Presentation - Shop Floor Control - The Road to Integrated Manufacturing

8/9/2019 Presentation - Shop Floor Control - The Road to Integrated Manufacturing

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MIT Solution Team Manager -

September 2013 / SAP Manufacturing

Shop FlooThe Road to Integrated Man


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Introducing ASMLA cornerstone of the chip industry

Impact on OperationsA lean program to streamline production processes

Program: Shop Floor Control

The IT enabler for achieving business value

Questions

Agenda


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Introducing ASML

A cornerstone of the chip industry


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ASML - A cornerstone of the chip industry


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ASML employees

in US:1,617

Source: VLSI Research/ASML Q4 2012

Over 55 sales and service offices located worldwide

ASML employees

in Europe: 5,068

ASML em

in Asia:

Salesto Europe

27%

sales

to US

69%

sales

to ASI

4%

ASML:

Worlds largest semiconductor equipment vendor


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Moores Law holds steady for more than 40 years

Double

computpower p

At equivpowerconsum

For halfprice

Every 12 years

1970 1975 1980 1985 1990 1995 2000 2005 2010

101

102

103

104

105

106

107

108

109

1010

100

Tra

nsistorsperDie

Memory

Microprocessor

This graphic

shows how h

transistor sh

realized over

Source: Intel


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Overlay down to

2 nanometers

1 nm = 4 silicon atoms

The technical challenges

Stacking layers: what does that mean


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m/sec2

0 10 20 40 7030 50 60 80 90 100 110 120 130

The technical challenges

Acceleration: a comparison...

A stone drops at 9.8 m/sec2

A dragster accelerates at 33 m/sec2

A jet fighter in a catapult at 44 m/sec2

An attack missile at 50 to 120 m/sec2

A TWINSCAN NXT reticle stage at 150 m/sec2


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resulting in the systems that conquered the ma

1984:

PAS 2000Resolution:

>1m

Overlay: 250 nm

1989:

PAS 5000Resolution:


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Impact on Operations

A lean program to streamlineproduction processes


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Or do you want to become the best factory?Does your factory look like this?

What makes the differ


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ASML Manufacturing process

WH

SuppliersBuild OperationsDelivery Operations

+/- 350 Suppliers

Added Value >90%

60 Partners (80%)

+/- 10.000 People

9 Modules /system

18000 m2

2000 Buy in Items /system

+/- 300 goods receipts /day

6-12 months Training / Engineer

2 shifts per day /wk, 1 shift per d

7x24 Test Area

3-8 Systems / week

Suppl iers Bui ld Operations Delivery Op


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ASML Manufacturing process

WH

What makes manufacturing @ ASML special?

Suppl iers Bui ld Operations Delivery Op

Dynamic Master Data - high number of Engineering Changes (100

Rework, Recovery, Repair - continuously due to searching the limitMaster Production Sequences - contain all possible technical depe

Operators - highly educated


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Flow: 8 key changes


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FLOW - High level impact

The "blueprint" is introduced

TaktsRegular rebalanced to improve

cycletime and delivery

Kits are adjusted onbasis of the Takts

After approval:the changes are

implemented

Support andissue resolution

are improved

ImprovedTransparency

Takted way ofworking isintroduced


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Program: Shop Floor Control

The IT enabler for achieving business v


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Shop Floor Control program @ASML

Work InstructionsDynamic customized per machine configuration

Introducing SAP ME

- Fair work packages per operator per shift- Blueprinting & Sequencing tooling

- Real-time monitoring / progress tracking

Production Orders- Customized per customers order

Detailed integral planningof materials, skills, people, cabins, etc.

Alert ManagementReal-time logging & progress trackingof disturbances in production

Management ReportingBased on a single source of truth

MES Machine InterfacingFully automated system qualification

Increased dplanning re

Reduced c

Reduced s

Improved p

Transparen


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Shop Floor Control functions mapped on ISA95

Machine - Level 1 & 2

MES - Level 3

ERP - Level 4

Production

OperatorDashboard(GU

I)

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

QuintiqOperational

Planning

SiemensTCE

RSuite / Coach

Test Scripts

SAP MII - Manufacturing

Integration & Intelligence


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MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Production


I)

SAP MII

QuintiqOperational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

QuintiqOperational

Planning

SiemensTCE

RSuite / Coach

Test Scripts



Work PreparationCreate and Release Routing in E


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Work Preparation - Create sub-routings in GRE


MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Production


I)

SAP MII

QuintiqOperational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

QuintiqOperational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts




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Work preparation:RoutingSub-routingWork package per operator

1 2 3 8

4 5

6 7

10 20Main routing in SAP-ECC

Sub-routing in Graphical Routing Editor

Optimized Work Package in SAP-ME1 4 5 8

2 3 6

Operator A

Operator B


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MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Production


I)

SAP MII

QuintiqOperational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

QuintiqOperational

Planning

SiemensTCE

RSuite / Coach

Test Scripts



Work Preparation - Create optimal sequence per ope


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MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Production


I)

SAP MII

QuintiqOperational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

QuintiqOperational

Planning

SiemensTCE

RSuite / Coach

Test Scripts



Work PreparationRelease routing to SAP ME,report to SAP ECC

M f i E i


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MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Production


I)

SAP MII

QuintiqOperational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

QuintiqOperational

Planning

SiemensTCE

RSuite / Coach

Test Scripts



Manufacturing Execution: Create Production Order in

M f t i E ti R l O d t SAP


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Manufacturing Execution: Release Order to SAP


MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Production


I)

SAP MII

Quintiq

Operational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

QuintiqOperational

Planning

SiemensTCE

RSuite / Coach

Test Scripts




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M f t i E ti St t 1st R ti St i t


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MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

ProductionOperatorDashboard(GU

I)

SAP MII

Quintiq

Operational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Quintiq

Operational

Planning

SiemensTCE

RSuite / Coach

Test Scripts



Manufacturing Execution: Start 1stRouting Step in tProduction Operator Das


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Manufacturing Execution: POD d hb


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MES - Level 3

ERP - Level 4

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

ProductionOperatorDashboard(GU

I)

SAP MII

Quintiq

Operational

Planning

SiemensTCE

Indicenter /

Coach

Test Scripts

SAP

Manufacturing

Execution

SAP ECC

Graphical Routing

Editor

Quintiq

Shift Planning

Quintiq

Operational

Planning

SiemensTCE

RSuite / Coach

Test Scripts



Manufacturing Execution: POD accesses dashboarreports, work instructions


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Shop Floor Control impact on FLOW improvemen


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Shop Floor Control impact on FLOW improvemen

Graphical Rodefine bluep

Calculate opt

(in 2 min. ins

Fair Work Packages

per operator, per shift

Dynamic sequencing

Real-time progress tracking

(even available for operator during shift)

Monitoring and reporting

Escalate disturbance

notifications

Assure production

progress

Trigger the just-in-time

delivery of kit carts

Dynamic Work inst

Operator assignme

Execute Work Packages in takt

Disturbance

resolution process

Whats next ?


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What s next ?

This week : Start of Work preparation in PRD

Next week : Final UAT

Sept. 30 : Start Roll-out to 1st

workcentersTill end Q1 : Roll-out in ASML Netherlands

To be planned / follow-up projects:

- Potential enhancements after pilot in EUV factory;

- MESMachine interfacing;

- World-Wide roll-out:USA - Wilton

USA - San Diego

Taiwan - Linkou

- Next step for disturbance resolution (QIM ??)

- Workplace efficiencyUse of Mobile / iPad


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Questions


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Presentation - Shop Floor Control - The Road to Integrated Manufacturing

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