance to scanning processing procedure, has raising in various degree as can be seen from this figure, depends on the planning to gold-tinted processing procedure production capacity and improvement to a great extent.
In addition, when not buying new Al scanning machine, by systematized capacity planning and optimization, improve the production capacity of association processing procedure and improve the load unbalanced state of different platform, its output hits new peak repeatly, by 86185K added value 92170K, achieves the effect of highly significant.
The present invention is illustrated by above-described embodiment, but should be understood that, above-described embodiment just for the object of illustrating and illustrate, and is not intended to the present invention to be limited in described scope of embodiments.In addition it will be appreciated by persons skilled in the art that the present invention is not limited to above-described embodiment, more kinds of variants and modifications can also be made according to instruction of the present invention, within these variants and modifications all drop on the present invention's scope required for protection.Protection scope of the present invention defined by the appended claims and equivalent scope thereof.
Claims (13)
1., based on the capacity planning of line balancing and a system for optimization, comprising:
Load module, for collecting board production data and integrating described data;
Computing module, for being undertaken calculating, simulate, optimize and assessing by integrating the data obtained, to obtain the scheme that processing procedure-board production capacity is optimized;
Output module, for exporting the scheme of described optimization.
2. system according to claim 1, is characterized in that, described load module comprises:
Data input cell, for collecting board production data;
Data Integration unit, for integrating described board production data, to obtain the data being applicable to described computing module.
3. system according to claim 1 and 2, it is characterized in that, described board production data comprises the production procedure of the current corresponding matrix system at goods, the in the recent period plan of rolling off the production line, each product processing procedure and available board, the classification of each board group and board list, board processing procedure unit-hour output and each product.
4. system according to claim 1, is characterized in that, described computing module comprises:
Model creating unit, for setting up production model by integrating the data obtained;
Digital simulation unit, for carrying out simulated production to described production model;
Algorithm optimization unit, for being optimized described model;
Process assessment unit, for assessing the simulated production of described model, to obtain the scheme that processing procedure-board production capacity is optimized.
5. system according to claim 1, is characterized in that, described output module comprises:
Optimum results unit, for exporting the scheme of described optimization;
Balancing programme unit, for finely tuning the scheme of described optimization.
6., based on the capacity planning of line balancing and a method for optimization, comprising:
Step (a): collect board production data, and described data are integrated, to obtain the data being applicable to linear programming;
Step (b): the described data according to obtaining in step (a) carry out calculating, simulate, optimize and assessing, to obtain the scheme that processing procedure-board production capacity is optimized;
Step (c): export the scheme that the processing procedure-board production capacity obtained in step (b) is launched to optimize.
7. method according to claim 6, is characterized in that, described step (a) comprises following sub-step:
Step (a-1): collect board production data;
Step (a-2): integrate described board production data, to obtain the data being applicable to described computing module.
8. method according to claim 7, it is characterized in that, described board production data comprises the production procedure of the current corresponding matrix system at goods, the in the recent period plan of rolling off the production line, each product processing procedure and available board, the classification of each board group and board list, board processing procedure unit-hour output and each product.
9. method according to claim 6, is characterized in that, described step (b) comprises following sub-step:
Step (b-1): set up production model according to integrating the data obtained;
Step (b-2): simulated production is carried out to described model;
Step (b-3): described model is optimized;
Step (b-4): for assessing the simulated production of described model, to obtain the scheme that processing procedure-board production capacity is optimized.
10. method according to claim 9, is characterized in that, the method setting up production model in described step (b-1) comprises:
Step (b-1-1): integrate in selecting step (a) the product processing procedure production capacity that obtains compared to demand production capacity 1/90% load breach array, with the common factor of board relative load in group compared to processing procedure corresponding to the difference array of average, part that processing procedure production capacity breach the best part is minimum with board relative load and board, set up programming evaluation equation;
Step (b-1-2): according to described solving equation, obtains the parameter of satisfactory optimization processing procedure-board capacity planning scheme.
11. methods according to claim 9, is characterized in that, the constraint condition in described step (b-1) is that processing procedure production capacity is not less than 1/90% of Production requirement, and board relative load is not less than 80% of average load.
12. methods according to claim 9, is characterized in that, described step (b-3) optimal anchor direction is that the board relative load coefficient of variation is less than 20%, and the coefficient of variation of processing procedure production capacity is less than 20%.
13. methods according to claim 6, is characterized in that, described step (c) comprises following sub-step:
Step (c-1): the scheme exporting described optimization;
Step (c-2): the scheme of described optimization is adjusted.
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| CN109445382B (en) * | 2018-09-30 | 2020-08-18 | 北京国双科技有限公司 | Processing capacity evaluation method and device, monitoring method and system for oil field combined station |
| CN110147596A (en) * | 2019-05-09 | 2019-08-20 | 中国航空工业集团公司西安航空计算技术研究所 | A kind of aeronautical product production capacity appraisal procedure |
| CN110147596B (en) * | 2019-05-09 | 2023-05-26 | 中国航空工业集团公司西安航空计算技术研究所 | Aviation product production capacity assessment method |
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