Block-Based Workflow for Semiconductor Manufacturing Planning
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Solution Overview
Problem
Manufacturing facilities, especially semiconductor manufacturing environments, face challenges in accurately predicting production capabilities and adapting planning systems due to the complexity and inflexibility of traditional planning methods, such as spreadsheet applications and commercial systems, which are cumbersome, difficult to customize, and lack the ability to evaluate plans effectively.
Innovation Solution
Implementing block-based workflows that allow users to generate plans by specifying operations through a series of blocks, enabling the conversion of planning data schemas, determining capacity, and suggesting changes to meet demand, without requiring specialized programming knowledge, thus creating a flexible and customizable planning system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional planning systems (spreadsheets, custom-built systems, commercial systems) are used, then planning can be performed, but the systems are cumbersome, difficult to customize, and lack flexibility when manufacturing conditions change
Solution Approach 1:
The planning system is segmented into discrete, reusable blocks that represent individual operations or functions. Each block is independently defined and can be selectively assembled into workflows, allowing the system to adapt to changing conditions by reconfiguring block arrangements rather than modifying the entire system. This modular structure resolves the contradiction by enabling adaptability through simple block recombination while maintaining manageable complexity through standardized block definitions.
Solution Approach 2:
The system employs dynamic workflows where the sequence and configuration of blocks can be modified based on changing manufacturing conditions. Rather than a static planning system, the block-based architecture allows workflows to be dynamically reconfigured by adding, removing, or reordering blocks, enabling the system to adapt to new equipment, processes, or demand conditions without requiring complete system redesign.
2Ease of manufacture
If custom-built planning systems are implemented, then specific manufacturing needs can be addressed, but the systems require significant technical expertise and time to maintain and modify
Solution Approach 1:
The system uses lightweight, easily replicable block definitions that can be created and modified without significant investment. Each block represents a discrete, self-contained function that can be independently developed and reused across multiple workflows. This approach reduces the cost and complexity of creating custom planning systems while maintaining ease of modification through simple block-level changes rather than system-wide modifications.
Solution Approach 2:
Block definitions serve as reusable templates that can be copied and applied across different workflows and manufacturing scenarios. Once a block is defined with its specific logic and parameters, it can be instantiated multiple times with different configurations, eliminating the need to recreate similar planning logic repeatedly. This copying mechanism significantly reduces the technical expertise and time required to maintain and modify the planning system.
3Productivity
If commercial planning systems are purchased, then planning capabilities are available, but the systems are closed black box solutions that do not allow customization or control by end users
Solution Approach 1:
The block-based workflow system provides universal planning capabilities that can address diverse manufacturing scenarios through a common framework. The same block library and execution engine can handle different product types, manufacturing processes, and planning horizons by simply reconfiguring which blocks are used and how they are arranged. This universal approach delivers comprehensive planning capability while maintaining full customization flexibility, resolving the contradiction between productivity and adaptability.
Solution Approach 2:
The system enables end users to independently customize and control their own planning workflows using the block-based interface, without requiring vendor support or proprietary system modifications. Users can define their own blocks, assemble workflows according to their specific needs, and modify configurations as conditions change. This self-service capability provides both the productivity of a comprehensive planning system and the adaptability of full customization control.
4Reliability
If traditional planning systems are used, then plans can be generated, but the systems lack the ability to evaluate determined plans and troubleshoot problems effectively
Solution Approach 1:
The system incorporates feedback mechanisms that automatically evaluate generated plans against defined criteria and manufacturing constraints. Each block can include validation logic that checks plan feasibility, and the workflow execution process provides feedback on plan quality and potential issues. This feedback capability enhances reliability by systematically evaluating plans rather than simply generating them, while the modular block structure keeps the evaluation logic manageable and maintainable.
Solution Approach 2:
Plan evaluation and troubleshooting are segmented into discrete block-level checks rather than requiring system-wide analysis. Each block can independently validate its inputs and outputs, identify errors, and provide localized troubleshooting information. This segmentation makes the planning system more reliable through comprehensive validation while reducing the apparent complexity by breaking down evaluation into manageable, independent units that can be understood and modified separately.
Data Source
AI summary
Embodiments presented herein provide techniques for executing a block-based workflow to perform a planning process for a semiconductor manufacturing environment. The block-based workflow includes a plurality of blocks that specify a set of operations for performing the planning process. One embodiment includes extracting planning data from a spreadsheet application, converting the data from a first schema to a second schema, generating a plan for the semiconductor manufacturing environment, and publishing the plan to the spreadsheet application, based on the plurality of blocks in the block-based workflow.