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日月光半導體 e 化 之 進程與問題之分享. 日月光高雄廠資訊中心 盛敏成 Nov. 23, 2006. Agenda. ASE Group Our business models Our IT strategy A follower, a partner and a leader 由服務中學習 , 由學習中改善服務 ASEKH IT system evolution Case study 晶采計劃 Smart customer SAP II project Experience sharing Conclusion. ASE MISSION.

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4650549

日月光半導體e化之進程與問題之分享

日月光高雄廠資訊中心

盛敏成

Nov. 23, 2006


Agenda

Agenda

  • ASE Group

  • Our business models

  • Our IT strategy

    • A follower, a partner and a leader

      • 由服務中學習,由學習中改善服務

  • ASEKH IT system evolution

  • Case study

    • 晶采計劃

    • Smart customer SAP II project

  • Experience sharing

  • Conclusion


Ase mission

ASE MISSION

ASE offers the Best Design Manufacturing Services for IC Packaging, IC Substrates, IC Testing, and Systems.

ASE will act as an Extension of Our Customers’ Own Operations in Achieving the Maximum Business Objectives with Minimum Resources.


Ase vision the complete solution

ASE VISION: THE COMPLETE SOLUTION

  • DMS (Design Manufacturing Services)

  • Board Assembly

  • Hybrids & Electronic

  • Packaging

  • Logistic Management

  • Substrate Design

  • Manufacturing Service

  • Modeling & Simulation

Material

System

ASE Group

  • Package & Module Design

  • IC Assembly

  • Multi-chip Assembly

  • Micro & Hybrid Module

  • Program Development

  • Wafer Probing

  • IC & Module Test

  • Burn-In

  • Warehousing

  • Drop-Shipment

Test

Assembly


Ase vision the complete solution1

ASE VISION: THE COMPLETE SOLUTION

Module, Board Assembly & Test (DMS)

  • Operation sites

    • ASEKH(A/T/M), ASECL(A/T/M), ASEKr(A/T), ASEM(A/T), ASESg(T), ISE(T)

    • USI

Final Test

Assembly

Wafer Bumping/Probing

Foundry

Materials

Circuit Design

Engineering Test


Electronics industry supply chain

Electronics Industry Supply Chain

180+ suppliers

customers

GST

1200+ other

suppliers

100+ suppliers

customers

Japan, US, Taiwan

15+customers

Other suppliers

50+ suppliers

customers

suppliers

Customer

OEM

EMS

Sub-Assembly

Components

Foundry, Pkging & Test


Our business model

Our Business Model

  • Engineering/Manufacturing service provider

    • Make the parts upon customer specification and instruction

      • Key success factor: operation excellence and quality

      • Compete with other service provider and customers’ MFG teams

      • Without ERP system until 2004

  • Business guideline

    • Easy for customer to do business with ASE

      • Seamless integration with customers’ process flow

    • Quality, Flexibility, Efficiency


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Supply Chain & Quality Strategy

Environmental Conditions

Demand Uncertainty

Launch Phenomenon

Cost Pressure

High Quality Expectations

Speed & Flexibility

Security of Supply

Efficient Supply Chain

Proactive & Responsive

Best Customer Experience


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Customers’ Supply Chain Objectives

“Building sustainable competitive advantage into the collective supply chain”

LEAN

SPEED

FLEXIBILITY

  • Collaborative forecast, order and inventory management solution connected with key suppliers.

  • Exception basedmanagement

  • Scalable business process integration with suppliers

  • Centralized visibility to business processes

  • Performance metrics for supplier management


Multi company process management enables a synchronized supply chain

Multi-Company Process Management enables a synchronized Supply-Chain

Business Value

Multi-tier Execution

Decision Support

Exception Management

Data Aggregation

ExceptionAlerts

Multi-tier Visibility

Exception Management Across Multiple Tiers of the Value Chain

Synchronized Processes,

Timely and Quality Information

Multi-Company Process Management

Closed-loop, Positive Response With Exception Alerts

Two-way Information Exchange

One-way Information

Posting

Data Exchange

Process Breadth, Number of Trading Partners


Customers goal

Customers’ Goal

Sub Con Assemblers

Consignment

Materials

Suppliers

Allentown

Shipping Notices

Thailand

Forecasts

Purchase Orders

I-BOX

Singapore

Indirect

Materials

Suppliers

Shipping Notices

Orlando

Foundries

Twin Cities


Approach for i box

Approach for I-Box

Client-Server Architecture

“Thick at the Edge”

“Point-to-Point”

Service Oriented Architecture

“Thin at the Edge”

“Intelligent Network”

Partner A

Partner B

Partner B

Partner A

Intelligent

Network

Partner C

Partner F

Partner F

Partner C

Partner E

Partner D

Partner E

Partner D

Functionality at the edge

  • Point-to-Point Integration

  • One trading partner at a time

Functionality in the network

  • Connect once and leverage

  • Shared service economics


Our it strategy

Our IT Strategy

  • A followerLearn

    • Leverage the best practice from customers, competitors, and industry leaders

    • ASE has the fortune to work with the most competitive companies in the IC supply chain

    • Research: Re-Search

  • A partnerDo

    • Build up quality information links with customer

    • Provide process integration solution model to customers

  • A leaderContinuous Improvement

    • Identify the core function of information integration process

    • Develop systematic approach to identify the critical information links to make business model successful


Ase it system evolution

ASE IT System Evolution

  • Home grown legacy systems

    • Two independent operation company for different services (Assembly and Test)

    • Did not build up integrated process with well-organized information links

    • IRS system build up for short term solution

  • Big-Bang Approach

    • Driving force: to provide turnkey service to customers

    • GRP project: kicked off on March, 2002

    • System went live Jan/5/2004

    • Material operation: KH/CL Jan/2005; SH Sep/2005

  • Continuous Improvement

    • Separated instance for Material operation: Aug/2006

    • PLM system go live Dec/2006

    • SAP/e project kicked off Dec. 2005


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  • ASE_Assy_ IT 系統關聯圖(~2003)

Interface

Packing

Instruction

工程

資料庫

(PEDB)

晶片庫

系統

Wafer

Bank

M

E

S

保稅系統

Sales

Report

Data Flow

Forecast

Shipping

Plan

成本系統

Reference

出口系統/Price

(Export/Price)

成品庫管理

Finish Goods Stock

Notes AP

投料

系統

(T/T)

VB+

Oracle

獎工系統

(Bonus)

HR

總帳

(G/L)

應收帳款

(A/R)

出口

成品

系統

Other

System

保稅系統

(Bond)

產品成本系統

(Product COST)

SAP

T/T

出口系統

成品系統

固定資產

(A/M)

進口系統

(Import)

採購管理

(Purchase)

應付帳款

(A/P)

Controlling

(CO)

Cobol+

Informix

SPEC/ECN

庫存管理

(Inventory)

IQA

系統

IMQR

Access


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  • ASE_Test_ IT 系統關聯圖 (~2003)

TDRP

ASRS

Setup

Procedure

Shipping

PT

Plan

Price

Label

MES

PO

E-PR

MM

PEDB

SAP

HR

E-HR

Invoice

Packing

GUI

AOL

Intranet

Internet

Equ Time

Record

Spare

Parts

Tooling

Others :

Cost

Bonus

FCST

Extricity

TSMC

Ship Instr.

MES Menu

Hold Bank

TEV

CAR

SPEC

TesterConfig

Hold Lot


Grp erp scm

  • Sales

  • •Order taking

  • Pricing

  • Production Plan

  • Forecast

  • MRP

Quotation

  • Purchase

  • Wafer pur. plan

  • Purchasing

Quotation

PR

PO

Order to production

Final test

Wafer Sort

Assembly

Wafer consume

Finish Goods

Inventory

Vendor

Customer

Receive

Transfer

Pick/Pack

Ship

發料記錄

Validation

Billing

Inventory Documents

Invoice

Invoice

Invoice

Invoice

  • Financial

  • GL • AR• AP

  • Fixed asset • Budget/Cost • Cash management

Payment

Payment

GRP=ERP+SCM

SCM

Capacity optimization, Material planning and production plan optimization

ERP


Internal business flow

Plant 1

Plant 2

Package

Plant 9

Final Test

Wafer Sort

Internal Business Flow

WIP/ENG/Billing(ASSY/TK)

Finish Goods(ASSY)

  • ASEKH

  • - ASSY

Customer

Bumping

Order

ASSY

TEST

$$$

WIP/ENG/Billing

Turnkey

Wafer

  • ASEKH-TEST

Plant 1

Plant 2

Central OT

Central Planning

Finish Goods (TEST/Turnkey)

In Fab Planning

WIP/ENG/Billing(TEST)

Manufacture


Goal of ase grp project

Phase I

Ship

Goal of ASE GRP Project

  • Business processes Included:

  • Ass’y & Test in KH site

  • System To Be Implemented

  • ERP(Enterprise Resource Planning)

  • SCM(Supply Chain Management)

  • Middleware (System Integration)

Order Tacking

Order fulfillment

Cost Down

ASE Group

Ship

Ship

Ship

Ship

Ship

ASE-CL

ASE-China

ASE-Korea

ASE- Malaysia

ASE- others

ASET

ASEK

Test

Ass’y

Test

Ass’y

Test

Ass’y

Test

Ass’y

Test

Ass’y

Procurement

Procurement

Procurement

Procurement

Procurement

Procurement

Procurement

Integration System

ERP System

SCM System


Current it architecture

Current IT Architecture

Notes(w/f)

MES

PDM

HRS

Legacy

System

ASSY

Customer

Vendor

Interface

Order taking and Execution, MM, and FI/CO

Integrated Customer Interface

For CRP and MRP

Middleware

SCM

ERP

IRS

Data

Center

Enterprise Application Integration

Interface

Middleware

Notes(w/f)

MES

PEDB

HRS

Legacy

System

TEST


Grp system 1 5 2004

GRP System (1/5/2004)

  • ERP: SAP R3

    • SD (Sales and Distributions)

    • PP (Production Planning)

    • MM (Material Management)

    • CO (Controlling)

    • FI (financial)

  • SCM: Adexa

    • SCP (Supply Chain Planning) with CRP and MRP for monthly and weekly planning

    • PP (Plant planning) for daily planning

  • System Integration

    • Tibco BW (Business Work)


Application architecture

Application Architecture


Future plan

Future Plan

  • Strategy

    • Align with our Group strategy

    • Provide same information service for customers

    • Integrate cross operations and cross departments information for quality operation and efficient management

  • Approach

    • Continuous process improvements with internal customers

    • Refine IT system architecture to enhance management information provision

    • Leverage best practice from customers, partners and competitors


Future plan 1

Future Plan - 1

  • Phase 1.1

    • Include Material operation into GRP system

      • Project kick off on July/2004

      • Best practice deployment, including ASECL Material

    • More customer B2B enhancement

      • To facilitate the information links with customers

      • Proactive initiator for ASN and W/O B2B projects

    • Analytic information standardization and provision

      • Business intelligence data warehouse project

      • Provide more integrated information for SCPM


Continuous improvement

Continuous Improvement

  • Customer portal enhancement

    • Phase 1: July/2004; phase 2: Mar/2006

    • Phase 3: Dec/2006

  • Sales IT function support

    • Sales management: opportunity/quotation/forecast/order/revenue/profit

    • Customer activity management

  • SCM system enhancements

    • Planning/Scheduling/Dispatching

    • Supply management enhancement

  • Group ENG data architecture

    • PLM and more

    • Central vs. Distributed vs. Hybrid


Case study

Case Study

  • TSMC ePO, Work order project

    • Document transfer handling

  • Smart customer SAP II project

    • WIP transaction message


Work order business flow before

Mail or FAX

Mail or FAX

Create Work Order

ERP

( SAP)

Buyer

Customer Process

Transaction Process

ASE Process

WO Request Flow

Work Order Business Flow (Before)

WO Reply Flow

New WO Request

Work Order

  • 衍生問題 :

  • 流程中人為操作錯誤

  • Batch人工操作,作業時間過長

  • 不易確認資料傳送成功性

  • 缺乏資料傳送的不可否認性


Work order business flow before1

Spec.

WOs

Manually key in WO & Spec. data to system

Mail or FAX

Mail or FAX

Create Work Order

ERP

( SAP)

ERP

Buyer

Planner

Customer Process

Transaction Process

ASE Process

WO Request Flow

Work Order Business Flow (Before)

WO Reply Flow

New WO Request

Work Order

  • 衍生問題 :

  • 登打資料錯誤頻繁

  • 規格參照錯誤

  • 人工操作時間過長

  • 過於依賴人為判斷


Work order business flow before2

Spec.

WOs

Manually key in WO & Spec. data to system

Mail or FAX

Mail or FAX

Investigate can meet the Order or not

Contact with ASE for SOD & key in system

Create Work Order

Check the WO status

Follow up the Work Order

Follow up the Work Order

Telephone

Telephone

ERP

( SAP)

ERP

Buyer

Planner

Customer Process

Transaction Process

ASE Process

WO Request Flow

Work Order Business Flow (Before)

WO Reply Flow

New WO Request

Work Order

  • 衍生問題 :

  • 溝通時間過長

  • 人為溝通造成達交率降低

  • - 雙方認定標準不同


Work order business flow current

Create Work Order

Firewall

Firewall

Internet

Pip7B5

ERP ( SAP)

RosettaNet Gateway

Buyer

Customer Process

ASE Process

Transaction Process

( RosettaNet )

WO 7B5 Flow

Work Order Business Flow (Current)

WO 7B6 Flow

A New WO Request

  • 解決問題 :

  • 自動化,減少流程中人為操作錯誤

  • 無紙化,無須人工列印傳真

  • 提高資料傳送確實性

  • 減少人為判斷錯誤

  • 標準化規格溝通容易

  • - 大大減少資料溝通時間


Work order business flow current1

Confirm SOD and release to production line

Create Work Order

Planner

Firewall

Firewall

New WO Notice

Internet

Pip7B5

MES

ERP ( SAP)

ERP

RosettaNet Gateway

RosettaNet Gateway

Buyer

Customer Process

ASE Process

Transaction Process

( RosettaNet )

WO 7B5 Flow

Work Order Business Flow (Current)

WO 7B6 Flow

A New WO Request

  • 解決問題 :

  • 減少流程中人為操作錯誤

  • WO資料直接進入系統,無須人工介入

  • 減少大量登打資料,人力節省

  • 減少人為錯誤判斷


Work order business flow current2

Issue to WIP according to WO & PDM

Reply WO according to SCM system

Create Work Order

Planner

Query WO reply by vendor

Firewall

Firewall

New WO Notice

Internet

Pip7B5

Pip7B6

MES

ERP ( SAP)

ERP

RosettaNet Gateway

RosettaNet Gateway

Buyer

Customer Process

ASE Process

Transaction Process

( RosettaNet )

WO 7B5 Flow

Work Order Business Flow (Current)

WO 7B6 Flow

A New WO Request

  • 解決問題 :

  • 回覆資料直接進入系統

  • 回覆登打資料錯誤減少

  • 縮短資料覆核時間


4650549

Send PO through Fax to suppliers

Supplier received PO through Fax

PO

Purchasing Officer creates PO in ERP

ERP

ASE PO Process (Before)

PO Request Flow

PO Reply Flow

A New

PO Request

  • 衍生問題 :

  • 流程中人為操作錯誤

  • Batch人工操作,作業時間過長

  • 不易確認資料傳送成功性

  • 缺乏資料傳送的不可否認性

Vendors


4650549

Send PO through Fax to suppliers

Supplier received PO through Fax

A New

PO Request

PO

Purchasing Officer creates PO in ERP

PO

1. Entry the PO into system

2. Manually file the document

ERP

Sales Order System / Spreadsheet

Manually files it

ASE PO Process (Before)

PO Request Flow

PO Reply Flow

  • 衍生問題 :

  • 流程中人為操作錯誤

  • 人工操作時間過長

  • 登打資料錯誤頻繁

  • 過於依賴人工判斷

  • 檔案保存不易

Vendors


4650549

Send PO through Fax to suppliers

Supplier received PO through Fax

A New

PO Request

PO

Purchasing Officer creates PO in ERP

Reply the PO confirmation

Purchasing Officer follow-up with suppliers manually

Review inventory and confirm SOD

ERP

Backend System

Supplier deliver goods

ASE PO Process (Before)

PO Request Flow

PO Reply Flow

  • 衍生問題 :

  • 溝通時間過長

  • 雙方認定標準不同

  • 人為溝通造成達交率降低

  • 資料正確性易產生糾紛

  • 易產生斷料危機

PO

1. Entry the PO into system

2. Manually file the document

Sales Order System / Spreadsheet

Manually files it

Vendors


4650549

PO created in customer’s ERP

Firewall

Firewall

PO

Internet

B2B Server

3A4/8/9

PIP

Transport,

Translate,

Map & Load

ERP

ASE Process

(Private Process)

Transaction Process

Vendors Process

(Private Process)

(RosettaNet)

RN PO 3A4/7/8/9 with Vendors (Current)

RN PO Request Flow

RN PO Reply Flow

A New

PO Request

Vendors

  • 解決問題 :

  • 自動化,減少流程中人為操作錯誤

  • 無紙化,無須人工列印傳真

  • 提高資料傳送確實性

  • 減少人為判斷錯誤

  • - 大大減少資料溝通時間

  • - 標準化規格溝通容易


4650549

A New

PO Request

POs appear in supplier’s ERP System

PO created in customer’s ERP

Firewall

3A4/8/9

Notification

Firewall

PO

Confirm

PO Data

Internet

B2B Server

B2B Server

3A4/8/9

PIP

Transport,

Translate,

Map & Load

Transport,

Translate,

Map & Load

ERP

ERP

ASE Process

(Private Process)

Transaction Process

Vendors Process

(Private Process)

(RosettaNet)

RN PO 3A4/7/8/9 with Vendors (Current)

RN PO Request Flow

RN PO Reply Flow

  • 解決問題 :

  • 減少流程中人為操作錯誤

  • PO資料直接進入系統,無須人工介入

  • 減少大量登打資料,人力節省

  • 減少人為錯誤判斷

  • 資料系統化

Vendors


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Supplier deliver goods

A New

PO Request

POs appear in supplier’s ERP System

PO created in customer’s ERP

Firewall

3A4/8/9

Notification

Firewall

PO

Confirm

PO Data

3A7 Notification

Internet

B2B Server

B2B Server

3A4/8/9

PIP

3A7

PIP

Transport,

Translate,

Map & Load

Transport,

Translate,

Map & Load

ERP

ERP

ASE Process

(Private Process)

Transaction Process

Vendors Process

(Private Process)

(RosettaNet)

RN PO 3A4/7/8/9 with Vendors (Current)

RN PO Request Flow

RN PO Reply Flow

  • 解決問題 :

  • 回覆資料直接進入系統

  • 回覆登打資料錯誤減少

  • 減少人為判斷錯誤

Vendors


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Supplier deliver goods

A New

PO Request

POs appear in supplier’s ERP System

PO created in customer’s ERP

Firewall

3A4/8/9

Notification

Firewall

PO

Confirm

PO Data

3A7 Notification

Internet

B2B Server

B2B Server

3A4/8/9

PIP

3A7

PIP

Transport,

Translate,

Map & Load

Transport,

Translate,

Map & Load

ERP

ERP

ASE Process

(Private Process)

Transaction Process

Vendors Process

(Private Process)

(RosettaNet)

RN PO 3A4/7/8/9 with Vendors (Current)

RN PO Request Flow

RN PO Reply Flow

Vendors

Touch-less, seam-less and trading partners information in your own system


Result

Result

  • TSMC provide turnkey service to customers

    • ASE provide turnkey service to customers, too

  • Most complete data link among our customers

    • Frontier project and benchmarking

  • More variants of turnkey model coming up

    • Material flow, information flow, cash flow


Project objective sap ii project

Project Objective – SAP II Project

  • A Fabless customer started the WIP tracking project

    • Can consolidate WIP data from global sub-contractor sites, with multiple data formats.

    • Allows quick reporting and analysis using data from one system, which is SAP.

    • Has been particularly challenging for virtual manufacturing companies. The company is looking forward to building a strategic alliance with its manufacturing partners. This venture should be mutually beneficial to all parties.

    • Took this opportunity to establish an end-to-end business process tying together its operations, costing, purchasing, and accounting departments. This is expected to give the company more finance and purchasing control.


System dual

System Dual

Customer

Vendors

SAP

PP

Txn

Record

Biz

Talk

ABR/MBR

BC

Txn

Record

PP

MES

WIP Txn

MM

MM

SHIP

SD

SD

D/N


System dual in wip tracking

Subcon

Customer

W0

W0

T1

W1

W1

T2

Wi

Wi

Ti+1

Wi+1

Wi+1

System Dual in WIP Tracking

.

.

.

.

.

.

.

.

.

: Represent the WIP status at time=0.

W0

: Represent the WIP transaction during that period.

Ti


Results

Results

  • Come from behind

    • Reach 98.5% accurate for consecutive 3 month

  • A generic WIP-TS system model

    • Build up for other three customers

    • Fast deployment, reliable system performance


Experience sharing

Experience Sharing

  • Product consultant vs. Business consultant

    • Learn from SAP project

  • Your project vs. Our project

  • Expectation management

  • Training and coaching

    • The way

    • Methodology

    • Discipline

    • Management


Experience sharing1

Experience Sharing

  • System

    • The output from project: the least important

    • Loading test, stress test

  • Process

    • Business process review, re-engineer

    • Integration test, user acceptance test

  • People

    • Teaming, vendor selection

    • Change management, expectation management, training, coaching, change enablement

  • Data

    • Data conversion, legacy system integration

  • Time

    • Schedule control, scope control, environmental factors


Conclusion

Conclusion

  • PDCA-embedded IT system

    • Plan/Operation/Comparison/Action, instead of operation support only

    • Build up business intelligence to support Strategic Enterprise Management (SEM)

  • Process centric information links

    • Business process is the key

    • IT vs. domain knowledge

  • Customer-oriented

    • Rigid, but flexible, architecture to fulfill different business model


Integrated management processes

Integrated Management Processes

External communication

Strategy

update

Define objectives,

Set targets,

Launch initiatives

Strategic Planning

Mid-term planning

B/S, I/S, Cash Flow

3-5 year

strategic planning

Cascade targets

to lower Bus.Units

Strategy

analysis and

assessment

Evaluate

scenarios

Risk estimation

Strategy and Business Management

Forecast

Detailled operational

planning

Performance Management

Measure

performance

Adjust operations

Business process

optimization


Sem and business analytics

SEM and Business Analytics

External

communication

Strategic Enterprise Management

Strategy

update

Objectives,

Targets,

Initiatives

StrategyManagement

PerformanceMeasurement

Business

Planning &

Simulation

Business

Consolidation

StakeholderRelationshipManagement

Mid-term planning

B/S, I/S, Cash Flow

3-5 year

Strategic planning

Strategic

Planning

  • Manage strategy of Enterprise / Business Units(BU) to create long-term value

  • Manage performance of BU to improve short-term results

Cascade targets

to lower Bus.Units

Evaluate

scenarios

Strategy analysis

and assessment

Strategy & Business Mgmt.

Risk

estimation

Business Analytics

Financial Analytics

CRMAnalytics

SCMAnalytics

PLMAnalytics

HRAnalytics

Forecast

Detailled

operational

planning

Measure

performance

  • Adapt business operations based on results from Business Analytics

  • Optimize business processes across functions to improve overall business performance

Performance Management

Business process

optimization

Adapt operations

Transactional processing (ERP, CRM, SCM, ...)

Suppliers

Customers

business processes


4650549

Q & A

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