Capacity Adjustment in Semiconductor Fabrication During Peak Periods
M.A.Chik1, A.Z.Md Rejab2, M.Z.Darudin3, Hasbullah Ashaari4, M.R.Muhamad5
1M.A.Chik, SilTerra Malaysia Sdn. Bhd. Lot 8, Phase 2, Kulim Hi-Tech Park, Kulim, Kedah, Malaysia. Department of Business Management, Universiti Utara Malaysia, Sintok, Kedah, Malaysia.Sustainable and Responsive Manufacturing Research Group, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka, Malaysia.
2A.Z.Md Rejab, SilTerra Malaysia Sdn. Bhd. Lot 8, Phase 2, Kulim Hi-Tech Park, Kulim, Kedah, Malaysia. Department of Business Management, Universiti Utara Malaysia, Sintok, Kedah, Malaysia.Sustainable and Responsive Manufacturing Research Group, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka, Malaysia.
3M.Z.Darudin, SilTerra Malaysia Sdn. Bhd. Lot 8, Phase 2, Kulim Hi-Tech Park, Kulim, Kedah, Malaysia. Department of Business Management, Universiti Utara Malaysia, Sintok, Kedah, Malaysia.Sustainable and Responsive Manufacturing Research Group, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka, Malaysia.
4Hasbullah Ashaari, SilTerra Malaysia Sdn. Bhd. Lot 8, Phase 2, Kulim Hi-Tech Park, Kulim, Kedah, Malaysia. Department of Business Management, Universiti Utara Malaysia, Sintok, Kedah, Malaysia.Sustainable and Responsive Manufacturing Research Group, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka, Malaysia.
5M.R.Muhamad, SilTerra Malaysia Sdn. Bhd. Lot 8, Phase 2, Kulim Hi-Tech Park, Kulim, Kedah, Malaysia. Department of Business Management, Universiti Utara Malaysia, Sintok, Kedah, Malaysia.Sustainable and Responsive Manufacturing Research Group, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Durian Tunggal, Melaka, Malaysia.
Manuscript received on 24 May 2019 | Revised Manuscript received on 11 June 2019 | Manuscript Published on 26 June 2019 | PP: 56-62 | Volume-8 Issue-1S5 June 2019 | Retrieval Number: A00110681S519/2019©BEIESP
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© The Authors. Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open access article under the CC-BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Abstract: Semiconductor demand is dominated by a three-year cycle compounded by unpredictable slumps and peaks in customer orders. During the peaks, demand may exceed available foundry capacity, and during a slump period, the drop in demand often results in plant utilization of 50% capacity. The constraint in the overall supply chain lies in the capacity of the semiconductor fabrication plant to fabricate chips on the wafer. Cycle times are usually 30 to 60 days with 300 to 900 steps, of which 30% are reentrants to the same equipment depending on recipe complexity. The largest semiconductor suppliers continue to expand factory capacity to cater to periods of high demand. However, smaller suppliers need other methods to maneuver through the demand cycle. This research applies a capacity adjustment approach for smaller high-mix foundries to optimize throughput and meet shortterm spikes in demands using existing resources. A what-if simulation model that adjusted the shared equipment capacity was successful in increasing fabrication output over a two-month period by selecting wafer lots with few remaining shared equipment steps. The output for the first month was increased 21% versus the standard approach, which was followed by an output decrease of 50%. This approach has been successfully implemented in a wafer fabrication foundry.
Keywords: Semiconductor Fabrication, Foundry, Cycle Time, Capacity; Re-entrance.
Scope of the Article: Social Sciences