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日月光半導體 e 化 之 進程與問題之分享. 日月光高雄廠資訊中心 盛敏成 Nov. 23, 2006. Agenda. ASE Group Our business models Our IT strategy A follower, a partner and a leader 由服務中學習 , 由學習中改善服務 ASEKH IT system evolution Case study 晶采計劃 Smart customer SAP II project Experience sharing Conclusion. ASE MISSION. - PowerPoint PPT Presentation
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日月光半導體日月光半導體ee化化之之
進程與問題之分享進程與問題之分享
日月光高雄廠資訊中心盛敏成Nov. 23, 2006
Agenda
ASE Group Our business models Our IT strategy
– A follower, a partner and a leader• 由服務中學習 ,由學習中改善服務
ASEKH IT system evolution Case study
– 晶采計劃– Smart customer SAP II project
Experience sharing Conclusion
ASE offers the Best Design Manufacturing Services for IC Packaging, IC Substrates, IC Testing, and Systems.
ASE will act as an Extension of Our Customers’ Own Operations in Achieving the Maximum Business Objectives with Minimum Resources.
ASE MISSION
ASE Group
Test
• Substrate Design
• Manufacturing Service
• Modeling & Simulation
• Program Development
• Wafer Probing
• IC & Module Test
• Burn-In
• Warehousing
• Drop-Shipment
• Package & Module Design
• IC Assembly
• Multi-chip Assembly
• Micro & Hybrid Module
Assembly
System
• DMS (Design Manufacturing Services)
• Board Assembly
• Hybrids & Electronic
Packaging
• Logistic Management
Material
ASE VISION: THE COMPLETE SOLUTION
Engineering Test
Wafer Bumping/Probing
Materials
Assembly
Final Test
Module, Board Assembly & Test (DMS)
Foundry
Circuit Design
ASE VISION: THE COMPLETE SOLUTION
Operation sites–ASEKH(A/T/M), ASECL(A/T/M), ASEKr(A/T), ASEM(A/T), ASESg(T), ISE(T)–USI
Electronics Industry Supply Chain
Customer OEM EMS Sub-Assembly Components
customers
customers
customers
suppliers
50+ suppliers
180+ suppliers
1200+ othersuppliers
Japan, US, Taiwan
Other suppliers15+customers
100+ suppliers
GST
Foundry, Pkging & Test
Our Business Model
Engineering/Manufacturing service provider– Make the parts upon customer specification and
instruction• Key success factor: operation excellence and quality• Compete with other service provider and customers’
MFG teams• Without ERP system until 2004
Business guideline– Easy for customer to do business with ASE
• Seamless integration with customers’ process flow
– Quality, Flexibility, Efficiency
Supply Chain & Quality Strategy
Demand Uncertainty
Launch Phenomenon
Cost Pressure
High Quality Expectations
Speed & Flexibility
Security of Supply
Efficient Supply Chain
Proactive & Responsive
Environmental Conditions
Best Customer Experience
Customers’ Supply Chain Objectives
Collaborative forecast, order and inventory management solution connected with key suppliers.
Exception based management Scalable business process integration
with suppliers Centralized visibility to business processes Performance metrics for supplier
management“Building sustainable competitive advantage into the collective supply chain”
LEANSPEED
FLEXIBILITY
Multi-tier Execution
Business Value
Process Breadth, Number of Trading Partners
Multi-Company Process
Management
One-way Information
Posting
Two-way Information Exchange
Closed-loop, Positive Response With Exception
Alerts
Synchronized Processes, Timely and Quality Information
Multi-tier VisibilityException Management Across Multiple
Tiers of the Value Chain
Data Exchange
Multi-Company Process Management enables a
synchronized Supply-Chain
Decision Support
Exception Management
Data Aggregation
ExceptionAlerts
Customers’ Goal
Allentown
Thailand
Singapore
Orlando
Twin Cities
Sub Con Assemblers
Foundries
Forecasts
Purchase Orders
Shipping Notices
Shipping Notices
IndirectMaterialsSuppliers
Consignment
Materials
Suppliers
I-BOX
Approach for I-Box
Functionality at the edge
Point-to-Point Integration One trading partner at a
time
Client-Server Architecture“Thick at the Edge”
“Point-to-Point”
Service Oriented Architecture“Thin at the Edge”
“Intelligent Network”
Functionality in the network Connect once and leverage Shared service economics
Partner F Partner C
Partner E
Partner A Partner B
Partner D
Partner F
Partner E
Partner A Partner B
Partner D
IntelligentNetwork
Partner C
Our IT Strategy
A follower Learn– Leverage the best practice from customers, competitors,
and industry leaders– ASE has the fortune to work with the most competitive
companies in the IC supply chain– Research: Re-Search
A partner Do– Build up quality information links with customer– Provide process integration solution model to customers
A leader Continuous Improvement– Identify the core function of information integration
process– Develop systematic approach to identify the critical
information links to make business model successful
ASE IT System Evolution
Home grown legacy systems– Two independent operation company for different services
(Assembly and Test)– Did not build up integrated process with well-organized
information links– IRS system build up for short term solution
Big-Bang Approach– Driving force: to provide turnkey service to customers– GRP project: kicked off on March, 2002– System went live Jan/5/2004– Material operation: KH/CL Jan/2005; SH Sep/2005
Continuous Improvement– Separated instance for Material operation: Aug/2006– PLM system go live Dec/2006– SAP/e project kicked off Dec. 2005
ASE_Assy_ IT 系統關聯圖 (~2003)
採購管理(Purchase)
庫存管理(Inventory)
進口系統(Import)
保稅系統(Bond)
IQA
系統
應收帳款(A/R)
應付帳款(A/P)
總帳(G/L)
固定資產(A/M)
產品成本系統(Product COST)
Forecast
出口系統 /Price
(Export/Price)
投料系統(T/T)
晶片庫系統Wafer
Bank
成品庫管理Finish Goods Stock
工程資料庫(PEDB)
獎工系統(Bonus)
M
E
S
HR
出口系統成品系統
保稅系統成本系統
出口成品系統
SAP
Cobol+
Informix
Access
Other
System
InterfaceData FlowReference
T/T
Controlling
(CO)
Shipping
Plan
Sales
ReportPacking
Instruction
Notes AP
SPEC/ECN IMQR
VB+
Oracle
ASRS
Packing
PEDB
Label
PTSetup
Procedure
TDRP
Shipping
Price
PO
SAP
GUI
MES
Invoice
MM
AOL Intranet InternetEqu TimeRecord
BonusCost
Spare Parts
Tooling
Extricity
Others :
FCST TSMCShip Instr.
MES Menu
Plan
TEVHold Bank SPECCAR TesterConfig Hold Lot
E-PR
HR E-HR
ASE_Test_ IT 系統關聯圖 (~2003)
GRP=ERP+SCM
ERP Inventory
Sales •Order taking•Pricing
Sales •Order taking•Pricing
Purchase•Wafer pur. plan•Purchasing
Purchase•Wafer pur. plan•Purchasing
Financial• GL • AR • AP
•Fixed asset • Budget/Cost • Cash management
Financial• GL • AR • AP
•Fixed asset • Budget/Cost • Cash management
Receive CustomerVendor
Quotation
PO
Transfer Pick/Pack Ship
Inventory Documents BillingValidation
Invoice
發料記錄
PaymentPayment
Invoice
Invoice
Invoice
Quotation
PR
Assembly
Finish GoodsWafer consume
Order to production
Wafer Sort Final test
Production Plan•Forecast
•MRP
Production Plan•Forecast
•MRP
Capacity optimization, Material planning and production plan optimizationSCM
Internal Business Flow
ASEKH- ASSY
ASEKH-TEST
CustomerWafer Sort
Package
Plant 1
Plant 9
Plant 2
Final Test
Order
WIP
/EN
G/B
illi
ng
Central OT
Central Planning
Manufacture
Wafer
In Fab Planning
ASSYTEST
Turnkey$$
$
WIP/ENG/Billing(TEST)
WIP/ENG/Billing(ASSY/TK)
Finish Goods(ASSY)
Finish Goods (TEST/Turnkey)
Bumping
Plant 1
Plant 2
Goal of ASE GRP Project
Ship
Phase I
Business processes Included :
• Ass’y & Test in KH site
System To Be Implemented
• ERP(Enterprise Resource Planning)
• SCM(Supply Chain Management)
• Middleware (System Integration)
Order Tacking
Integration System
SCM System
ERP System
ASE Group
Procurement
ASET ASEK
Procurement ProcurementProcurementProcurement Procurement
ASE-CL
Ass’yTest
Ship
ASE-China
Ass’yTest
Ship
ASE-Korea
Ass’yTest
Ship
ASE- Malaysia
Ass’yTest
Ship
ASE- others
Ass’yTest
Ship
Procurement
Order fulfillmentCost Down
Current IT ArchitectureLegacySystemMES PDM
Integ
rated C
usto
mer In
terfaceHRS
Middleware
Middleware
ERP
Notes(w/f)
IRSData
CenterSCM
Interface
LegacySystemMES PEDB HRS Notes(w/f)
Cu
stom
er
Ve
ndo
r
Interface
ASSY
TEST
For CRP and MRP
Order taking and Execution, MM,
and FI/CO
Enterprise Application Integration
GRP System (1/5/2004)
ERP: SAP R3– SD (Sales and Distributions)– PP (Production Planning)– MM (Material Management)– CO (Controlling)– FI (financial)
SCM: Adexa– SCP (Supply Chain Planning) with CRP and MRP for mon
thly and weekly planning– PP (Plant planning) for daily planning
System Integration– Tibco BW (Business Work)
Application Architecture
Notes
SAP Adexa
BONUS
PriceCalculation
MES
WorkStream
PromisFactoryWorks
VMI(Web)
B2B(Customer)
2003/6/19Date
ASE GRP project Application Architecture (Total View)Chart Title
Page
Version 1.0
1 of 9
Legend:
ASEKH-Assy System ASEKH-Test System
Data to GRP
Data from GRP
GRP System ASEKH A/T shared sys.
HRIS
應收帳款資料傳送
ePMS
eHR
借機系統
Quotation
Forecast(Web)
ASEKH A/Tseparated sys.
Not existed
ASEKInternet
FTP Server
SpecialCharge
零用金系統
CM
PackingCustomer
Layout系統
ED
PGI
TrackingEngineering Data System
EnoviaPDM
POS
CustomerReport
DataCenter
IRS
B2BProcessor
B2B(Vendor)
Label
33 機密資料/僅限GRP專案內部使用2004/6/4
Special Process Flow – General Assembly
TSMC收料 IQA 入庫
發料領料單Issue工單Assy SO Adexa
ASSY MES
轉暫存倉 Test庫房收料
Test SO
TEST MES
領料單
入成品庫
出貨DN/Billing
DN/Billing Test IQA
入Test庫
Test庫房發料
工單
confirm工單
入ASSY出貨虛擬倉
入Test成品庫/虛擬倉
Adexa 工單
帳流實體物流MESAdexaGRP
Future Plan Strategy
– Align with our Group strategy– Provide same information service for customers– Integrate cross operations and cross departments
information for quality operation and efficient management
Approach– Continuous process improvements with internal
customers– Refine IT system architecture to enhance
management information provision– Leverage best practice from customers, partners
and competitors
Future Plan - 1
Phase 1.1– Include Material operation into GRP system
• Project kick off on July/2004• Best practice deployment, including ASECL
Material
– More customer B2B enhancement• To facilitate the information links with customers• Proactive initiator for ASN and W/O B2B projects
– Analytic information standardization and provision
• Business intelligence data warehouse project• Provide more integrated information for SCPM
Continuous Improvement Customer portal enhancement
– Phase 1: July/2004; phase 2: Mar/2006– Phase 3: Dec/2006
Sales IT function support– Sales management:
opportunity/quotation/forecast/order/revenue/profit– Customer activity management
SCM system enhancements– Planning/Scheduling/Dispatching– Supply management enhancement
Group ENG data architecture – PLM and more– Central vs. Distributed vs. Hybrid
Case Study
TSMC ePO, Work order project– Document transfer handling
Smart customer SAP II project– WIP transaction message
Work Order Business Flow (Before)
Customer Process Transaction Process ASE Process
Buyer
ERP ( SAP)
Create Work Order
New WO Request
WO Request Flow
WO Reply Flow
Work Order
Mail or FAX
Mail or FAX
衍生問題 :- 流程中人為操作錯誤- Batch 人工操作 ,作業時間過長- 不易確認資料傳送成功性- 缺乏資料傳送的不可否認性
Work Order Business Flow (Before)
Customer Process Transaction Process ASE Process
Buyer
ERP ( SAP)
Create Work Order
New WO Request
WO Request Flow
WO Reply Flow
Work Order
Mail or FAX
Mail or FAX
Planner
WOsSpec.
Manually key in WO & Spec. data to system
ERP
衍生問題 :- 登打資料錯誤頻繁- 規格參照錯誤- 人工操作時間過長- 過於依賴人為判斷
Work Order Business Flow (Before)
Customer Process Transaction Process ASE Process
Buyer
ERP ( SAP)
Create Work Order
New WO Request
WO Request Flow
WO Reply Flow
Work Order
Mail or FAX
Mail or FAX
Planner
WOsSpec.
Manually key in WO & Spec. data to system
ERP
Check the WO status
Investigate can meet the Order or not
衍生問題 :- 溝通時間過長- 人為溝通造成達交率降低- 雙方認定標準不同
Telephone Telephone
Follow up the Work Order
Follow up the Work Order
Contact with ASE for SOD & key in system
Buyer
Customer Process Transaction Process
( ( RosettaNet ))
ASE Process
Work Order Business Flow (Current)WO 7B5 Flow
WO 7B6 Flow
A New WO Request
ERP ( SAP)
Create Work Order
RosettaNet Gateway
Internet
Firewall Firewall
Pip7B5
解決問題 :- 自動化 ,減少流程中人為操作錯誤- 無紙化 ,無須人工列印傳真- 提高資料傳送確實性- 減少人為判斷錯誤- 標準化規格溝通容易- 大大減少資料溝通時間
Buyer
Customer Process Transaction Process
( ( RosettaNet ))
ASE Process
Work Order Business Flow (Current)
MES
Confirm SOD and release to production line
WO 7B5 Flow
WO 7B6 Flow
A New WO Request
ERP ( SAP)
Create Work Order
RosettaNet Gateway
RosettaNet Gateway
Internet
Firewall Firewall
Pip7B5
Planner
ERP
New WO Notice
解決問題 :- 減少流程中人為操作錯誤- WO 資料直接進入系統 ,無須人工介入- 減少大量登打資料 ,人力節省- 減少人為錯誤判斷
Buyer
Customer Process Transaction Process
( ( RosettaNet ))
ASE Process
Work Order Business Flow (Current)
Query WO reply by vendor
MES
Issue to WIP according to WO & PDM
Reply WO according to SCM system
WO 7B5 Flow
WO 7B6 Flow
A New WO Request
ERP ( SAP)
Create Work Order
RosettaNet Gateway
RosettaNet Gateway
Internet
Firewall Firewall
Pip7B5 Pip7B6
Planner
ERP
New WO Notice
解決問題 :- 回覆資料直接進入系統- 回覆登打資料錯誤減少- 縮短資料覆核時間
ASE PO Process (Before)
VendorsVendors
PO Request Flow
PO Reply Flow
Purchasing Officer creates PO in ERP
A NewPO
Request
Send PO through Fax to suppliers
Supplier received PO through Fax
PO
ERP 衍生問題 :- 流程中人為操作錯誤- Batch 人工操作 ,作業時間過長- 不易確認資料傳送成功性- 缺乏資料傳送的不可否認性
ASE PO Process (Before)
Send PO through Fax to suppliers
Supplier received PO through Fax
PO
1. Entry the PO into system 2. Manually file the document
Sales Order System /
Spreadsheet
Manually files it
VendorsVendors
PO Request Flow
PO Reply Flow
Purchasing Officer creates PO in ERP
A NewPO
Request
ERP 衍生問題 :- 流程中人為操作錯誤- 人工操作時間過長- 登打資料錯誤頻繁- 過於依賴人工判斷- 檔案保存不易
PO
PO
ASE PO Process (Before)
Send PO through Fax to suppliers
Supplier received PO through Fax
Supplier deliver goods
Purchasing Officer follow-up with suppliers manually
Sales Order System /
Spreadsheet
Manually files it
PO
VendorsVendors
PO Request Flow
PO Reply Flow
Purchasing Officer creates PO in ERP
A NewPO
Request
ERP
Review inventory and confirm SOD
Backend System
Reply the PO confirmation
衍生問題 :- 溝通時間過長- 雙方認定標準不同- 人為溝通造成達交率降低- 資料正確性易產生糾紛- 易產生斷料危機 1. Entry the PO into system
2. Manually file the document
RN PO 3A4/7/8/9 with Vendors (Current)
PO created in customer’s ERP
PO
ERP
ASE Process ASE Process (Private Process)(Private Process)
Vendors ProcessVendors Process(Private Process)(Private Process)
Transaction ProcessTransaction Process
(RosettaNet)(RosettaNet)
VendorsVendors
RN PO Request Flow
RN PO Reply Flow
A NewPO Request
Transport, Translate,
Map & Load
B2B ServerInternet
Firewall Firewall
3A4/8/9PIP
解決問題 :- 自動化 ,減少流程中人為操作錯誤- 無紙化 ,無須人工列印傳真- 提高資料傳送確實性- 減少人為判斷錯誤- 大大減少資料溝通時間- 標準化規格溝通容易
RN PO 3A4/7/8/9 with Vendors (Current)
PO created in customer’s ERP
ERP
ASE Process ASE Process (Private Process)(Private Process)
Vendors ProcessVendors Process(Private Process)(Private Process)
Transaction ProcessTransaction Process
(RosettaNet)(RosettaNet)
VendorsVendors
RN PO Request Flow
RN PO Reply Flow
A NewPO Request
Transport, Translate,
Map & Load
B2B ServerInternet
Firewall Firewall
3A4/8/9PIP
B2B Server
ERP
POs appear in supplier’s ERP System
Transport, Translate,
Map & Load
3A4/8/9
Notification ConfirmPO Data
解決問題 :- 減少流程中人為操作錯誤- PO 資料直接進入系統 ,無須人工介入- 減少大量登打資料 ,人力節省- 減少人為錯誤判斷- 資料系統化
PO
RN PO 3A4/7/8/9 with Vendors (Current)
PO created in customer’s ERP
ERP
ASE Process ASE Process (Private Process)(Private Process)
Vendors ProcessVendors Process(Private Process)(Private Process)
Supplier deliver goods
Transaction ProcessTransaction Process
(RosettaNet)(RosettaNet)
VendorsVendors
RN PO Request Flow
RN PO Reply Flow
A NewPO Request
Transport, Translate,
Map & Load
B2B ServerInternet
Firewall Firewall
3A4/8/9PIP
3A7 Notification
3A7PIP
B2B Server
ERP
POs appear in supplier’s ERP System
Transport, Translate,
Map & Load
3A4/8/9
Notification
解決問題 :- 回覆資料直接進入系統- 回覆登打資料錯誤減少- 減少人為判斷錯誤PO Confirm
PO Data
RN PO 3A4/7/8/9 with Vendors (Current)
PO created in customer’s ERP
ERP
ASE Process ASE Process (Private Process)(Private Process)
Vendors ProcessVendors Process(Private Process)(Private Process)
Supplier deliver goods
Transaction ProcessTransaction Process
(RosettaNet)(RosettaNet)
VendorsVendors
RN PO Request Flow
RN PO Reply Flow
A NewPO Request
Transport, Translate,
Map & Load
B2B ServerInternet
Firewall Firewall
3A4/8/9PIP
3A7 Notification
3A7PIP
B2B Server
ERP
POs appear in supplier’s ERP System
Transport, Translate,
Map & Load
3A4/8/9
Notification
Touch-less, seam-less and trading partners information in your own system
PO ConfirmPO Data
經 濟 部
T S M C & A S E
M a r . 2 0 0 4 P . 4
• 涵 蓋 台 積 電 與 日 月 光 供 應 鍊 之 工 程 協 同 合 作 ( E n g i n e e r i n g C o l l a b o r a t i o n ) 與 運 籌 協 同 合 作 ( L o g i s t i c s C o l l a b o r a t i o n )
• 包 含 b u s i n e s s l i f e c y c l e 中 所 有 重 要 之 作 業 流 程
專 案 範 圍
封 裝 測 試
台 積 電( 晶 圓 代 工 W a f e r F o u n d r y )
在 製 品出 貨
釘 架 / 基 板 供 應 商
供 應 商
委 工 單 在 製 品 資 料 良 率 資 料 成 品 資 料 測 試 結 果 . . . .等
電 子 訂 單 庫 存 資 料 在 製 品 資 料 出 貨 資 料
日 月 光
整 合 元 件 製 造 商 ( I D M ) /
I C 設 計 公 司 ( F a b l e s s )
電 子 訂 單 在 製 品 資 料 出 貨 資 料 發 票 資 料 測 試 工 程 資 料
專 案 範 圍
上 游
下 游
Result
TSMC provide turnkey service to customers– ASE provide turnkey service to customers, too
Most complete data link among our customers– Frontier project and benchmarking
More variants of turnkey model coming up– Material flow, information flow, cash flow
Project Objective – SAP II Project
A Fabless customer started the WIP tracking project – Can consolidate WIP data from global sub-contractor site
s, with multiple data formats. – Allows quick reporting and analysis using data from one s
ystem, which is SAP. – Has been particularly challenging for virtual manufacturi
ng companies. The company is looking forward to building a strategic alliance with its manufacturing partners. This venture should be mutually beneficial to all parties.
– Took this opportunity to establish an end-to-end business process tying together its operations, costing, purchasing, and accounting departments. This is expected to give the company more finance and purchasing control.
System Dual
SAP
PP
SD
MM MES
PP
SD
MM
TxnRecord
BizTalk
BC TxnRecord
D/N
ABR/MBR
Customer
WIP Txn
SHIP
Vendors
System Dual in WIP Tracking
W0 : Represent the WIP status at time=0.
Ti: Represent the WIP transaction during that period.
Subcon Customer
W1
W0
Wi
Wi+1
W1
W0
Wi
Wi+1
T1
T2
Ti+1
.
.
.
.
.
....
Results
Come from behind– Reach 98.5% accurate for
consecutive 3 month A generic WIP-TS system model
– Build up for other three customers– Fast deployment, reliable system
performance
Experience Sharing
Product consultant vs. Business consultant– Learn from SAP project
Your project vs. Our project Expectation management Training and coaching
– The way– Methodology– Discipline– Management
Experience Sharing System
– The output from project: the least important– Loading test, stress test
Process– Business process review, re-engineer– Integration test, user acceptance test
People– Teaming, vendor selection– Change management, expectation management,
training, coaching, change enablement Data
– Data conversion, legacy system integration Time
– Schedule control, scope control, environmental factors
Conclusion
PDCA-embedded IT system– Plan/Operation/Comparison/Action, instead of
operation support only– Build up business intelligence to support
Strategic Enterprise Management (SEM) Process centric information links
– Business process is the key– IT vs. domain knowledge
Customer-oriented– Rigid, but flexible, architecture to fulfill
different business model
Integrated Management Processes
External communication
Strategy update
Mid-term planningB/S, I/S, Cash Flow
3-5 year strategic planning
Evaluate scenarios
Cascade targets to lower Bus.Units
Detailled operationalplanning
Measureperformance
Business processoptimization
Strategy and Business Management Strategy and Business Management
Performance Management Performance Management
Strategyanalysis and assessment
Adjust operations
Risk estimation
Define objectives, Set targets,
Launch initiatives
Forecast
Strategic PlanningStrategic Planning
SEM and Business Analytics
Strategic Enterprise Management
PLMAnalytics
Financial Analytics
HRAnalytics
SCMAnalytics
CRMAnalytics
Business Analytics
business processes
BusinessPlanning &Simulation
StrategyManagement
Business Consolidation
PerformanceMeasurement
Suppliers Customers
StakeholderRelationshipManagement
Adapt operations
Detailledoperational
planning
External communication
Strategy update
Mid-term planningB/S, I/S, Cash Flow
3-5 year Strategic planning
Evaluate scenarios
Cascade targets to lower Bus.Units
Strategy analysisand assessment
Strategy & Business Mgmt. Strategy & Business Mgmt.
Manage strategy of Enterprise / Business Units (BU) to create long-term value
Manage performance of BU to improve short-term results
Business processoptimization
Performance Management Performance Management Measure
performance Adapt business operations based on results from Business Analytics
Optimize business processes across functions to improve overall business performance
Transactional processing (ERP, CRM, SCM, ...)
Risk estimation
Strategic Planning
Strategic Planning
Objectives, Targets,Initiatives
Forecast
Q & AQ & A
Thanks for your listening
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