Scalability of Reinforcement Learning Methods for Dispatching in Semiconductor Frontend Fabs: A Comparison of Open-Source Models with Real Industry Datasets

Benchmark datasets are crucial for evaluating approaches to scheduling or dispatching in the semiconductor industry during the development and deployment phases. However, commonly used benchmark datasets like the Minifab or SMT2020 lack the complex details and constraints found in real-world scenarios. To mitigate this shortcoming, we compare open-source simulation models with a real industry dataset to evaluate how optimization methods scale with different levels of complexity. Specifically, we focus on Reinforcement Learning methods, performing optimization based on policy-gradient and Evolution Strategies. Our research provides insights into the effectiveness of these optimization methods and their applicability to realistic semiconductor frontend fab simulations. We show that our proposed Evolution Strategies-based method scales much better than a comparable policy-gradient-based approach. Moreover, we identify the selection and combination of relevant bottleneck tools to control by the agent as crucial for an efficient optimization. For the generalization across different loading scenarios and stochastic tool failure patterns, we achieve advantages when utilizing a diverse training dataset. While the overall approach is computationally expensive, it manages to scale well with the number of CPU cores used for training. For the real industry dataset, we achieve an improvement of up to 4% regarding tardiness and up to 1% regarding throughput. For the less complex open-source models Minifab and SMT2020, we observe double-digit percentage improvement in tardiness and single digit percentage improvement in throughput by use of Evolution Strategies.

Semiconductor Fab Scheduling with Self-Supervised and Reinforcement Learning

Semiconductor manufacturing is a notoriously complex and costly multi-step process involving a long sequence of operations on expensive and quantity-limited equipment. Recent chip shortages and their impacts have highlighted the importance of semiconductors in the global supply chains and how reliant on those our daily lives are. Due to the investment cost, environmental impact, and time scale needed to build new factories, it is difficult to ramp up production when demand spikes. This work introduces a method to successfully learn to schedule a semiconductor manufacturing facility more efficiently using deep reinforcement and self-supervised learning. We propose the first adaptive scheduling approach to handle complex, continuous, stochastic, dynamic, modern semiconductor manufacturing models. Our method outperforms the traditional hierarchical dispatching strategies typically used in semiconductor manufacturing plants, substantially reducing each order's tardiness and time until completion. As a result, our method yields a better allocation of resources in the semiconductor manufacturing process.