Cycle Time Reduction, Simulation Modeling, Efficiency Consulting

Reduce Cycle Time By Up to 33% using MIVP:
MIVP is a scheduling and release policy (like FIFO) designed to reduce overall average production cycle time. Average cycle time of all the product mix in production is defined as the summation of all the process times plus the wait time (queue time) at each process step from the raw wafer entering the FAB until it is shipped. MIVP is specifically designed for semiconductor manufacturing. MIVP has been proven to work at SEMATECH member companies resulting in average cycle time reductions from 7% up to 33% (savings estimated $21 - $100 plus million per year).

MIVP implementation is done after the following three steps:
Step 1: Collection and organization of all product process flows, step by step, including the process time, number of wafers in the process step, and equipment data to calculate theoretical cycle time.

Step 2: Preparation of a baseline simulation model of the FAB using existing scheduling policies and/or FIFO policy. Operation of the model for validation, cycle time and WIP data are saved for comparisons.

Step 3: Switch existing scheduling policies and/or FIFO with MIVP policies and rerun the model to demonstrate how MIVP benefits the reduction in cycle time and WIP data.

Once the benefit is seen offline on the simulation model the client can decide to implement MIVP live in the FAB to obtain improvements.

Capacity Modeling to Maximize Efficiency:
Theoretical models show the average capacity of each piece of equipment on the factory floor making bottlenecks and factory constraints apparent. Factory models are made to mirror actual factories using simulation software to accurately mimic real life scenarios including machine downtime and repair time with 95% confidence.

Simulation Modeling for Risk Analysis:
Simulated factory models can be set up by our staff to your specifications to provide quantitative solutions to factory scheduling problems. These models are run off line to determine different scenarios. What If Scenarios could include changing the current product mix to see how it affects each machine's capacity, each product's cycle time and overall manufacturing cost.

Simulation Modeling For New Plants:
We provide simulated factory models to determine equipment capacity for each section in the factory for given and future product mixes. Once a model is built different equipment comparisons can be made. This data determines if a new plant can handle future orders.

Simulation Modeling to Avoid Bottlenecks:
Models can be used for determining bottlenecks offline prior to scheduling production mix.