[논문]AHP를 활용한 반도체부품 생산공정 시뮬레이션 연구

허특; 문덕희; 박철순; 장병림

doi:10.9709/jkss.2009.18.2.065

AHP를 활용한 반도체부품 생산공정 시뮬레이션 연구
A Simulation Study on the Manufacturing Process of Semiconductor Parts Using AHP 원문보기

한국시뮬레이션학회논문지 = Journal of the Korea Society for Simulation, v.18 no.2, 2009년, pp.65 - 75

허특 (창원대학교 산업시스템공학과) , 문덕희 (창원대학교 산업시스템공학과) , 박철순 (창원대학교 산업시스템공학과) , 장병림 (창원대학교 산업시스템공학과)

초록
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반도체 생산공정은 다양한 장비들이 복잡하게 서로 연관된 일련의 작업들로 구성되어 있다. 이들 장비들은 공학적 또는 환경적 요인들을 고려하여 직렬 또는 병렬의 혼합구조로 배치되어 있다. 따라서 많은 비용이 발생하고, 동시에 고려해야할 사항이 복잡하므로 한 번 설치되면 레이아웃 변경이 거의 불가능한 실정이다. 따라서 생산량의 변동이나 신제품의 개발과 같은 상황에서 새로운 설비의 투자나 레이아웃의 변경은 매우 신중하게 결정되어야 한다. 본 논문은 반도체의 부품을 생산하는 공장에 대해 시뮬레이션을 적용한 사례연구다. 시뮬레이션 모델은 $QUEST^{(R)}$라는 도구를 이용하여 개발되었으며, 시뮬레이션을 통하여 생산환경의 변화에 대응하는 다양한 전략을 검토하였다. 또한 본 연구에서는 결정인자가 다수인 대안에서 최적안을 도출해 내기 위하여 AHP 기법을 사용하였다.

Abstract ▼ AI-Helper

The semiconductor manufacturing process normally includes a great number of complex sequential steps those are related with various types of equipment. Such equipments are installed with the mixed patterns of serial or parallel structures while considering a number of engineering or environmental factors at the same time. It is thus extremely difficult to change the layout after installation due to expensive costs and other related factors. Because of these reasons, a new investment or layout change, which is usually caused by the production policy such as product mix or production quantity, must be carefully considered. This case study introduces a simulation conducted in a semiconductor parts production company which produces the Board on Chip (BOC)-type of packaging substrate and has plans to change the facility layout. For this study, we used $QUEST^{(R)}$ for simulation modeling and evaluated various strategies which may cause layout changes. Further, the Analytic Hierarchy Process (AHP) is applied to select the best strategy from several alternatives with multiple decision criteria.

주제어

AI 본문요약
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문제 정의

The objective of the As-is analysis is to confirm the correctness of the simulation model. Using the data collected from the existing line, the simulation results of the As-is analysis should correspond to the real system.
In fact, in the simulation experiments phase, several performance measures have already been applied for the scenario analysis. Thus, when establishing the criteria layer of the AHP structure, the focus is to translate these into criteria measures. After gathering advice from managers and engineers, Throughput, WIP, Lead time, Labor Number, and Shift are regarded as the important factors affecting the performance of the substrate line.

제안 방법

Figure 6 shows the utilization of bottleneck processes in the existing line. In this analysis of results, we categorized the whole simulation time related to machines into four categories, and they were processing time, blocking time, failure time and idle time (including starving time). Processing time included loading/unloading time and operation time.
We aimed to develop a two-layer type model and increase production quantity. In this study, we used QUEST^® for simulation modeling as well as evaluated various other strategies for corresponding environmental changes. We likewise applied the AHP approach to establish the relationship of effect factors and chose the best solution among several similar simulation scenarios.
” For each scenario, five replications were conducted. The As-is analysis was carried out to validate the simulation model and investigate the performance of the initial layout of the line. With the results obtained from the As-is analysis, some improvements were suggested and then verified in a What-if simulation.
The purpose of this scenario was to reduce the working days in one week from 7 to 5, and to keep the Throughput within 120million/month. However, after reducing the working days to 5, the Throughput remained at 84million/month (Scenario 3-1).
The what-if experiments of this system had two main objectives: one was to improve the performance of the machines and increase the throughput, and the other was to explore the possibility of changing the product mix with the new product (two-layers). The new throughout target was set at 120 million pieces/month.
From the comparison, we convinced that the simulation model was valid for representing the real production system. Upon ensuring the validity of the model, the experiments for the new layout with two types of products will then be carried out in the What-if analysis.
The As-is analysis was carried out to validate the simulation model and investigate the performance of the initial layout of the line. With the results obtained from the As-is analysis, some improvements were suggested and then verified in a What-if simulation.

대상 데이터

The raw materials of the products consist of the reel type of Copper Clad Laminate (CCL). The width of a reel is 80-350mm, and the length of a reel is 50-100m.

이론/모형

Therefore, it is difficult to get the conclusion directly just by simple observation. This is the reason why AHP method has been applied in this paper. Since that Scenario 4-3 is not a reasonable solution because of its higher WIP, Lead Time, and inconsequential Shifts, only the other five other scenarios will be discussed.

참고문헌 (12)

Adolfsson, J., Ng A., Olofsgard P., Moore P., Pu J.S. and Wong, C.B. (2002). "Design and simulation of component-based manufacturing machine systems." Mechatronics, Vol. 12, pp. 1239-1258.

상세보기
Chao, C.Y, Huang, Y.L., Wang, M.Y. (2006). "An Application of the Analytic Hierarchy Process (AHP) For A Competence Analysis of Technology Managers from the Manufacturing Industry in Taiwan". World Transactions on Engineering and Technology Education, Vol. 5, No. 1. pp. 61-62.
Ertay, T., Ruan, D. and Tuzkaya, U. (2006). "Integrating Data Envelopment Analysis and Analytic Hierarchy for the Facility Layout Design in Manufacturing Systems", Information Sciences, Vol. 176, pp. 237？262.

상세보기
Finan, J.S., Hurley, W.J. (1999). "Transitive calibration of the AHP verbal Scale". European Journal of Operational Research, Vol. 112, pp. 367-372.

상세보기
Finch, B.J. (2006). Operations Now: Profitability, Processes, Performance, 2nd ed. Boston: McGraw- Hill/Irwin.
Moon, D. H., Xu, T. and Shin, W. Y. (2008). "A Simulation Study of the Crankshaft Line in an Automotive Factory". Journal of the Korea Society for Simulation, Vol. 17, No. 2, pp. 1-11.
Tracy, D.P., (1999). "Opportunities and Challenges for Package Substrate Suppliers", Chip Scale Review, January-February, (http://www.chipscalereview.com/archives/ ES/issues/0199/home.htm).
QUEST User Manual (2006). Delmia Cooperation, Michigan, U.S.A.
West, A.A, Harrison, R., Wright, C.D. and Carrott, A.J. (2000). "The visualisation of control logic and physical machine elements within an integrated machine design and control environment." Mechatronics, Vol. 10, pp. 668-698.
Wong, G. (1999). "Multi-Criteria Decision-AID For Building Professionals". The Journal of Building Surveying, Vol. 1(1). pp. 5-10.
Yang, T.H., Kuo, C.W. (2002). "A hierarchical AHP/DEA methodology for the facilities layout design problem". European Journal of Operational Research, Vol. 147. pp. 128-136.
http://www.siliconfareast.com/leadframes.htm

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