半導體封裝測試產業生產力改善

Abstract

台灣半導體產業面臨產業型態的轉變，從早期的PC電子、消費性電子單一生產線大量生產，逐漸邁向IOT產業的少量多樣產品生態、汽車工業電子多段溫度規格要求導致的快速換線，嚴重衝擊工廠生產資源規劃，工廠必須隨時調整因應，否則隨時得面臨生產力不佳、營利下降的結果。除了產業型態轉變之外，台灣勞動力面臨更大的挑戰則是全球都面臨的挑戰和問題──「人口生育率的下降、人口結構老化造成的勞動力短缺」。因此提昇生產力，是半導體產業提昇競爭力的必要課題。 本研究以半導體後段測試為研究範例，在不增加勞動力的前提下、尋求提昇產出的改善方式，從工廠管理4M分析出發：在機器設備方面，以新的管理績效指標針對全局設備效率中的表現損失與減速損失，以平衡積分卡的概念出發，兼顧設備改善指標的短期（製造生產）、長期（工程設備）平衡，用新綜合指標─設置成功率來衡量並改善設備穩定度。在人員與方法方面：將公司生產力戰略─增進設備穩定度連結到第一線員工的績效考核，增強員工對戰略目標的當責心，積極發揮第一線員工的主動改善動力、並針對特定表現不佳員工加以改善。在原料方面：則以新的績效指標研究派料方式，期待達成生產時間與設備改變次數的平衡，兼顧客戶送貨達成率與勞動力投入減少。此外，在既有廠房投入自動化派料抑是派料方式改善的重要哩程。

Taiwan Semiconductor industry is in the transition of product portfolio from computer electronics and personal electronics to IOT electronics and automotive/ industrial electronics. The former manufacturing is usually a single/massive production line required less changes, and the latter has challenges of small quantity order/ manufacturing from analog products (IOT), high change over kits (COK) due to spec requirement in various temperatures from automotive/industrial products. The semiconductor factories are impacted from this portfolio changes and need to improve the productivity to keep compatible in profits. In addition to product portfolio changes, Taiwan companies also have the severe issue of “labor force shortage due to decreasing of birth rate and aging population” which every global company has. This research studied the final test production of a global semiconductor company, looking for the output improvement with same labor hours input. This research starts from factory management 4M analysis: It uses a new index (setup success rate, SSR) for tool stability management, the index is setup based on the balanced scorecard concepts which balances short term/long term improvement of performance loss in OEE. It links the strategical goal (tool stability) to the 1st line operator/repaired-technician by implementing personal SSR. This improves the accountability and the self-improvement of 1st production employees. It studies the new dispatching based on the balanced performance index of manufacturing cycle time/ change over kit counts, and expects to achieve a better output performance, customer delivery with less change over kits/labor hours. In addition, the dispatching automation is also an important factor of dispatching improvement study.