IC設計公司常面臨光罩浪費與庫存水準過高問題，而晶圓投片在早期的生產策略採用預測生產，晶圓的採購以單一光罩版本組合對應單一產品下單的生產模式，以目標交期為投片起始點。對IC設計公司而言，要預測多個光罩版本的晶圓產出，容易因市場全球化與多樣化的客戶需求，讓預測常超出400%以上成本。 為了解決上述運作問題，本研究提出以晶圓生產延遲策略探討產品在設計階段，就考量為製造而設計的原則，設計模組化與製造流程模組化並嵌入多重減震點的形成方法。
本研究討論之個案公司在過去幾年來為達成大量客製、產品多樣化、降低cycle time及晶圓庫存的營運目標，常因此造成庫存與光罩成本暴增，為解決此問題，認為研發產品設計階段應結合光罩改善及生產製程與流程結構進行重設計。透過設計共用光罩模組，在晶圓半成品的投片前決定適合的半成品緩衝區，是延遲策略的核心，並作為生產計劃建置晶圓半成品庫存的依據。 本研究利用延遲策略中，依形式延遲與模組化延遲提出以共用光罩模組化與Design For Manufacturing的概念，整合多重減震點之差異化管理概念，減少IC設計產業產品庫存、降低Cycle time，並提升IC設計與製造一條龍的整合方法，為IC產業再添核心競爭力。
I. 本論文提出優化方法包含: (1)多重減震點(2)整合Design For Manufacturing共用光罩模組化的概念，應用於案例公司，已獲得成效包含: (1) 生產成本降低45%，(2) 庫存成本降低50%，(3)交期縮短20%等可見之成效。本論文提出根據延遲策略在IC設計的觀點，提出優化之步驟，包含:模組化設計、延遲策略與多重減震點之設計與執行、製程標準化與製程重排、推拉式生產策略等改善方法，完成建置多重減震點的重設計製造流程。

Abstract

IC design industry is a highly competitive Industry in the world. Although there are many demands for different applications such that IC design companies can survive by fulfilling these requirements, products are has shorter and shorter life cycles, However, they face a mask design cost wasted issue (over 400%) and an high level inventory cost.
A factory of wafer production cycles need usually 2 to 2.5 months. It has the most effort of an IC design company who produces his devices and tries to deliver to his customer. How to shorter an IC design company production cycle time would be an important issue for increasing an IC design company’s kernel competitive a advantage.
To solve these issues, this study proposes a novel postpone strategy methodology which base on design for manufacturing in which We propose a concept of common mask design within multi- decoupling point concepts to plan wafer production schedule.
In this paper, we develop a which can integrate and optimize design process and production process for an IC design company. In addition, we provide some production damping composite design and optimization algorithms to make product plan and management method smarter than traditional management method of production plan which includes: (1) multi decoupling point and (2) integration DFM concept (Design For Manufacturing) within common mask design principle.
After Implemented our research concept in case study company, we receive some good consequences which included (1) production cost reduced 40%, (2) inventory cost reduced 50% and (3) lead time reduced 20%.
II
This study collected the opinions of experts and scholars, and industries concepts of mass Customization and postponement strategies under various customizations to investigate how to enhance an IC design company’s kernel competitive capability. Furthermore, our research integrate four methods which include modular design, postponement strategy and multiple damping point execution, process standardization, process rearrangement and push-pull production strategies to increasing an IC design company’s kernel competitive capability.

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