Address the increasingly complex scheduling challenges of the rapidly changing semiconductor industry
Yokogawa unites a flexible scheduler with end‑to‑end services to overcome the unique complexity and immediacy of semiconductor plants—enabling more optimal operations.
- Constraint-based Scheduling Optimization:
Automated optimal allocation considering equipment, jigs, workforce, and process constraints - Regular Manufacturing Feasibility Check:
Simulation of production volumes and equipment capacity on a weekly basis to validate feasibility based on actual condition - Real-Time Schedule Feedback from the Shop Floor:
Frequent plan adjustments (every one to few hours) based on monitoring part arrivals and production progress - Seamless ERP and Shop Floor Integration :
Sharing of master data and real-time production progress to ensure synchronized planning - Knowledge-based Standardization:
Captures expert know-how to ensure consistent schedules even with new personnel
These benefits are enabled by FLEXSCHE products. For more product features, specifications, and case studies, visit the official FLEXSCHE website.
Details
Challenges
Complex manufacturing constraints increase lead times and reduce productivity and yield
Difficulty Balancing Supply and Demand
- Supply adjustments are difficult in response to sudden surges or drops in demand
- Inventory poses a management risk; achieving supply-demand balance is a major challenge
- Cannot accurately assess production feasibility
Increasing Complexity in Multi-Product, Multi-Process Operations
- Multi-product, multi-lot planning is complex, making it impossible to manage with manual scheduling
- Testing processes become bottlenecks, causing manufacturing delays
- Difficulty in selecting the appropriate combination of items, processes, and equipment
Discrepancy between plan and on-site results
- Progress cannot be seen, making it impossible to revise plans, leading to delivery delays and decreased operational rates
- Reviewing plans and coordinating with production areas takes time
Solutions
By linking upper- and lower-level systems, manufacturing constraints are shared to create plans tailored to plant conditions
Flexibly respond to changes in demand and plant conditions
- Long-term simulation that balances supply and demand by linking with ERP
- Flexible scheduling aligned with inventory, raw material arrivals, and production results
- Scheduling based on capacity planning and result feedback
Precise scheduling adhering to manufacturing constraints
- Creates executable schedules through constraint-based scheduling that satisfies complex and diverse constraints
- Standardizes expert knowledge and reflects it in the model to reduce human dependencies
- Master synchronization with ERP keeps manufacturing conditions up-to-date
End-to-end synchronization
- Bridges the production floor, visualizing plant conditions
- Periodic automatic rescheduling to absorb discrepancies between plans and plant results
Benefits
Supports decision-making, improves productivity, and ensures stable operations with flexible, up-to-date scheduling
Decision making support
- Balances supply and demand, responds to mid-term and short-term changes to improve operating rates, maximize capacity utilization, and enhance on-time delivery rates
Productivity improvement
- Optimally allocates equipment, personnel, and jigs, reduces jigs changeover frequency, and improves bottlenecks around constrained resources to shorten lead times
- Generates schedules quickly that would be difficult to create manually
Stable operation
- Manufacturing constraints are kept up-to-date, enabling operations according to plan
- Plans flexibly adjust to plant progress, reducing operational load
-
OpreX Batch MES C1-T1
Optimize chemical batch production with OpreX Batch MES C1-T1. Seamlessly integrate workflows and management processes for quick updates and efficient operations.
Op zoek naar meer informatie over onze mensen, technologie en oplossingen?
Contact