Manufacturing powerhouse: Gintic system gets Carsem on track

A manufacturer turns to Gintic when it wants to streamline its processes to achieve shorter cycle time and enhance operational effectiveness.

A semiconductor sub-contractor company, Carsem decided to use Gintic Scheduling System (GSS) as a finite capacity planning and scheduling system for its integrated information for manufacturing excellence project (I2Mec). The company offers assembly, test and finishing solutions to the semiconductor sector.

The main objective of I2Mec is to enable the company to leverage on IT as its strategic tool to do business more effectively in this new e-economy era. The I2Mec project consists of three key components - finite capacity scheduling (FCS), manufacturing execution system (MES), and enterprise resource planning (ERP) systems.

The GSS fulfils the FCS requirement and consists of a total of four integrated planning and scheduling modules. They comprise the capacity planning (CP), daily lot release (DLR), daily production scheduling DPS), and dynamic operation scheduling (DOS) modules.

The usage and the deployment of various GSS modules in Carsem's environment are being completed in phases. The CP module went 'live' for all production lines in December last year. Some production lines are utilizing the DLR module which is expected to be implemented palnt-wide by December 2000.

The CP module handles longer term planning requirements. It allows for checking of excess or shortfall of machine resources upon the receipt of the customer forecast.

The committed forecast is then passed to the DLR module which helps the planner to release the right mix of mother-lots into production. In its calculation, it takes into account factors like the actual die receipt from the MES system, machine utilization and baseline and bottleneck capacities.

Chart 1 - GSS work flow

Click to enlarge

Critical materials status can also be verified during the release of the mother-lots. Although automated, the process is designed for manual override by the planner.

The next process is carried out by the DPS module. It allows the production personnel to dispatch sub-lots into the right machine. In addition to t he DLR released lots, it also considers the machine and WIP status during each scheduling run.

The DOS module is designed to be deployed for local re-scheduling and optimization. It helps the production personnel to react quickly to unexpected events and manage the resources more effectively.

Said Carsem's FCS project leader, Lee C K, "GSS has a lot to offer. It is one of the best planning and scheduling systems in the market. Gintic has the expertise to fulfill our expectation and requirements."

The company's vision is to achieve shorter cycle time, improve administrative operational efficiency, and enhance operational effectiveness by making available accurate and timely information.

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