生產規劃之供應鏈支援模式─ 以某半導體廠為研究案例

Decision Support Models for Production Planning ─ A Case of a semiconductor Manufacturer

劉永林

指導教授 ： 陳飛龍

國立清華大學/工學院/工業工程與工程管理學系工程碩士在職專班/碩士(2009年)

摘要

有鑒於企業規模越來越大，同時擁有多廠的情形也日愈增加，在訂單的不斷湧入下，企業必須思考如何承接訂單的所有訂購數量，以避免失去訂單而降低獲利。在考慮如何接單的問題上，企業需要一套接單輔助模式，來幫助企業在評估訂單承接時，能夠以企業獲利為優先考慮因素。在產能調度時，則應該排除許多主觀性與非技術性的因素影響，避免讓各廠間的產能支援程度大打折扣。因此，如何在現行的基本經營管理模式下，建立一套客觀、有系統的方法來評估訂單承接及分配各廠現有的產能，將是影響公司整體獲利的關鍵。
本研究針對多廠區生產規劃問題，在企業最大銷售產能及既有的資源設備下，發展出二階段規劃模式，分別以「企業利潤最大」及「生產成本最小」為目標。在第一階段訂單承接評估階段模式，以企業最大銷售產能為限制下，以線性規劃的方式求解出企業利潤最大的訂單承接組合。第二階段在各廠區產品產能負荷及外包商產能限制已知的條件下，針對第一階段所承接的訂單需求量，進行生產成本最小之跨廠區產能規劃，求解各廠區在生產成本、外包成本總和最小的情況下，求得各廠區的產品產出量、訂單外包量與各廠區產能利用率，各廠區並可得知需要在規劃區間內完成那些訂單，以提供後續細部生產排程或物料規劃參考依據。
為了驗證方法的實用性，本研究以國內某半導體製造公司之訂單承接與產能規劃為例，依照上述之方法流程，求解出最佳訂單承接組合與生產計劃。

關鍵字

訂單承接 ； 生產規劃 ； 線性規劃 ； 跨廠區產能規劃

並列摘要

The enterprises usually have many factories in different locations, now. In facing the growth of customer orders, a company usually to face the problem that it cannot accept all the orders because of the lack of capacity. In order to avoid the lost orders and profit, a company requires an assist model to find out the better orders as their first priority. Due to the increasing production scale, a company must adopt a multi-plant manufacturing strategy to increase the capacity to satisfy the ordered demands. Under this consideration, it is important to develop a coordinated capacity planning in the manufacturing model to meet the change in such production environment.
The objective of this research is to develop two integrate capacity planning models in two phases. This model is aimed at maximizing the enterprises order’s profit under the maximum capacity volumes and minimizing the total production cost under the consideration of plants and constraints of resources and equipment.The model is analyzed according to the maximum capacity volumes, order allocation by capacity constrain, bottleneck workstation capacity load by machine capacity constrain to find out the dispatching production plan. In this model, we obtain the minimal integrated cost including production cost, manufacturing cost, out-sourcing cost. In phase one, we can obtain the amount of product order requirement of enterprises. In phase two the workstation capacity load and bottleneck workstation of each plant is obtained. The enterprises order evaluation and multi-plant capacity are modeled and solved using the linear programming formulation and technologies. In this way, we can found an optimal order planning solution and an optimal multi-plant capacity planning solution. We can arrange the production planning and schedule planning according to the optimal solution of multi-plant capacity planning.
A case study of a semiconducting manufacturer is conducted to verify the feasibility of the proposed methodology. The results show that it can be used to find the optimal order solution and optimal production plan.

並列關鍵字

Order evalution ； production planning ； linear planning ； Multi-Plant Capacity Planning

參考文獻

曾煥雯，「跨廠訂單分配模式之建構—應用模擬退火演算法」，私立元智大學，碩士論文，桃園中壢，民國89 年。

陳建銘，「多廠區緊急訂單承接評估及跨廠產能規劃探討」，私立元智大學，碩士論文，桃園中壢，民國92 年。

張美滿，「多廠區跨廠產能規劃之探討」，元智大學工業工程研究所碩士論文，桃園中壢，2002。

Rohit Bhatnagar, Pankaj Chandra, and Suresh K. Goyal.”Models for multi-plant coordination”, European Journal of Operational Research, 67, pp. 141-160, 1993.

Atherton, L. F., and Atherton, R. W., Wafer fabrication: factory performance and analysis, Kluwer Academic, 1995.