Matching Items (6)
Filtering by
- All Subjects: Semiconductor Industry
- All Subjects: Unit commitment
- Creators: Zhang, Muhong
- Creators: Corral, Esteban
Description
A good production schedule in a semiconductor back-end facility is critical for the on time delivery of customer orders. Compared to the front-end process that is dominated by re-entrant product flows, the back-end process is linear and therefore more suitable for scheduling. However, the production scheduling of the back-end process is still very difficult due to the wide product mix, large number of parallel machines, product family related setups, machine-product qualification, and weekly demand consisting of thousands of lots. In this research, a novel mixed-integer-linear-programming (MILP) model is proposed for the batch production scheduling of a semiconductor back-end facility. In the MILP formulation, the manufacturing process is modeled as a flexible flow line with bottleneck stages, unrelated parallel machines, product family related sequence-independent setups, and product-machine qualification considerations. However, this MILP formulation is difficult to solve for real size problem instances. In a semiconductor back-end facility, production scheduling usually needs to be done every day while considering updated demand forecast for a medium term planning horizon. Due to the limitation on the solvable size of the MILP model, a deterministic scheduling system (DSS), consisting of an optimizer and a scheduler, is proposed to provide sub-optimal solutions in a short time for real size problem instances. The optimizer generates a tentative production plan. Then the scheduler sequences each lot on each individual machine according to the tentative production plan and scheduling rules. Customized factory rules and additional resource constraints are included in the DSS, such as preventive maintenance schedule, setup crew availability, and carrier limitations. Small problem instances are randomly generated to compare the performances of the MILP model and the deterministic scheduling system. Then experimental design is applied to understand the behavior of the DSS and identify the best configuration of the DSS under different demand scenarios. Product-machine qualification decisions have long-term and significant impact on production scheduling. A robust product-machine qualification matrix is critical for meeting demand when demand quantity or mix varies. In the second part of this research, a stochastic mixed integer programming model is proposed to balance the tradeoff between current machine qualification costs and future backorder costs with uncertain demand. The L-shaped method and acceleration techniques are proposed to solve the stochastic model. Computational results are provided to compare the performance of different solution methods.
ContributorsFu, Mengying (Author) / Askin, Ronald G. (Thesis advisor) / Zhang, Muhong (Thesis advisor) / Fowler, John W (Committee member) / Pan, Rong (Committee member) / Sen, Arunabha (Committee member) / Arizona State University (Publisher)
Created2011
Description
This thesis discusses methodology used to assess the financial health of Company X's suppliers. Each suppliers' industry characteristics and key risk exposures are identified using the Porter's Five Forces. Along with qualitative analysis, financial data is analyzed with the Altman Z-Scores, forecasted financial statements, and comparative ratio analysis. The focus is narrowed down throughout the process to enable further investigation on Supplier E and the semiconductor-memory industry.The procedure and results of the analysis lead to the final recommendation to Company X on how it should assess the financial health of suppliers in the semiconductor-memory industry, and possibly other industries, using our methodology.
ContributorsBanda, Janelle (Co-author) / McDermott, Eric (Co-author) / Park, Hye Jun (Co-author) / Corral, Esteban (Co-author) / Hertzel, Michael (Thesis director) / Simonson, Mark (Committee member) / Schulz, Matthew (Committee member) / Barrett, The Honors College (Contributor) / Department of Finance (Contributor) / School of Mathematical and Natural Sciences (Contributor) / School of Accountancy (Contributor) / Economics Program in CLAS (Contributor)
Created2014-05
Description
Ramping up a semiconductor wafer fabrication facility is a challenging endeavor. One of the key components of this process is to schedule a large number of activities in installing and qualifying (Install/Qual) the capital intensive and sophisticated manufacturing equipment. Activities in the Install/Qual process share multiple types of expensive and scare resources and each activity might potentially have multiple processing options. In this dissertation, the semiconductor capital equipment Install/Qual scheduling problem is modeled as a multi-mode resource-constrained project scheduling problem (MRCPSP) with multiple special extensions. Three phases of research are carried out: the first phase studies the special problem characteristics of the Install/Qual process, including multiple activity processing options, time-varying resource availability levels, resource vacations, and activity splitting that does not allow preemption. A modified precedence tree-based branch-and-bound algorithm is proposed to solve small size academic problem instances to optimality. Heuristic-based methodologies are the main focus of phase 2. Modified priority rule-based simple heuristics and a modified random key-based genetic algorithm (RKGA) are proposed to search for Install/Qual schedules with short makespans but subject to resource constraints. Methodologies are tested on both small and large random academic problem instances and instances that are similar to the actual Install/Qual process of a major semiconductor manufacturer. In phase 3, a decision making framework is proposed to strategically plan the Install/Qual capacity ramp. Product market demand, product market price, resource consumption cost, as well as the payment of capital equipment, are considered. A modified simulated annealing (SA) algorithm-based optimization module is integrated with a Monte Carlo simulation-based simulation module to search for good capacity ramping strategies under uncertain market information. The decision making framework can be used during the Install/Qual schedule planning phase as well as the Install/Qual schedule execution phase when there is a portion of equipment that has already been installed or qualified. Computational experiments demonstrate the effectiveness of the decision making framework.
ContributorsCheng, Junzilan (Author) / Fowler, John W (Thesis advisor) / Kempf, Karl (Thesis advisor) / Mason, Scott J. (Committee member) / Zhang, Muhong (Committee member) / Arizona State University (Publisher)
Created2015
Description
Traditional deterministic reserve requirements rely on ad-hoc, rule of thumb methods to determine adequate reserve in order to ensure a reliable unit commitment. Since congestion and uncertainties exist in the system, both the quantity and the location of reserves are essential to ensure system reliability and market efficiency. The modeling of operating reserves in the existing deterministic reserve requirements acquire the operating reserves on a zonal basis and do not fully capture the impact of congestion. The purpose of a reserve zone is to ensure that operating reserves are spread across the network. Operating reserves are shared inside each reserve zone, but intra-zonal congestion may block the deliverability of operating reserves within a zone. Thus, improving reserve policies such as reserve zones may improve the location and deliverability of reserve.
As more non-dispatchable renewable resources are integrated into the grid, it will become increasingly difficult to predict the transfer capabilities and the network congestion. At the same time, renewable resources require operators to acquire more operating reserves. With existing deterministic reserve requirements unable to ensure optimal reserve locations, the importance of reserve location and reserve deliverability will increase. While stochastic programming can be used to determine reserve by explicitly modelling uncertainties, there are still scalability as well as pricing issues. Therefore, new methods to improve existing deterministic reserve requirements are desired.
One key barrier of improving existing deterministic reserve requirements is its potential market impacts. A metric, quality of service, is proposed in this thesis to evaluate the price signal and market impacts of proposed hourly reserve zones.
Three main goals of this thesis are: 1) to develop a theoretical and mathematical model to better locate reserve while maintaining the deterministic unit commitment and economic dispatch structure, especially with the consideration of renewables, 2) to develop a market settlement scheme of proposed dynamic reserve policies such that the market efficiency is improved, 3) to evaluate the market impacts and price signal of the proposed dynamic reserve policies.
As more non-dispatchable renewable resources are integrated into the grid, it will become increasingly difficult to predict the transfer capabilities and the network congestion. At the same time, renewable resources require operators to acquire more operating reserves. With existing deterministic reserve requirements unable to ensure optimal reserve locations, the importance of reserve location and reserve deliverability will increase. While stochastic programming can be used to determine reserve by explicitly modelling uncertainties, there are still scalability as well as pricing issues. Therefore, new methods to improve existing deterministic reserve requirements are desired.
One key barrier of improving existing deterministic reserve requirements is its potential market impacts. A metric, quality of service, is proposed in this thesis to evaluate the price signal and market impacts of proposed hourly reserve zones.
Three main goals of this thesis are: 1) to develop a theoretical and mathematical model to better locate reserve while maintaining the deterministic unit commitment and economic dispatch structure, especially with the consideration of renewables, 2) to develop a market settlement scheme of proposed dynamic reserve policies such that the market efficiency is improved, 3) to evaluate the market impacts and price signal of the proposed dynamic reserve policies.
ContributorsWang, Fengyu (Author) / Hedman, Kory W. (Thesis advisor) / Zhang, Muhong (Committee member) / Tylavsky, Daniel J. (Committee member) / Ayyanar, Raja (Committee member) / Arizona State University (Publisher)
Created2015
Description
This research develops heuristics for scheduling electric power production amid uncertainty. Reliability is becoming more difficult to manage due to growing uncertainty from renewable resources. This challenge is compounded by the risk of resource outages, which can occur any time and without warning. Stochastic optimization is a promising tool but remains computationally intractable for large systems. The models used in industry instead schedule for the forecast and withhold generation reserve for scenario response, but they are blind to how this reserve may be constrained by network congestion. This dissertation investigates more effective heuristics to improve economics and reliability in power systems where congestion is a concern.
Two general approaches are developed. Both approximate the effects of recourse decisions without actually solving a stochastic model. The first approach procures more reserve whenever approximate recourse policies stress the transmission network. The second approach procures reserve at prime locations by generalizing the existing practice of reserve disqualification. The latter approach is applied for feasibility and is later extended to limit scenario costs. Testing demonstrates expected cost improvements around 0.5%-1.0% for the IEEE 73-bus test case, which can translate to millions of dollars per year even for modest systems. The heuristics developed in this dissertation perform somewhere between established deterministic and stochastic models: providing an economic benefit over current practices without substantially increasing computational times.
Two general approaches are developed. Both approximate the effects of recourse decisions without actually solving a stochastic model. The first approach procures more reserve whenever approximate recourse policies stress the transmission network. The second approach procures reserve at prime locations by generalizing the existing practice of reserve disqualification. The latter approach is applied for feasibility and is later extended to limit scenario costs. Testing demonstrates expected cost improvements around 0.5%-1.0% for the IEEE 73-bus test case, which can translate to millions of dollars per year even for modest systems. The heuristics developed in this dissertation perform somewhere between established deterministic and stochastic models: providing an economic benefit over current practices without substantially increasing computational times.
ContributorsLyon, Joshua Daniel (Author) / Zhang, Muhong (Thesis advisor) / Hedman, Kory W (Thesis advisor) / Askin, Ronald G. (Committee member) / Mirchandani, Pitu (Committee member) / Arizona State University (Publisher)
Created2015
Description
This dissertation carries out an inter-disciplinary research of operations research, statistics, power system engineering, and economics. Specifically, this dissertation focuses on a special power system scheduling problem, a unit commitment problem with uncertainty. This scheduling problem is a two-stage decision problem. In the first stage, system operator determines the binary commitment status (on or off) of generators in advance. In the second stage, after the realization of uncertainty, the system operator determines generation levels of the generators. The goal of this dissertation is to develop computationally-tractable methodologies and algorithms to solve large-scale unit commitment problems with uncertainty.
In the first part of this dissertation, two-stage models are studied to solve the problem. Two solution methods are studied and improved: stochastic programming and robust optimization. A scenario-based progressive hedging decomposition algorithm is applied. Several new hedging mechanisms and parameter selections rules are proposed and tested. A data-driven uncertainty set is proposed to improve the performance of robust optimization.
In the second part of this dissertation, a framework to reduce the two-stage stochastic program to a single-stage deterministic formulation is proposed. Most computation of the proposed approach can be done by offline studies. With the assistance of offline analysis, simulation, and data mining, the unit commitment problems with uncertainty can be solved efficiently.
Finally, the impacts of uncertainty on energy market prices are studied. A new component of locational marginal price, a marginal security component, which is the weighted shadow prices of the proposed security constraints, is proposed to better represent energy prices.
In the first part of this dissertation, two-stage models are studied to solve the problem. Two solution methods are studied and improved: stochastic programming and robust optimization. A scenario-based progressive hedging decomposition algorithm is applied. Several new hedging mechanisms and parameter selections rules are proposed and tested. A data-driven uncertainty set is proposed to improve the performance of robust optimization.
In the second part of this dissertation, a framework to reduce the two-stage stochastic program to a single-stage deterministic formulation is proposed. Most computation of the proposed approach can be done by offline studies. With the assistance of offline analysis, simulation, and data mining, the unit commitment problems with uncertainty can be solved efficiently.
Finally, the impacts of uncertainty on energy market prices are studied. A new component of locational marginal price, a marginal security component, which is the weighted shadow prices of the proposed security constraints, is proposed to better represent energy prices.
ContributorsLi, Chao (Author) / Hedman, Kory W (Thesis advisor) / Zhang, Muhong (Thesis advisor) / Mirchandani, Pitu B. (Committee member) / Wu, Teresa (Committee member) / Arizona State University (Publisher)
Created2016