Dynamic simulator for WIP analysis in semiconductor manufacturing

We present a FAB Simulator (FS) and Capacity Planner (CP) that permits the operational planner to introduce new product into an existing production mix with confidence as to the customer delivery dates and FAB Capacity This paper describes the implementation of these two dynamic tools in a semiconductor FAB in Arizona. These tools assist the operational planner with the planning of the daily production mix. This FAB produces 100´s of different bipolar devices using 36 process flows. The key to success in calculating present and future production goals is real time operational level tracking. Real time tracked data includes data gathered from the Manufacturing Execution System (MES) for each product´s work-in-process (WIP), process flow routing, and data gathered from the equipment utilization and emergency maintenance databases. This key information is fed through a GUI linked to the CP which in turn controls the stochastic dynamic simulation model of the FS. These links provide the operational planner with dynamic production data in real time and simulated time for decision-making. The CP and FS are running in parallel and are linked directly with the FAB´s MES maintaining current production data