An applied manufacturing system for highly-complex assembly factory

Abstract

This thesis focuses on a manufacturing system at a semiconductor equipment manufacturing company (SEMC). The company faces highly variable demand for its products that require highly-complex assembly within the factory. When the demand is low, the manufacturing factory must to adjust the production performance, and implement various cost reductions in order to maintain profit. Hence, the major motivation of this thesis is to explore how a manufacturing factory that assembles highly-complex products can increase the degree of production volume flexibility. The current situation of the factory is analyzed, using a three dimensional model of the current layout, based on the manual measurements on the floor. The key metrics to describe the concrete problems are defined, and the possible solutions for each problem are generated. Proposed layouts are designed to embody these solutions. The feedback on the proposals is collected from the different levels of managers, line leaders, and operators at the job floor. Based on the feedback, various analyses are performed to prove the practicality and effectiveness of proposed improvements, and the pilot proposal that focuses on one floor are made. Potential solutions include sharing test equipment with several working spaces, aligning the product lines parallel to the overhead cranes, and consolidating inventory area. The results of simulations and experiments show clearly the reduced costs, improved safety and operations, efficient use of space and improved inventory management. Finally, the scaled-down pilot proposal, which focuses on the consolidated inventory and generic workbenches, was implemented.