Semiconductor and Electronics Manufacturing Industry Challenges
Common challenges faced in the industry and PMC solutions
Challenge #1 - Acheive extreme economies of scale
As the pressure to reduce manufacturing costs intensifies, and the pressures to invest in R&D increase, semiconductor and electronics manufacturers are faced with a need to improve yields and reduce production costs. PMC can utilize a full range of optimization tools to help manufacturers improve efficiency, throughput, and quality while eliminating excessive inventory, operational costs and other wastes in the manufacturing process. Whether providing a simulation model of a highly re-entrant production area using leading simulation software packages such as AutoMOD®, ExtendSIM®, Simul8®, WITNESS® and ED®, or implementing a lean culture in the manufacturing organization, PMC can tailor a solution that maximizes the ROI for the client thus helping you gain economies of scale, reduce costs, increase purchasing leverage and remain competitive.
Challenge #2 - High capital investment risks
Semiconductor and related device manufacturers utilize high-tech equipment that demands high-capital expenditure. PMC’s simulation solutions can help identify key problem areas and allow you to quantify the impact/cost-benefit of each of the feasible solutions through what-if scenarios. This technique is used to study the uncertainties involved and reduces the risk of capital investments. PMC’s systematic data-driven and integrated approach to Lean, TOC and Six Sigma can help extract the maximum benefits out of every investment by ensuring quality, flow and efficiency throughout the manufacturing system and supply chain. Also, PMC’s fab layout optimization tools such as Flow Planner® and Workplace Planner® can help in designing the right environments and work places to achieve highest productivity from each piece of equipment.
Challenge #3 - Very short product lifecycles
Given that the semiconductor manufacturing process, from start to packaging, could take from 6 to 8 weeks (source: IBISworld) lead time reduction is key to ensure that your company is the first to market with its products which can then generate maximum sales before the demand falls in relatively short time due to a technology overhaul. PMC’s advanced planning and scheduling system – Asprova® -- is tailor-made to cut through numerous product types, die specifications and customized routings to generate a schedule that allows optimal resource utilization combined with low inventories and reduced lead times. Asprova® can interact with MES, lot tracking or ERP systems through customized interfaces. Besides scheduling, PMC’s work & time study solutions using EASE® can help minimize touch time and maximize value-added processing time.
Challenge #4 - Complex supply chain systems
As manufacturing outsourcing and global distribution requirements in the high-tech industry increase, PMC can apply the latest tools to optimize your supply chain network. These tools include utilizing advanced network modeling and simulation software such as Supply Chain Guru®, planLM®, and DPS LogiX® to achieve substantial reductions in inventory, warehousing, and transportation costs while assuring that manufacturing efficiencies and customer service are maintained. PMC’s methods focus on maximizing the dollar flow in your supply chain system, helping you stay ahead of competing supply chains.
Challenge #5 - Survival in very competitive markets
As the high-tech industry is heavily reliant on quick design to delivery turnovers, cost-effective, productive and efficient manufacturing is essential. Making the right choice of products to invest in and the right capacities to produce in can be the key to success. PMC’s PDSim® can help upper management make strategic investment decisions, while Simulation and Scheduling solutions can help the operations team make implementation decisions. Lean, TOC and Six Sigma cultures can help in problem identification, waste reduction and quality improvements while work and time measurement solutions can help streamline labor costs. This holistic approach to operations engineering and continuous improvement ensures that PMC brings to its clients can help your company stay productive and a few steps ahead of competition throughout the product lifecycle.
PMC's solutions for typical operational problems in high-tech manufacturing:
Differentiators - PMC's approach:
