Methods, systems, and computer program products for managing movement of work-in-process materials in an automated manufacturing environment

Abstract

Methods, systems, and computer program products for managing movement of work-in-process materials (WIPs) between processing units are provided. A system includes a host system and an application executing thereon. The application implements a method that includes receiving a list of WIP lots, and indexing a list of routes with raw process time by process steps and with safe holding points. The method also includes indexing a scheduled start time of shutdown for the process units and calculating transport time for moving each of the lots to the next nearest safe holding point in the route. For each lot, the method includes determining whether the lot is at a safe holding point, and assigning a dispatch priority to the lot if it is not at the safe holding point. The method further includes sending a list of assigned dispatch priorities to a dispatcher for transporting the lots to corresponding safe holding points prior to initiating the shutdown.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation application of U.S. Ser. No. 11 / 621,693, filed on Jan. 10, 2007, the disclosure of which is incorporated by reference herein in its entirety.BACKGROUND OF THE INVENTION[0002]The present disclosure relates generally to automated material handling systems and, in particular, to methods, systems, and computer program products for managing movement of work-in-process (WIP) materials in an automated manufacturing environment.[0003]In a production environment, quantities of materials are transported through a defined route in an automated manufacturing line, e.g., among processing units, as well as temporary storage locations (e.g., stockers) situated within the route where the materials await further transport and processing. Oftentimes, there are instances where the materials sit idle in these storage locations until a production machine, or processing unit, is ready to receive them. When there is a large am...

AI Technical Summary

Benefits of technology

The system effectively minimizes material damage and reduces costs by prioritizing the transport of work-in-process materials to safe holding points before shutdown, maintaining material integrity and optimizing production processes.

Problems solved by technology

When a manufacturing line is shut down, either by a planned maintenance, retooling or by unforeseen circumstances, the production materials may be subject to various degrees of degradation.

For example, in a semiconductor fabrication facility, certain production materials, such as chemically treated wafers, if left exposed in a location within the production route for a specified period of time, may suffer oxidation or similar types of hazards.

Depending upon the length of the equipment shutdown period, the results can be devastating, particularly when expensive production materials need to be scrapped as a result of damage due to environmental exposure.

Moreover, the costs of additional cycle time and reduced equipment utilization exacerbate this problem.

Images