Build a seamless system for Fabless semiconductor ... · PDF fileBuild a seamless system for...

A Day in the Life of a Planner

Copyright © 2009 Idhasoft Inc.. All Rights Reserved.Copyright © 2009 Idhasoft Inc. All Rights Reserved.www.idhasoft.com

Vision Packaged . Delivered

Build a seamless system for Fabless

semiconductor companies using OraclePresenter: Sid Nandi

&

Raul Tomasi

Sr. Manager IT

EXAR Corporation

NorCal OAUG Training Day

January 19, 2010


Copyright © 2009 Idhasoft Inc.. All Rights Reserved.

• Idhasoft Introduction

• Key Challenges to the Semiconductor Industry

• Our Solution Approach

• Business and Application Solutions Modeling

• Lot Processing

• Yield based Costing

• Invoice Payments

• Tracking Distributor Inventory, Claim Processing and Revenue Recognition

• Supply chain Planning and Customer Commit (ATP)

• Pick and Ship (WMS)

• EXAR Implementation

• Implementation Key Success Factors

• Discussion and Q&A

Structure of the Presentation


Copyright © 2009 Idhasoft Inc.. All Rights Reserved. 3

Global Operations

• $180 M Services Company

• 1200+ Employees

• 200+ Oracle Consultants

IndiaAtlantaLos Angeles

BostonNew York

Toronto

New JerseySan Francisco

Chennai

Hyderabad

Delhi

BangaloreMumbai

ERP Solutions Supply Chain Solutions Technology Solutions Staffing

Locations

Switzerland

Japan

Korea

Taiwan

Singapore



xOracle Business Unit

Oracle

Licensing

Oracle

ebusiness

Suite

Oracle Fusion

Middleware

Managed

Support

Business

Intelligence

o Licensing Service

o ERP Implementation

o SOA & Middleware Technologies

o BI (OBIEE and Hyperion)

o Professional Services

o Infrastructure & 24/7 DBA Services

o Managed Services & India Development Center

Largest practice at Idhasoft - $60M in annual revenues

One Stop Shop



Sample Customers

5

Vertical focus

Big Box RetailersBig Box Retailers

Department Stores Department Stores

OthersOthers

SemcnductorsSemcnductors

High TechHigh Tech

Internet

& Software

Internet

& Software



Semiconductor Manufacturer

Distributor

OEM

OEM Hubs

Business Direct

Channel

Consumer Direct

3PL’s

Component Manufacturer

Contract Manufacturer

Evolving Challenges

• Complexity of Business

� Globalization

� Outsourcing

� Shorter Lifecycle

• Variability of Supply and Demand

� Less Customer Loyalty

� Mass Customization

� Shorter Order Lead Time

• Growth and Competition

� Mergers and Acquisitions

� Maximize Profitability During Growth

Evolving Challenges

• Complexity of Business

� Globalization

� Outsourcing

� Shorter Lifecycle

• Variability of Supply and Demand

� Less Customer Loyalty

� Mass Customization

� Shorter Order Lead Time

• Growth and Competition

� Mergers and Acquisitions

� Maximize Profitability During Growth

Global High Tech Business Flow

Business is ComplexPlanning happens in day’s, Execution happens in hours



Design Complexity• Part Standardization

• Increasing Product Mix

• Engineering Changes to improve product

• Design cycle time, and development of customer-specific products

• Part/Designs standardization

Design Complexity• Part Standardization

• Increasing Product Mix

• Engineering Changes to improve product

• Design cycle time, and development of customer-specific products

• Part/Designs standardization

Supply Management• High component lead times

• Single Vs Multi Sourcing

• Leveraging global manufacturing and supply base

• Manage high volume Supplier Transactions

Supply Management• High component lead times

• Single Vs Multi Sourcing

• Leveraging global manufacturing and supply base

• Manage high volume Supplier Transactions

Demand Management• Customer Order changes several

times

• Inconsistent Forecast

• Demand fluctuations

Demand Management• Customer Order changes several

times

• Inconsistent Forecast

• Demand fluctuations

Planning & Configuration Management

• Managing the flow of materials & information through multiple stages of manufacturing, transportation & distribution

• Inventory Optimization

Planning & Configuration Management

• Managing the flow of materials & information through multiple stages of manufacturing, transportation & distribution

• Inventory Optimization

A Seamless Integrated System

High Tech Industry Challenges



• Fabless Semiconductor - $200 Billion Industry and growing

• High Cost of Fabs move the industry towards Fabless

• Growth can happen in rapid manner

• Many Challenges

• Complex Manufacturing; High Lead Time

• High Volume and Mix

• Quick Response Time Needed

• Low Margin (in many cases)

• High Competition

• Low Product Life Cycle (Technology overrun)

• Fluctuating Demand

• High Inventory

• Poor Supply Chain Visibility

• Ability to Plan and meet customer Demand

• No Integrated Manufacturing System

Semiconductor Challenges



• I wish I could build my business in order to:

o Configure (and reconfigure) processes rapidly to respond to change

and new business models,

o Support the reconfigured processes with technology –quickly,

o Identify shared functionality across divisions and geographies with

greater precision and granularity,

o Interface with customers and suppliers with greater ease, granularity

and precision, and have a far more sophisticated discussion about

«make or buy» than currently possible,

o Assess acquisition candidates based on a granular, effective and

realistic perspective of synergy and breakup values.

CEO’s Dream



Simple & Flexible



• Build a seamless Application System

• Understand the business

• Use standard Application System like Oracle

• Know your application system

• Plan your Master Data Management carefully

• Integrate using the right technology

• Do not forget report strategy

• Use Business Intelligence to gain competitive advantage

Our Solution Approach

Goal – Integrated Manufacturing System

3PL



Business Process & Applications Modeling

• Common Source of Master Data ( Customers, Suppliers, Parts)

• Part Number and Attributes

• Product Structure

• Lot Number scheme & Lot Attributes

• Organization Structure

• Routing, Resources

• Cost Structures and how to manage it

• Purchasing Approval Hierarchy

• Invoice Matching process

• Reschedule and reservation process

• Pick and Ship Process

• Credit Check and Approval Process

• POS and Revenue Recognition Process

• RMA Process

• Service integration

• Month End Closing Process

obpm_whitepaper.pdf



• Transactions related to Lot Based Jobs

– New Lot Based Job

– Lot Creation

– Move

– Scrap

– Update Job Quantity

– Job Split

– Job Merge

– WIP Lot Rename

– Lot Hold & Release

– Bonus

• Transactions related to Inventory Lots

– Lot Split

– Lot Merge

– Lot Transfer

– Lot Translate

– Lot Issue

– Lot Receipt

OSFM – Supported Transactions



Lot Processing – Using Oracle OSFM

• Transaction Intensive

• User Interface

• Loose Couple Between WIP & Purchasing

Shortcomings

Solutions

• Workbench

• B2B Solution – Virtual Manufacturing System (VMS)



Lot Processing Workbench









• Features

– Automates collection & integration of supplier data

– Monitors data for problems & generates alerts

Lot Processing Automation



Supplier Data Differs



Supplier Integration - VMS



Supplier Integration - VMS



• Delivers instant access to critical info.

– Manufacturing views: orders, WIP, delivery schedule

– Exceptions: parts on hold

• Provides “early warning” system

– Automatically generates & sends email alerts

– Analyzes real-time data to identify potential problems

• Streamlines manufacturing operations

– Detects/cleanses imperfect data: lot splits, merges,

scrap, out of step movements

– Automates WIP/yield data from suppliers into Tier 1

ERP/yield systems

– Developed using scalable SOA and J2EE architecture

Powered by eSilicon Access and IdhasoftVMS – Key features



VMS Flows

• WIP Processing

– WIP Updates - FAB Schedule to Finished Goods

– Correction Rules

– Resubmissions

– Lot Monitoring Alerts

– Setup Validation Alerts

• Browsing Capabilities

– Lots, Items, Routings, Channel, Transaction Processing,

Process Flow etc.

• Admin Pages Overview

– Control Panel

– Supplier Sources/Exception Summary

• Adding a New Supplier

• Internal Discoverer Reports

– Lot Report, Cycle Time, Yield Reports, Costed WO & Inventory

etc.

VMS – Key features



Suppliers Data Supported

• FAB– TSMC(TSV), UMC(csv), SMIC(csv)

• Assembly and Test– Amkor (text), SPIL(XML), ISE(excel)

– ASE Singapore (XML),

– ASE Malaysia (XML)

– Unsem, Carsem

• Update Types– Status snapshots

– Transactional (Rosettanet 7B1)

– Transaction history

– Supplier specific proprietary transactions

• Adding a new Supplier support for automation is

easily doable

– Need Isolated data conversion specific to supplier

– Process Flow configuration

VMS – Supplier data Supported



Important Reports

• Master Data Reports– Indented Bills of materials with Cost

– Item details Report

• Valuation Reports– Inventory Value

– WIP Value

• Variance Reports

– PPV Report

– IPV Report

– Yield Variance Report

• Transaction Reports– Lot Tracking Report

– Shipment Report

– BBB Report

– Horizontal Plan Report



Item Number Subinventory Locator Lot Number Category Prod Code Quantity Cost Total Value Prod Family Item Class

S0880C0AG DB-AMKOR K1 DP2178.00 PHY.LXT9880 60350 3548 1.00 3548.00 PHY LXT9880


S0880C0AG DB-AMKOR K1 DN9735.00 PHY.LXT9880 60350 8663 1.00 8663.00 PHY LXT9880

S0880C0AG DB-AMKOR K1 0652A05A PHY.LXT9880 60350 9135 1.00 9135.00 PHY LXT9880

S0880C0AG DB-AMKOR K1 0638A00A PHY.LXT9880 60350 3548 1.00 3548.00 PHY LXT9880

S0386E0BC DB-AMKOR K1 DR8751.00.1 T1/E1.LXT386 61275 30883 1.00 30883.00 T1/E1 LXT386

S0386E0BC DB-AMKOR K1 DR5172.00 T1/E1.LXT386 61275 30423 1.00 30423.00 T1/E1 LXT386

S0384E0BB DB-AMKOR K1 DR8750.00 T1/E1.LXT384 61250 16953 1.00 16953.00 T1/E1 LXT384

S0384E0BB DB-AMKOR K1 DR8749.00 T1/E1.LXT384 61250 16664 1.00 16664.00 T1/E1 LXT384

S0384E0BB DB-AMKOR K1 DR3988.00.1 T1/E1.LXT384 61250 2042 1.00 2042.00 T1/E1 LXT384

S0384E0BB DB-AMKOR K1 DP9949 T1/E1.LXT384 61250 7211 1.00 7211.00 T1/E1 LXT384

S0380E0BE DB-AMKOR K1 0541A13A T1/E1.LXT380 61225 4074 1.00 4074.00 T1/E1 LXT380

S0360E0AC DB-AMKOR K1 Z55007 T1/E1.LXT360 61200 5768 1.00 5768.00 T1/E1 LXT360

S0386E0BC DB-AMKOR K3 DR3987.00 T1/E1.LXT386 61275 12901 1.00 12901.00 T1/E1 LXT386



MONZA-SW DB-AMKOR K4 G67111.1 ETHERNET.CS3400 50125 2 1.00 1.78 ETHERNET CS3400

27-0024-00F DB-AMKOR K4 ETHERNET.CS3470 50150 628 1.00 628.00 ETHERNET CS3470

VALENCIA-A1-S DB-AMKOR K4 G67004.1 ETHERNET.CS3470 50150 434 1.00 434.00 ETHERNET CS3470

VALENCIA-A1-S DB-AMKOR K4 GY5991.1 ETHERNET.CS3470 50150 1208 1.00 1208.00 ETHERNET CS3470

KATANA-B3-S DB-AMKOR K4 FS5895.1 FRAMER.CS5000 51200 75 1.00 75.00 FRAMER CS5000

Sample Report – Inventory Value



Horizontal Forecast Report for Supplier



• Phase – I

Goal : Replace existing MES (FW) with OSFM and streamline Lot Processing

with scalable software and hardware infrastructure

• Build New Industry Standard Scalable Infrastructure

• Implement Oracle OSFM

• B2B Implementation – Supplier Integration

• AP Invoice Automation

• Go Live – Feb 21 ( 7 Months)

• Phase – II

• Stabilization, Reporting & BI etc…

EXAR Implementation



EXAR ImplementationxEXAR Implementation

• Project preparation

o Project Team

o Project Plan

• Understanding the business Requirements

• Solution Modeling and Core Team Agreement

• Documentation and close Tracking of Issues

• Commitment to make the project a top priority

• Data Review & Cleansing

• Testing, Testing & Testing and Sign-Off

• EXAR Executive Management Involvement

Methodology

Challenges Faced

• Data Cleansing

• Supplier Data Quality



Cultural Change – A Paradigm Shift

Planner/ Buyer

What can I do for you?



Thank [email protected]

650-517-9729

Discussion and Q&A

Date post:	28-Mar-2018
Category:	Documents
Upload:	truongxuyen
View:	218 times
Download:	2 times

Build a seamless system for Fabless semiconductor ... · PDF fileBuild a seamless system for...

Documents