Designing a Flexible Production Flow Using IDEF1x--- an IC Packaging WIP System

Long-Chin Linab, Chih-Hung Tsaic, Kai-Ying Chenb, Rong-Kwei Lia

aDepartment of Industrial Engineering and ManagementNational Chiao Tung University, Hsinchu, Taiwan, ROC.

.bMechanic Industry Research Laboratories,

Industrial Technology Research Institute, Hsinchu, Taiwan, ROC.

cDepartment of Industrial Engineering and ManagementTa Hwa Institute of Technology, Hsinchu, Taiwan, ROC.

Abstract

The IC packaging industry relies heavilyon shop floor information, necessitating thedevelopment of a data model to flexiblydefine shop floor information in theproduction flow. For this purpose, this workdesigns a novel data model by usingIDEF1x. The proposed data model consistsof four modules: operation template setup,general process setup, enhanced bill ofmanufacture (EBOMfr) setup, and work-order process setup. In addition to allowingthe user to flexibly define the required shopfloor information and decision rules, thedata model provides the flexibility to allowone to adopt changes. Since the data modelis static, to handle manufacturing data timelythis work also suggests a WIP (work-in-process) execution module to monitor andcontrol production flow. Finally, anillustrative example, the MIRL WIP System

integrated the data model with a WIPexecution module (developed by MechanicalIndustrial Research Laboratories ofIndustrial Technology Research Institute),demonstrates the effectiveness of theproposed data model.

Keywords --- Bill of manufacture, IDEF1x,Manufacturing execution system, Shop floorinformation system, WIP system

Introduction

Integrated circuit (IC) manufacturingcan generally be divided into five majorparts: design, fabrication, chip probe testing,packaging and final testing. IC packagingtransforms wafers into chips. Since theproduct cycle time is short and the arrival ofthe product can not be planned, IC packaging

industry managers heavily rely on shop floorinformation to timely handle dynamic shopfloor environments and respond to customerrequests. Therefore, improving thecompetitiveness of a company mostlydepends on flexibly incorporating shop floorinformation into the production flow andhandling manufacturing data quicklyaccording to the production flow.

A standard IC packaging productionflow consists of the following operations :wafer grinding, wafer sawing, die bonding,epoxy cure, wire bonding, post-bondinginspection (PBI), molding, marking,dejunking/trimming, solder plating,forming/singulation, open/short testing, leadscan, final inspection, packaging, outgoingQC et al.. Typically recorded on a run card,the manufacturing information of theproduction flow for each lot is manuallynoted by floor personnel, and latersummarized by an assigned department. Thiscard is filled out as the production batcharrives on the floor, recorded by the floorpeople based on the production facts at everyoperation, and finished when the productionbatch reaches completion.

Although easy to process, the run cardcreates several problems: (1) The exceptionson the floor cannot be effectively handledsince such information is difficult to obtaintimely; (2) The best resolution time is misseddue to the slow rate of accumulating timecritical information; and (3) The data isinvalid due to human error.

To overcome the above problems andensure good customer service, an ICpackaging WIP system is required. The WIPsystem should allow the user to perform thefollowing tasks: (1) Flexibly define shopfloor information in the production flowbefore production; (2) Timely handle the lotactivities of customer orders according topredefined production flow during

production; and (3) Easily modify productionflow information to allow fulfilling ofchanging product requirements and floorsituations.

Generally, a WIP system is the core ofthe shop floor information system.Meanwhile, the shop floor informationsystem bridges the planning and controllevels. This system takes orders from theplanning level, then coordinates, controls,monitors equipment in the control level.Melnyk (Melnyk, 1985,1987) defined a shopfloor information system narrowly asincluding the following five functions: orderreview and release, detailed assignment, datacollection and monitoring, feedback andcorrective action, and order disposition.Besides these functions, Vollman, Berry &Whybark (Vollman, 1992), and Sartori(Sartori, 1988) also cited scheduling,dispatching, and monitoring. The system canalso be broadly defined as a manufacturingexecution system (MES). Manyinvestigations (Deuel, 1994; Hakanson,1996; Leibert, 1997) have stressed the role ofMES in bridging Manufacturing ResourcePlanning (MRPII) and the shop floorsupervisory system. In addition to integratingindividuals, materials, machines, time, andcost via a relational database, this systemalso provides operation tracking, feedsinformation back to the planning system, andproduces managerial reports for decisionsupport.

Narrowly defined, shop floorinformation system uses BOM and routes inthe planning level, and is combined with ashop floor reporting system to monitorproduction flow. Thus, its application islimited by the lack of a flexible productionflow data scheme capable of assisting theuser to define what shop floor information tocollect and how to handle exceptions timely.Shop floor information systems such asPromis (Promis, 1990), WorkStream

(Consilium, 1991), Poseidon (IBM, 1994) etal. provide a flexible production flow datascheme to support the user. However, thedata scheme of such commercial systems isproprietary. Therefore, modifying the datascheme in these commercial systems forfuture requirements is difficult. However, notmany small, medium firms can afford suchsystems, since they are highly complex,customized, and costly.

Hastings and Yeh (Hastings, 1992)described a data structure called the bill ofmanufacture (BOMfr), capable of integratingrouting and BOM. BOMfr has the followingfeatures: (1) A product may have one ormore operations; and (2) Materials requiredby an operation should be presented in thecorresponding BOM as the next lower levelof component items, and resources such aslabor, machines and cost information canalso be added. An advantage of BOMfr is itsability to incorporate a data structure withintegrated manufacturing information into anoperation at the planning level. However, italso lacks the necessary shop floorinformation and decision rules to facilitateshop floor activities, such as how to definethe data items to be collected and rules forhandling exceptions. Therefore, its shopfloor applications are limited.

To overcome the above problems, thisstudy presents a novel flexible productionflow data scheme for the shop floor. Theproposed scheme comprises four modules:operation template setup, general processsetup, enhanced bill of manufacture(EBOMfr) setup and work-order processsetup. This data model is characterized bythe ability to flexibly define shop floorproduction flow, allowing effective responseto changes on the shop floor. Additionally,the proposed model can cooperate with aWIP execution module to monitor andcontrol the production flow to timely handlemanufacturing data and enhance the floor

decision making.

Designing a Flexible Production Flow

Figure 1 schematically depicts the shopfloor activities of the IC packaging industry.According to this figure, the proposed datamodel views the shop floor activities of ICpackaging as an accumulation of sequentialoperations. Applying the four basic modulesof the data model, that is, operation template,general process, enhanced bill ofmanufacture (EBOMfr), and work-orderprocess, as Fig. 2 depicts, allows shop floorproduction flow to be designed in aconfigurable manner.

Basically, a product, semi-product orproduct family can own multiple sets ofEBOMfr. Meanwhile, each EBOMfrcontains available materials setup, availableequipment setup and override attributes. Awork-order process is a specific EBOMfrwith corresponding available materialassignments, equipment assignments andoverride attributes, based on customerrequirements before the review and releaseof a work order. Each EBOMfr is linked to ageneral process. Meanwhile, a generalprocess, consisting of a group of sequencedoperations, is used to control productionflow. An operation is the basic tracking uniton a shop floor. The contents of an operationare copied and modified from thecorresponding contents of an operationtemplate. Meanwhile, the contents of anoperation template can be defined freely bythe user. For example, a user can establishattributes of operation templates, such asyield rate, input quantity, or defineexceptional rules, such as low-yield-rate ruleand unmatched-input-quantity rule. Thetemplate contents are summarized accordingto shop floor activities. The concept ofEBOMfr closely resembles that of BOMfr.However, the EBOMfr described herein is

made after the general process and operationtemplate. A user can easily alter theproduction conditions of a production floweither by (1) adding, modifying or deletingan operation in the general process or (2)adding, modifying or deleting the contents ofan operation template to effectively respondto changing product requirements and floorsituations. This data model is characterizedby its ability to provide users with thefollowing functions : (1) flexible definition ofproduction flows and the pertinent dataconsisting of items to be collected and actioncontrol rules through early standardization ofan operation template, general process andEBOMfr. (2) To establish related attributes,equipment and materials according tocustomer requirements at the time of workorder review and release through latecustomization of the work-order process.

Operation template

The contents of an operation templateinclude attribute setup (including presetvalue setup, check-in value setup, check-outvalue setup and calculated value setup),formula setup, check-in rule setup, check-outrule setup, and global parameter setup. Thesesetups are also the basic components of theEBOMfr and general process.

The data scheme of the operation

template can be described in IDEF1x(Kusiak, 1997) presentation as Fig. 3illustrates. Table tblWipOPData provides thename (OPNo) of each operation template.Meanwhile, Table tblWipAttibData definesthe name (AttibName), type and property ofeach attribute. The type of attribute can beclassified as either user-defined or system-defined. System-defined attributes, such as,sample number and acceptance number ofthe inspection operation template, do notallow the user to do any editing. Meanwhile,checking the properties of attribute, such as,numerical number, date, bin, percentage and

string, reveals whether or not the systemlegitimates their value.

General process

A general process controls productionflow and handles shop floor exceptions. Thisprocess includes operations and operationalsequence. Operational sequence is the orderof an operation in a process. The content s ofan operation in the general process, includingattribute setup, formula setup, check-in rulesetup, check-out rule setup, and globalparameter setup, are copied from anoperation template. According to thepredefined operation template, a user caneasily add, modify, or delete an attribute,rule, or formula of operation contents tocreate the production flow. Automatictransfer and exceptional handling of the shopfloor are then performed based on the ruledefined in each operation of the generalprocess.

Figure 4 illustrates the data schemeof a general process which can bedescribed in IDEF1x presentation. TabletblWipProcessData defines the name(ProcessNo) and related information of eachgeneral process. Each record intblWipProcessData corresponds to severalrecords of tblWipProcessOP. Meanwhile, theProcessOPPK, incorporates of process name(ProcessNo), operation name (OPNo), andorder (OPOrder) of the operation in theprocess, is the primary key of tabletblWipProcessOP. As mentioned earlier, themajor content s of the operation in the generalprocess, except primary key (includingattribute, formula, check-in rule, check-outrule, and global parameter setup), arecopied from the operation template. Theuser can modify the above data throughaddition, modification, or deletion. Theoperational sequence is established in thefield (OPOrder) of tblWipProcessOp.Additionally, Table tblWipProcessOP can

also define the properties of an operation,such as alternate operation, checklistoperation, and check-in and check-outoptions. The result (ThenOption) ofoperation rules defines the flow controls.

Enhanced bill of manufacture (EBOMfr)

Table tblWipMBom defines EBOMfr.MBomNo is the primary key of tabletblWipMBom. Its foreign keys consist of aproduct name (ProductNo) from TabletblWipProduct, and a general process name(ProcessNo) from Table tblWipProcessData.Those keys imply that several differentprocesses can be defined for a specificproduct, or a process can be defined forseveral different products. Figure 5 depictsthe data scheme of EBOMfr. In EBOMfr, itsassociated factors can be further divided intotwo categories: (1) Factors related to theproduct and operation of the process (asshown in the shaded portion) and (2) Factorsrelated only to the product.

Work-order process

Table tblWOData defines the work-order process. The primary key of tabletblWOData is WoNo. The foreign keysconsist of only a product (ProductNo) fromTable tblWipProduct, and an EBOMfr(MbomNo) from Table tblWipMBom. Thosekeys imply that the production planner canspecify an appropriate EBOMfr for theproduct according to the special productrequirement, and then reassign the productrelated factors, including (1) Factors relatedto the product and operation of the process;(2) Factors related only to the product. Theinformation used by the work-order processis modified from the information ofEBOMfr. The work-order process can thenbe carried by a lot, i.e. a basic trackingquantity on the floor, and the productionflow is guided all the way on the floor.Figure 6 illustrates the data scheme of the

work-order process.

Executing a Flexible Production Flow

Through its early standardization ofoperation template, general process andEBOMfr, and late customization of work-order process, the data model of shop floorproduction flow gives the user a flexibledescriptive mechanism to define the relevantproduction information and action controlrules of shop floor activities. However, totimely handle manufacturing data in ICpackaging industry, the data modelincorporates a WIP (i.e. work-in-process)execution module to monitor and control theproduction flow on the shop floor as Fig. 7illustrates.

The WIP execution module normallymonitors any transferred quantity from thefirst to the final operation according to thepredefined work-order process, and controlsthe following events in each operation. (1)During check-in, the module can assesswhether or not an operation can be executedbased on user check-in attributes andpredefined check-in rules. (2) During check-out, the module can assess what the nextoperation is based on the user check-outattributes and the predefined check-out rules.If exceptional production problems occur ina certain operation, the WIP executionmodule initiates the predefined handlingprocedure. To accumulate information onshop-floor production lots for everyoperation in the packaging industry,including associated material, equipment,people, quality, and time, an additional datascheme called lot-based tracking process, isrequired, to record lot status and course.

Lot-based tracking process

Figure 8 depicts the IDEF1xpresentation of lot-based tracking process.

Table tblWipLotData defines the name of thelot (LotNo). When the lot status is “ready forrelease”, the WIP execution module creates arecord of the lot in Table tblWipLotState,and adds a corresponding record (LotSerial)in the table tblWipLotTracking.Additionally, the module records thematerial (MaterialNo) used in the tabletblWipLotMaterialContent, notes theequipment (EquipmentNo) used in the tabletblWiplotEquipmentContent, and documentsthe attribute name (AttribName) and value(AttribValue) used in the tabletblWipLotAttribContent. If defects exist, thenumber of defects, defective lot, anddefective reasons (ErrorNo) are recorded inTable tblWipLotFailContent. Normally, thelot proceeds from the first to the finaloperation according to the predefined work-order process. If an abnormality occurs in aspecific operation, a record (LotErrorSerial)will be added to Table tblWipLotErrorLog,and the cause of the error (ErrorNo) will beinserted into Table tblWipLotErrorContent.The lot will then be put in the exceptionalhandling procedure. According to the results,the lot-based tracking process records theinformation and events and, simultaneously,reflects exactly what occurred on the floor.

Example

Figure 9 illustrates the post-bondinginspection (PBI) operation (which canoriginate from the PBI operation templateestablished previously) of the productionflow of a certain product in the packagingindustry. The lower portion of this figuredepicts the setup of the operation. Theattribute setup determines the characteristicsof “key-in quantity”, “good quantity”,“scrape quantity”, “lost quantity”, “outputquantity”, “move-in quantity”, and “targetquantity”. Meanwhile, three calculatedformulae such as “output quantity = goodquantity + scrape quantity + lost quantity”,“move-in quantity = transfer quantity” and

“transfer quantity = good quantity” areestablished. Moreover, the operation alsodefines the check-in, check-out rules and theglobal parameters like transfer quantity. Theupper half of the picture represents theprocessing of a WIP execution module. Themodule is executed according to theoperation defined in the lower half of thefigure. Thus, performing a check-in at PBIoperation requires inputting the key-inquantity while performing check-out, andneeds to input good, scrape and lostquantities. When the input number satisfiesthe defined check-in and check-out rules, themodule issues actions (such as displayingwarning messages) according to the handlingprocedure. Otherwise, if the input scrapequantity does not equal zero, which is thetarget quantity, the user is asked to input thecause of the scrape. As stated above, eachproduct lot is executed according to theoperation defined in the production flow forthe product.

To let users easily modify information inthe production flow to fulfill varied floordynamics with little or no programming skill,the MIRL WIP System combines the datamodel with a WIP execution module, whichprovides generic user interfaces for mostoperations. The interfaces include check-ininterface, check-out interface, exceptionalhandling interface, and close lot interface.The user can also develop their own specificinterfaces. Figure 10 presents the examplescreen of the general process setup. Theupper portion of the screen presents thename, type and valid date of the generalprocess. Meanwhile, the lower portiondepicts the operational sequence setup of thecorresponding general process. Theoperation setup button provides an entry tothe attribute setup, formula setup, check-inrule setup, check-out rule setup, globalparameter setup, as Fig. 11 indicates.

When the operator enters employee

identity and lot number during login, thesystem can inform the user of the lot statusand immediately take the appropriate action.For example, Fig. 12 represents the check-out screen. This figure also contains therequired information for viewing andchecking out entries. The upper portion ofthe screen shows the operation name andmove-in quantity, the left portion shows thepreset attributes, material description andmaterial used, and the right portion depictsthe selected equipment and operator entries.Meanwhile, the check-in screen displaysinformation on selected material, equipmentand check-in values which is the same as inthe check-out screen.

Conclusion

This work presents a data model offlexible production flow which incorporatesfour modules: operation template setup,general process setup, enhanced bill ofmanufacture (EBOMfr) setup, and work-order process setup. The proposed datascheme provides users with a descriptivescheme for the shop floor execution level:(1) to flexibly define shop floor informationand decision rules required for productionflow, and to allow easy adjustment of thesystem to fulfill the floor dynamics, (2) tomonitor and control the execution ofproduction flow through a WIP executionmodule, and thus facilitate reliable andtimely managerial decisions. In the future,industry can adopt the WIP system toconstruct shop floor information systems andenhance productivity.

Acknowledgements

The authors would like to thank theMechanical Industrial Research Laboratoryof Industrial Technology Research Institutefor financially supporting this research. The

authors would also like to thank Colleaguesin the Department of ManagementInformation Technology for their valuableassistance and discussion.

References

Consilium (1991), WorkStream Overview.

Deuel, A. C. (1994), “Benefits of a MES forPlantwide Automation”, ISA Trans.,Vol. 33 No.2, pp.113-124.

Hakanson, Bill, (1996), “ManufacturingExecution Systems: Where’s thePayoff? ”, I&CS, March, pp.47-50.

Hastings, N. A. J. and Yeh, C. H. (1992),“Bill of manufacturing”, Productionand Inventory Management Journal,Fourth Quarter, pp.27-31.

IBM (1994), Poseidon General Information.

Kusiak, A., Letsche, T., and Zakarian, A.(1997), “Data modelling withIDEF1x”, Int. J. Computer IntegratedManufacturing, Vol. 10 No. 6, pp.470-486.

Leibert, John A. (1997), “ MES and the shifttoward a work flow environment”, IIESolutions, Vol. 29 No.1, pp.30-33.

Melnyk, S. A., Carter, P. L., Dilts, D. M. andLyth, D. M. (1985), Shop FloorControl, Dow Johns – Irwin, Illinois.

Melnyk, S. A. and Carter, P. L. (1987),Production Activity Control, RichardD. Irwin Inc., Illinois.

Promis (1990), Promis v5.0 FeaturesOverview.

Sartori, L. G. (1988), ManufacturingInformation Systems, Addison-WesleyPublishing Co..

Vollman, T. E., Berry, W. L., and Whybark,D. C. (1992), Manufacturing Planningand Control Systems, Dow Jones-Irwin,Illinois.

倉庫shopflooractivites

operation 1

exceptionalhandling

........

operation kreceving

stocking

subcontracting

shipping

materials

wafer packageIC

Figure 1: The shop floor activities of IC packaging industry

OPT F

operation 1(OPT B)

operation 2(OPT F)

operation 3(OPT G)

operation 4(OPT K)

operation 5(OPT M)

general process A A (operational sequence setup & operation modified from OPT）

OPT K

setup materials

setup equipment

override attributes

link toa general process A

EBOMfr

Link

product,semi-product, or product family

Link

assign materials

assign equipment

override attributes

imply toa general process A

work-order process

Specify

Assign

Imply

OPT: Operation template

attributes setup

formula setup

check-in rule setup

check-out rule setup

global parametersetup

attributes setup

formula setup

check-in rule setup

check-out rule setup

global parametersetup

Figure 2: The proposed structure of flexible production flow

OPNo(FK)RuleName

OPNo(FK)AttribName(FK)

ParameterName

AttribName

OPNo(FK)ParameterName(FK)

AttribName(FK)

OPNo(FK)ParameterName(FK)

AttribName(FK)

OPNotblWipOPData

tblWipTRuleCheckIn

OPNo(FK)RuleName

tblWipTRuleCheckOut

OPNo(FK)RuleName(FK)

AttribName1(FK)AttribName2(FK)

OperandLogicOP

tblWipTIFCheckIn

OPNo(FK)RuleName(FK)

AttribName1(FK)AttribName2(FK)

OperandLogicOP

tblWipTIFCheckOut

OPNo(FK)RuleName(FK)

ThenOption

tblWipTThenCheckOut

1 1

PP

OPNo(FK)ObjAttribName(FK)

AttribName(FK)

MethodOrderOperand

tblWipTMethodOut tblWipAttribOP

tblWipAttribData

tblWipParameter

tblWipTGetParameter tblWipTPutParameter

OPNo(FK)RuleName(FK)

ThenOption

tblWipTThenCheckIn

attributessetup

formulasetup

check-out rulesetup

check-in rulesetup

globalparameter setup

Figure 3: The data scheme of operation template

ProcessOPPK

ProcessNo(FK)OPNo(FK)OPOrder

ProcessNo OPNo

ProcessOPPK(FK)RuleName

ProcessOPPK(FK)RuleName(FK)

AttribName1(FK)AttribName2(FK)

OperandLogicOP

ProcessOPPK(FK)RuleName(FK)

ThenOption

ProcessOPPK(FK)ObjAttribName(FK)

AttribName(FK)

MethodOrderOperand

ProcessOPPK(FK)RuleName(FK)

AttribName1(FK)AttribName2(FK)

OperandLogicOP

ProcessOPPK(FK)RuleName(FK)

ThenOption

ProcessOPPK(FK)RuleName

ProcessOPPK(FK)AttribName(FK)

ParameterName

AttribName

ProcessOPPK(FK)ParameterName(FK)

AttribName(FK)

ProcessOPPK(FK)ParameterName(FK)

AttribName(FK)

tblWipRuleCheckIn

tblWipIFCheckIn tblWipIFCheckOut

tblWipRuleCheckOut

tblWipThenCheckIn tblWipThenCheckOut

P P

1

1

tblWipMethodOut tblWipAttribOP

tblWipAttribData

tblWipProcessOP

tblWipProcessData tblWipOPData

tblWipGetParameter tblWipPutParameter

tblWipGetParameter

the contents of operation are added, modified,deletedthe contents of operation are added, modified,deleted

from that of the predefined operation templatefrom that of the predefined operation template

Figure 4: The data scheme of general process

ProductNo

MBomNo

ProcessNo(FK)ProductNo(FK)

MBomNo(FK)ProcessOPPK(FK)MaterialNo(FK)

PackageNoMBomNo(FK)PackageNo(FK)

MBomNo(FK)PrintingNo(FK)

PrintingNo

ProcessOPPK

ProcessNo(FK)OPNO(FK)OPOrder

EquipmentNoMBomNo(FK)

ProcessOPPK(FK)EquipmentNo(FK)

MBomNo(FK)ProcessOPPK(FK)AttribName(FK)

MaterialNo

tblWipProduct

tblWipMBom

tblWipMBomMaterialOP

tblMstMaterial

tblWipMBomAttribOP

ProcessNotblWipProcessData tblWipProcessOP

tblMstEquipmenttblWipMBomEquipmentOP

tblWipMBomPackage tblWipPackageData

tblWipMBomPrinting tblWipPrintingData

OPNotblWipOPData

ProcessOPPK(FK)AttribName(FK)

tblWipAttribOP

AttribNametblWipAttribData

Z

Figure 5: The data scheme of EBOMfr

WoNo(FK)ProcessOPPK(FK)MaterialNo(FK)

WoNo(FK)PackageNo(FK)

WoNo(FK)PrintingNo(FK)

WoNo(FK)ProcessOPPK(FK)EquipmentNo(FK)

WoNo(FK)ProcessOPPK(FK)AttribName(FK)

tblWipWoMaterialOP

tblWipWoAttribOP

tblWipWoEquipmentOP

tblWipWoPrinting

ProductNo

MBomNo

ProcessNo(FK)ProductNo(FK)

ProcessOPPK

ProcessNo(FK)OPNO(FK)OPOrder

tblWipProduct

tblWipMBom

ProcessNotblWipProcessData

tblWipProcessOP

OPNotblWipOPData

LotNo

WoNo(FK)

WoNo

MBomNo(FK)ProductNo(FK)

tblWoData

1

1

tblWipLotData tblWipWoPackage

Figure 6: The data scheme of work-order process

OPT F

attributes setup

formula setup

check-in rule setupcheck-out rule setup

globalparameter setup

operation 1(OPT B)

operation 2(OPT F)

operation 3(OPT G)

operation 4(OPT K)

operation 5(OPT M)

general process A (operational sequence setup & operation modified from OPT)

OPT K

setup materials

setup equipmentoverride attributes

link to a general process A

EBOMfr

Link

product,semi-product, or product family

Link

assign materials

assign equipments

override attributes

imply to a general process A

work-orderprocess

Specify

Assign

Imply

Customer

sales orderprocessing

work-orderreview/released

lot quantityprocessing

check-in

check-out

stocking

finished goods

produc-tion

proble-ms

WIP executionmodule

EBOMfr

Guideline

The proposed structureof flexible production flow

attributes setupformula setup

check-in rule setup

check-out rule setupglobal

parameter setup

OPT: Operation template

Figure 7: The flexible production flow and the WIP execution module

LotNo

WoNo(FK)MBomNo(FK)

LotQtyStatusCode

LotNo

CurOPNo(FK)WoNo(FK)

MBomNo(FK)ProcessNo(FK)

OpOrderCurStatusCurNum

LotSerial(FK)

AttribName(FK)AttribValue

LotSerial

LotNo(FK)ProcessNo(FK)

OPOrderOPNo(FK)WoNo(FK)

MBomNo(FK)CheckInTime

CheckOutTimeEquipmentNo(FK)

GoodNumBadNum

EmployeeNameProductNo(FK)

ProductTypeCustomerNo(FK)

LotSerial(FK)

EquipmentNo(FK)

LotSerial(FK)

MaterialNo(FK)

LotSerial(FK)

ErrorNo(FK)ErrQty

LotSerial

LotNo(FK)MBomNo(FK)ProcessNo(FK)

OpOrderOPNo(FK)OPStatus

CheckInTimeCheckOutTime

WoNo(FK)CheckInEmployeeNo(FK)

CheckOutEmployeeNo(FK)

LotErrorSerial

LotNo(FK)WoNo(FK)

ProductNo(FK)MBomNo(FK)ProcessNo(FK)

OPNo(FK)OPName

RuleNameStartTimeEndTime

ResultEmployeeName

LotErrorSerial(FK)

ErrorNo(FK)

WoNo

MBomNo(FK)ProductNo(FK)

tblWoDatatblWipLotData

tblWipLotState

Z

tblWipLotTrackingtblWipLotLog tblWipLotErrorLog

tblWipLotFailContenttblWipLotMaterialContenttblWipLotEquipmentContenttblWipLotAttribContent tblWipLotErrorContent

PP

Figure 8: The data scheme of lot-based tracking process

t

Check InOperationOperation Check Out

formula setup: check-in rule setup:

output quantity = good quantity + scrape quantity + lost quantity

move-in quantity = transfer quantity

transfer quantity = good quantity

IF key-in quantity < > move-in quantityThen display the warning message" Error on input quantity "

check-out rule setup：

IF scrape quantity < > target quantityThen take the scrape causes

key-in quantity: 200

scrape quantity: check-out valuegood quantity: check-out value

lost quantity:check-out value

attribute setup:

key-in quantity: check-in value

transfer quantity: global parameter(= good quantity from previous op.)

target quantity¡Gpreset value (0)

global parameter setup:

scrape quantity: 3

good quantity: 197

lost quantity: 0output quantity: 200

IF output quantity < > key-in quantityThen display the warning message" Error on output quantity "

No.: 0100 Name: PBIType: normal

IF scrape quantity < > 0Then take the scrape causessuch as: lead broken * 3

transfer quantity: 200

check-in ruleas guideline

check-out ruleas guideline

setup of PBI operationsetup of PBI operation

move-in quantity: calculated valueoutput quantity: calculated value

Figure 9: Setup of the post bonding inspection operation (PBI)

Figure 10: The example screen of general process setup

Figure 11: The example screen of operation setup

Figure 12: The example screen of check-out procedure