Patent Application
20090299511
1. Field of the Invention
This invention relates to the art of manufacturing and, more particularly, to a method of releasing lots in a production facility.
2. Description of Background
Modern production facilities utilize many different tools to support a variety of manufacturing processes. Most manufacturing processes are operated in serial or batch modes. In serial mode, units are processed one after another in a process sequence. In batch mode, units are grouped together in a batch and processed contemporaneously. In order for a production line to run efficiently, each batch tool must be fully loaded when processing a batch. In addition, when operating in serial mode, processing like units minimizes tooling changes and setup time during a production period.
Current release strategies rely solely on customer demand and do not account for production line constraints. As a result, batch tools are often not fully loaded, and changes are made during a serial run in order to meet customer production requirements. In addition, units are run without sufficient “training” or test runs, resulting in excessive tool setup which slows production throughput and increases quality review.
The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method of releasing units in a production facility. The method includes forming a release plan for a production facility. The release plan establishes a number of units to be operated on by a production process, and creating a least one recipe bucket having an associated number of units each sharing common operational parameters. The method further requires evaluating production process throughput parameters, and comparing the number of units associated with the at least one recipe bucket with the number of units to be operated on by the production process in the release plan and production process throughput parameters. If the number of units associated with the at least one recipe bucket match the number of units to be operated on by the production process and production process throughput parameters, the at least one recipe bucket is released to the production process. However, if the number of units in the at least one recipe bucket does not match the number of units to be operated on by the production process and production process throughput parameters, the at least one recipe bucket is delayed from being released to the production process.
System and computer program products corresponding to the above-summarized methods are also described and claimed herein.
Additional features and advantages are realized through the techniques of exemplary embodiments of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
As a result of the summarized invention, technically we have achieved a solution which creates a release plan that utilizes production processes more efficiently. That is, before releasing units to a production process or tool, a determination is made that the number of units desired to be released substantially aligns with both a production strategy (daily, weekly goals) and tool throughput capabilities so as to ensure an efficient allocation of production resources.
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
The detailed description explains the exemplary embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
With initial reference to
Once the various recipe buckets are established in block 40, RSEV 20 sets release filter parameters for each recipe bucket as indicated in block 42. Release filter or batching parameters represent a set of variables arranged in a sequential order of importance that establish a release schedule based on a set of contingencies. For example, filter parameters can include variables such as throughput parameters including maximum capacity for a batching tool, changeover time for a series or training tool, available throughput for a process or tool or priority parameters such as need for a particular set of units, or an on time delivery percentage for a particular process or tool. After the release filter parameters are set, RSEV 20 evaluates which lots are selected for processing as indicated in block 44. That is, RSEV 20 determines whether each recipe bucket contains an optimal number of candidate units for processing by a production process or tool in order to make efficient use of production facility resources.
In the case of batch processing, RSEV 20 determines whether each recipe bucket contains an optimum number of candidate units to be operated on in a batch. In the case of serial processing, e.g. training, RSEV 20 determines whether each recipe unit contains an optimal number of candidate units to be processed in series before requiring retooling of a particular process or tool. In any case, if, in block 44, the recipe bucket matches the number of units established to be operated on by a particular process in the release plan, the lots are passed to a final, daily release plan and then on to the production facility for processing such as indicated in block 60.
If, however, RSEV 20 determines that the number of units associated with a particular recipe bucket is less than the number of units outlined in the release plan, a determination is made which job or lot associated with a particular recipe bucket has the highest preference as indicated in block 80. Next, RSEV 20 locates the next highest priority job or lot associated with the same recipe bucket as indicated in block 82. The job lot with the highest preference is then combined with the job lot having the next highest preference to form a combined job lot or bucket as indicated in block 84. After forming the combined job lot, RSEV 20 determines whether some of the units within the combined job lot approach a tool processing limitation as indicated in block 86. If not, RSEV 82 locates the next highest priority job lot which is in the same recipe bucket to add to the combined bucket until the sum of units in the combined bucket approaches the tool processing limitation. At this point, the combined job lot is added to a batch job that is recommended for a daily releasing total as indicated in block 88.
At this point, RSEV 20 determines whether the daily releasing total exceeds a total daily release limit for a particular day. That is, RSEV 20 determines whether the combined job lot can be added to other lots on a particular process or tool so as to be processed within a given production day as indicated in block 90. If the combined batch job, when added to the daily releasing total, does not exceed the daily release limit, the combined job lot is passed on or added to the daily release schedule as indicated in block 92 and passed back to block 94 to determine whether all lots in the original release plan are selected. If the combined batch job exceeds the daily release when added to the daily release schedule, the combined job lot is moved to a next day releasing total as indicated in block 94 and passed back to block 44 to determine whether all lots in the combined job lot meet the number of units to be operated on by a process tool in the release plan. In this manner, RSEV 20 ensures that each production process or tool is utilized in an efficient manner such that for example batching jobs are not carried out with partial batches or, serial process lines are not interrupted and retooled after processing a few units only to be re-tooled again to process additional units having similar requirements. Thus, RSEV 20 enhances an overall production output, while ensuring on time delivery and high quality.
Generally, the method of releasing units in a production facility described herein is practiced with a general-purpose computer and the method may be coded as a set of instructions on removable or hard media for use by the general-purpose computer.
ROM 420 contains the basic operating system for computer system 400. The operating system may alternatively reside in RAM 415 or elsewhere as is known in the art. Examples of removable data and/or program storage device 430 include magnetic media such as floppy drives and tape drives and optical media such as CD ROM drives. Examples of mass data and/or program storage device 435 include hard disk drives and non-volatile memory such as flash memory. In addition to keyboard 445 and mouse 450, other user input devices such as trackballs, writing tablets, pressure pads, microphones, light pens and position-sensing screen displays may be connected to user interface 440. Examples of display devices include cathode-ray tubes (CRT) and liquid crystal displays (LCD).
The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
