Hierarchical Production Planning for Semiconductor Wafer Fabrication Based on Linear Programming and Discrete-Event Simulation

This paper focuses on a production planning and scheduling problem in a semiconductor wafer fabrication facility. We propose a two-level hierarchical production planning (HPP) method that employs an itmmerative procedure for production planning and operations scheduling. In the method, production plans are obtained with a linear programming (LP) model in the aggregate level, and schedules at the machines are obtained with a priority-rule-based scheduling method and evaluated with discrete-event simulation in the disaggregate level. An iterative scheme is adopted for obtaining a good and feasible production plan. The proposed method is evaluated through simulation experiments and the results show that the method works better than an existing algorithm in terms of the total production cost and total tardiness of orders.

[1]  Hark Hwang,et al.  Simplification methods for accelerating simulation-based real-time scheduling in a semiconductor wafer fabrication facility , 2003 .

[2]  Sooyoung Kim,et al.  Production planning in semiconductor wafer fab considering variable cycle times , 1997 .

[3]  Yeong-Dae Kim,et al.  Production scheduling in a semiconductor wafer fabrication facility producing multiple product types with distinct due dates , 2001, IEEE Trans. Robotics Autom..

[4]  R. C. Leachman,et al.  A production planning methodology for semiconductor manufacturing based on iterative simulation and linear programming calculations , 1996 .

[5]  Rainer Leisten,et al.  An LP-aggregation view on aggregationin multi-level production planning , 1998, Ann. Oper. Res..

[6]  Toly Chen A fuzzy mid-term single-fab production planning model , 2003, J. Intell. Manuf..

[7]  Shi-Chung Chang,et al.  Design of a Lagrangian relaxation-based hierarchical production scheduling environment for semiconductor wafer fabrication , 2003, IEEE Trans. Robotics Autom..

[8]  Pravin K. Johri,et al.  Practical issues in scheduling and dispatching in semiconductor wafer fabrication , 1993 .

[9]  Mauricio G. C. Resende,et al.  A scheduling rule for job release in semiconductor fabrication , 1988 .

[10]  de Ag Ton Kok,et al.  The effect of updating lead times on the performance of hierarchical planning systems , 2006 .

[11]  Sooyoung Kim,et al.  Extended model for a hybrid production planning approach , 2001 .

[12]  J. Venkateswaran,et al.  Hybrid system dynamic—discrete event simulation-based architecture for hierarchical production planning , 2005 .

[13]  Jong-Kwan Baek,et al.  A Milestone Generation Algorithm for Efficient Control of FAB Process in a Semiconductor Factory , 2002 .

[14]  Chun-Hung Chen,et al.  Scheduling semiconductor wafer fabrication by using ordinal optimization-based simulation , 2001, IEEE Trans. Robotics Autom..

[15]  Yi-Feng Hung,et al.  A simulation study of dispatch rules for reducing flow times in semiconductor wafer fabrication , 1998 .

[16]  Manoj Kumar Tiwari,et al.  Modelling and analysis of wafer fabrication scheduling via generalized stochastic Petri net and simulated annealing , 2003 .

[17]  S.X.C. Lou,et al.  A robust production control policy for VLSI wafer fabrication , 1989 .

[18]  Carlos Andrés,et al.  A design and application methodology for hierarchical production planning decision support systems in an enterprise integration context , 2001 .

[19]  S. J. Mason,et al.  Rescheduling strategies for minimizing total weighted tardiness in complex job shops , 2004 .

[20]  R. Uzsoy,et al.  Tractable nonlinear production planning models for semiconductor wafer fabrication facilities , 2006, IEEE Transactions on Semiconductor Manufacturing.

[21]  J. George Shanthikumar,et al.  A Unifying View of Hybrid Simulation/Analytic Models and Modeling , 1983, Oper. Res..

[22]  M. D. Byrne,et al.  Production planning: An improved hybrid approach , 2005 .

[23]  Lawrence M. Wein,et al.  Scheduling semiconductor wafer fabrication , 1988 .

[24]  M. D. Byrne,et al.  Production planning using a hybrid simulation – analytical approach , 1999 .

[25]  Soo-Young Kim,et al.  Production Scheduling in Semiconductor Wafer Fabrication Process , 1995 .

[26]  Yeong-Dae Kim,et al.  Due-date based scheduling and control policies in a multiproduct semiconductor wafer fabrication facility , 1998 .

[27]  Sameer Kumar,et al.  Integrated simulation application design for short-term production scheduling , 2006 .

[28]  Yon-Chun Chou,et al.  A methodology for product mix planning in semiconductor foundry manufacturing , 2000 .

[29]  Lee Dong-Ho,et al.  A SIMULATION STUDY ON LOT RELEASE CONTROL, MASK SCHEDULING, AND BATCH SCHEDULING IN SEMICONDUCTOR WAFER FABRICATION FACILITIES , 1998 .