This report is the outcome of a Logistics Design Project carried out at ASML, a lithography machines manufacturer, from February 2009 till September 2009. ASML sees an increasing number of installed machines, an increasing complexity of machine part versions, and an increasing number of variants because of continuous product developments and engineering changes during the product life. To manage the configuration data becomes a big challenge for ASML. Therefore, this project focuses on the improvement of the current service BoM (i.e. a Bill-of-Material which contains the required spare parts and service tools for repair when the machines fail). To provide an improvement proposal that is capable of improving the current service BoM, the first step of this project is to perform a current configuration management description in ASML. Secondly, a cause-and-effect analysis is performed to analyze and investigate the current situation. Analyzing causes which lead to intermediate symptoms and final effect helps the company gain a deeper understanding of the situation and focus on improvement areas. The results show that the current service BoM is not optimal. In other words, some problem issues made an increase in operational costs and decrease in customer satisfaction eventually. Thirdly, a qualitative analysis and design is carried out to come to some new best alternatives of the service BoM on the basis of yearly and additional benefit criteria. Then, in order to select the new service BoM, a quantitative analysis and design is carried out: the best alternative has a significant cost savings (3.5M€) compared to the current situation. And, the current situation prime has a significant cost savings (0.9M€) compared to the current situation. Thus, the best alternative is selected for the new service BoM. The new service BoM is as below: 1. We propose to replace the top-level of the new service BoM by the machine type with machine number, which means each installed machine has its own 100% service BoM. 2. We propose to replace the middle-level of the new service BoM by making the subfunctions of the machines to strongly connect with development and engineering data, which brings a clear ownership and responsibility between development and logistics service. 3. We propose to replace the bottom-level of the new service BoM by making the spare parts to strongly connect with development and engineering data, which brings the better information transparency and consistency of the configuration data. 4. Furthermore, we propose to create the relation between spare parts and service tools in the new service BoM, which brings a better combined spare parts and service tools planning and reduction of the preparation time for engineers when machine fails. 5. And, we also propose to create the relation between high and low level spare parts in the new service BoM, which brings the reduction of high level spare parts usage and therefore, the cost savings of spare parts. Additionally, in order to have better information transparency and consistency of the configuration data, the following actions are suggested: 1. To create the extra information for spare parts and service tools in the development and engineering data. 2. To create the relation between spare parts and service tools in the development and engineering data. 3. To create the relation between high and low level spare part in the development and engineering data. An improvement proposal with the conceptual design to improve the current service BoM is developed in this project. ASML can use the improvement proposal as a basis for the future implementation. Although implementation itself falls out of the scope of the project, several related concerns are mentioned from a conceptual perspective.
|Award date||1 Jan 2009|
|Place of Publication||Eindhoven|
|Publication status||Published - 2009|