| { | |
| "fab": "precision_optics", | |
| "load": "baseline_mix", | |
| "disruption": "nominal", | |
| "strategy": "hybrid_rolling_horizon", | |
| "scenario_label": "Precision Optics Manufacturing \u00b7 Baseline Product Mix \u00b7 Nominal Operations", | |
| "summary": { | |
| "lots": 20, | |
| "machines": 14, | |
| "horizon_h": 288, | |
| "qualification_bottleneck": true | |
| }, | |
| "optimization": { | |
| "strategy": "hybrid_rolling_horizon", | |
| "algorithm": "Hybrid Rolling Horizon (CP-SAT + Dispatching + SimPy)", | |
| "status": "optimal", | |
| "solve_time_sec": 0.005, | |
| "schedule": [ | |
| { | |
| "lot_id": "LOT-0010", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 22.6, | |
| "end_h": 27.74, | |
| "setup_time_h": 0.0, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0004", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 27.74, | |
| "end_h": 31.21, | |
| "setup_time_h": 0.37, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0010", | |
| "operation_id": "etch_1", | |
| "step_index": 1, | |
| "machine_id": "etch_01", | |
| "machine_group": "etching", | |
| "start_h": 27.74, | |
| "end_h": 33.06, | |
| "setup_time_h": 0.0, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0019", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 31.21, | |
| "end_h": 37.09, | |
| "setup_time_h": 0.0, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0004", | |
| "operation_id": "etch_1", | |
| "step_index": 1, | |
| "machine_id": "etch_01", | |
| "machine_group": "etching", | |
| "start_h": 33.06, | |
| "end_h": 39.81, | |
| "setup_time_h": 0.41, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0010", | |
| "operation_id": "clean_1", | |
| "step_index": 2, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 33.06, | |
| "end_h": 36.04, | |
| "setup_time_h": 0.0, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-33", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0012", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 37.09, | |
| "end_h": 40.18, | |
| "setup_time_h": 0.41, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0004", | |
| "operation_id": "clean_1", | |
| "step_index": 2, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 39.81, | |
| "end_h": 43.52, | |
| "setup_time_h": 0.68, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-39", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0019", | |
| "operation_id": "etch_1", | |
| "step_index": 1, | |
| "machine_id": "etch_01", | |
| "machine_group": "etching", | |
| "start_h": 39.81, | |
| "end_h": 45.93, | |
| "setup_time_h": 0.0, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": true | |
| }, | |
| { | |
| "lot_id": "LOT-0020", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 40.18, | |
| "end_h": 43.21, | |
| "setup_time_h": 0.35, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0015", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 43.21, | |
| "end_h": 50.74, | |
| "setup_time_h": 0.71, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0012", | |
| "operation_id": "etch_1", | |
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| "machine_id": "etch_01", | |
| "machine_group": "etching", | |
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| "end_h": 51.99, | |
| "setup_time_h": 0.87, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0003", | |
| "operation_id": "litho_1", | |
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| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
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| "end_h": 55.29, | |
| "setup_time_h": 1.03, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0020", | |
| "operation_id": "etch_1", | |
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| "machine_id": "etch_01", | |
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| "end_h": 55.85, | |
| "setup_time_h": 1.0, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0007", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 55.29, | |
| "end_h": 60.89, | |
| "setup_time_h": 0.41, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0008", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 60.89, | |
| "end_h": 65.1, | |
| "setup_time_h": 1.13, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0016", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 65.1, | |
| "end_h": 70.93, | |
| "setup_time_h": 0.0, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0019", | |
| "operation_id": "litho_1", | |
| "step_index": 0, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 70.93, | |
| "end_h": 76.81, | |
| "setup_time_h": 0.0, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0010", | |
| "operation_id": "litho_2", | |
| "step_index": 3, | |
| "machine_id": "lith_01", | |
| "machine_group": "lithography", | |
| "start_h": 76.81, | |
| "end_h": 82.47, | |
| "setup_time_h": 0.39, | |
| "is_batch": false, | |
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| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0019", | |
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| "end_h": 82.93, | |
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| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0004", | |
| "operation_id": "litho_2", | |
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| "machine_id": "lith_01", | |
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| "end_h": 87.04, | |
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| "is_batch": false, | |
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| "is_rework": true | |
| }, | |
| { | |
| "lot_id": "LOT-0010", | |
| "operation_id": "inspect_1", | |
| "step_index": 4, | |
| "machine_id": "insp_01", | |
| "machine_group": "inspection", | |
| "start_h": 82.47, | |
| "end_h": 85.83, | |
| "setup_time_h": 0.0, | |
| "is_batch": false, | |
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| }, | |
| { | |
| "lot_id": "LOT-0015", | |
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| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0010", | |
| "operation_id": "deposit_1", | |
| "step_index": 5, | |
| "machine_id": "depo_01", | |
| "machine_group": "deposition", | |
| "start_h": 85.83, | |
| "end_h": 88.98, | |
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| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0004", | |
| "operation_id": "clean_1", | |
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| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
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| "end_h": 90.07, | |
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| "is_batch": true, | |
| "batch_id": "B-cleaning-87", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0013", | |
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| }, | |
| { | |
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| }, | |
| { | |
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| }, | |
| { | |
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| }, | |
| { | |
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| }, | |
| { | |
| "lot_id": "LOT-0017", | |
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| { | |
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| }, | |
| { | |
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| }, | |
| { | |
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| }, | |
| { | |
| "lot_id": "LOT-0013", | |
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| }, | |
| { | |
| "lot_id": "LOT-0009", | |
| "operation_id": "litho_1", | |
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| "machine_id": "lith_01", | |
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| }, | |
| { | |
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| { | |
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| }, | |
| { | |
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| { | |
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| }, | |
| { | |
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| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0011", | |
| "operation_id": "clean_2", | |
| "step_index": 6, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 286.11, | |
| "end_h": 290.36, | |
| "setup_time_h": 0.0, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-286", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0005", | |
| "operation_id": "deposit_1", | |
| "step_index": 5, | |
| "machine_id": "depo_01", | |
| "machine_group": "deposition", | |
| "start_h": 289.18, | |
| "end_h": 296.22, | |
| "setup_time_h": 1.11, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0001", | |
| "operation_id": "clean_2", | |
| "step_index": 6, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 290.36, | |
| "end_h": 295.49, | |
| "setup_time_h": 0.0, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-290", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0014", | |
| "operation_id": "clean_2", | |
| "step_index": 6, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 295.49, | |
| "end_h": 301.31, | |
| "setup_time_h": 1.02, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-295", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0002", | |
| "operation_id": "deposit_1", | |
| "step_index": 5, | |
| "machine_id": "depo_01", | |
| "machine_group": "deposition", | |
| "start_h": 296.22, | |
| "end_h": 300.68, | |
| "setup_time_h": 0.69, | |
| "is_batch": false, | |
| "batch_id": null, | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0019", | |
| "operation_id": "clean_2", | |
| "step_index": 6, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 301.31, | |
| "end_h": 307.05, | |
| "setup_time_h": 0.0, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-301", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0015", | |
| "operation_id": "clean_2", | |
| "step_index": 6, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 307.05, | |
| "end_h": 312.22, | |
| "setup_time_h": 0.0, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-307", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0005", | |
| "operation_id": "clean_2", | |
| "step_index": 6, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 312.22, | |
| "end_h": 316.19, | |
| "setup_time_h": 0.0, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-312", | |
| "is_rework": false | |
| }, | |
| { | |
| "lot_id": "LOT-0002", | |
| "operation_id": "clean_2", | |
| "step_index": 6, | |
| "machine_id": "clea_01", | |
| "machine_group": "cleaning", | |
| "start_h": 316.19, | |
| "end_h": 319.29, | |
| "setup_time_h": 0.51, | |
| "is_batch": true, | |
| "batch_id": "B-cleaning-316", | |
| "is_rework": false | |
| } | |
| ], | |
| "wip_snapshots": [ | |
| { | |
| "stage": "lithography", | |
| "wip_count": 7, | |
| "wip_cap": 7, | |
| "queue_time_h": 66.63 | |
| }, | |
| { | |
| "stage": "etching", | |
| "wip_count": 7, | |
| "wip_cap": 7, | |
| "queue_time_h": 16.05 | |
| }, | |
| { | |
| "stage": "cleaning", | |
| "wip_count": 7, | |
| "wip_cap": 7, | |
| "queue_time_h": 25.3 | |
| }, | |
| { | |
| "stage": "inspection", | |
| "wip_count": 7, | |
| "wip_cap": 7, | |
| "queue_time_h": 10.26 | |
| }, | |
| { | |
| "stage": "deposition", | |
| "wip_count": 5, | |
| "wip_cap": 7, | |
| "queue_time_h": 9.47 | |
| } | |
| ], | |
| "bottleneck_insights": [ | |
| { | |
| "stage": "cleaning", | |
| "constraint_type": "batch_wip_limit", | |
| "severity_score": 0.72, | |
| "explanation": "Cleaning WIP at 7/7 \u2014 batch machine starvation risk on reentrant cleaning pass.", | |
| "recommended_action": "Batch compatible lots at cleaning or increase batch chamber throughput." | |
| }, | |
| { | |
| "stage": "lithography (reentrant pass)", | |
| "constraint_type": "qualification", | |
| "severity_score": 0.7, | |
| "explanation": "Primary delay driver is NOT aggregate lithography capacity. Only 2 of 4 lithography tools are qualified for reentrant logic products at step 4. Lots queue waiting for qualified tools while other lithography machines remain underutilized.", | |
| "recommended_action": "Qualify additional lithography tools for logic_7nm reentrant passes, or temporarily dedicate one tool to reentrant lots to relieve step-4 WIP buildup." | |
| } | |
| ], | |
| "metrics": { | |
| "mean_cycle_time_h": 182.76, | |
| "p95_cycle_time_h": 269.01, | |
| "throughput_lots_per_week": 10.52, | |
| "avg_wip": 11.45, | |
| "on_time_delivery_pct": 0.0, | |
| "machine_utilization_pct": 49.5, | |
| "total_setup_h": 64.79, | |
| "num_reschedules": 0, | |
| "schedule_stability_score": 67.6, | |
| "yield_pct": 95.5, | |
| "tardiness_h": 3540.84 | |
| }, | |
| "notes": [ | |
| "Rework triggered for LOT-0019 at etch_1", | |
| "Rework triggered for LOT-0004 at litho_2", | |
| "Rework triggered for LOT-0002 at etch_1", | |
| "Rework triggered for LOT-0019 at litho_2", | |
| "Rework triggered for LOT-0002 at clean_1", | |
| "Rework triggered for LOT-0005 at deposit_1", | |
| "Rework triggered for LOT-0015 at clean_2", | |
| "Dispatching rule: critical_ratio \u2014 scheduled 154 operations.", | |
| "SimPy overlay: no failure-driven reschedules in this replication.", | |
| "Pipeline: qualification-aware dispatch \u2192 bottleneck diagnostics \u2192 SimPy failure overlay \u2192 local rescheduling." | |
| ] | |
| } | |
| } |