Abstract
Most semiconductor manufacturing companies in Taiwan own several wafer fabrication factories. If a factory need extra capacities and another factory has surplus capacities, the backup plan has to be determined through negotiation. However, they are unable to obtain a better capacity backup plan because of non-technical issues. This lowers the overall productivity and profitability of a multiple factories semiconductor manufacturer. Therefore, this study presents a systematic method capable of solving capacity backup plans for multiple factories semiconductor manufacturers.By using the “Production planning model” proposed by Hung and Leachman [1996], the production plan of each individual factory can be calculated by optimally allocating its available capacities and maximizing its cash flows. After listing the tight or the surplus of all the resources in various periods among all factories, the surplus and tight between two factories of the same resource could be matched. We continue the capacity matching process in period order until no surplus and tight items can be matched.Experiment results show that the proposed method can not only significantly improve the overall profitability but also solve the whole capacity backup plan quickly. It increases the profit margin by 8.7%. The average profit increase is 80% of the gap between the original profit and the optimal one. In addition, over 35% of the problems can obtain optimal production plans when the minimal capacity movement is zero. The average time it takes to solve the whole capacity backup plan is about 1 minute. It takes less than 10 seconds and less than 3 minutes for solving problems with fewer and more factories, respectively. The results of this study demonstrate that the method proposed herein allows multiple factories semiconductor manufacturers to objectively and efficiently draw up better capacity backup plans to enhance the overall productivity and profitability.Abstract ii第一章 緒論 11.1 研究背景 11.2 研究動機 31.3 研究目的 41.4 研究方法 51.5 論文架構與研究流程 7第二章 文獻探討 9第三章 多廠區生產計劃 133.1 問題假設與名詞定義 133.1.1 問題假設 133.1.2 Event-based模型與Rate-based模型 143.2 線性規劃生產計劃模型 153.3 產能支援方法 17第四章 實驗設計與結果分析 244.1 實驗設計 244.1.1 實驗問題基本設定 244.1.2 實驗設計因子 254.1.3 實驗績效評估方式 264.2 實驗結果與分析 284.2.1 因子檢定分析 294.2.2 綜合結果與圖表分析 33第五章 結論與未來研究方向 455.1 結論 455.2 未來研究方向 45參考文獻 47