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研究生: 潘姿寧
Tzu-Ning Pan
論文名稱: TFT-LCD組立廠與模組廠產能規劃之研究
A study of TFT-LCD Cell and Module capacity planning
指導教授: 林久翔
Chiuhsiang Joe Lin
陳建良
Chien-Liang Chen
口試委員: 吳建瑋
Chien-Wei Wu
學位類別: 碩士
Master
系所名稱: 管理學院 - 管理學院MBA
School of Management International (MBA)
論文出版年: 2012
畢業學年度: 100
語文別: 中文
論文頁數: 88
中文關鍵詞: 薄膜電晶體液晶顯示器組立廠模組廠產能規劃物料規劃
外文關鍵詞: TFT-LCD, Cell Process, Module Process, Capacity Planning, Material Planning
相關次數: 點閱:296下載:5
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  • TFT-LCD產業為資本、技術密集、產品生命週期短及生產技術更新快的產業,如何將產能極大化是終極目標。在產品多樣化的發展下,形成1.中小尺寸面板需求大增2.物料需求多樣性提高。由於生產小尺寸產品面板切裂數變多,產出的面板數激增,會造成Cell廠產能無法負荷,生產鏈的瓶頸也從Array製程飄移至Cell製程;物料需求多樣性的提高,使得Module廠物料規劃重要性大為提升。

    TFT-LCD的主要製造程序上Array製程、Cell製程及Module製程,彼此有依序的關係,Module依據顧客的客製化需求回推Cell的交期,再回推Array與CF的交期,故其生產型態為一個多階層的生產環境。然而在技術水準與顧客需求逐漸提升的趨勢下,TFT-LCD廠舊世代的廠區已無法與同業競爭及顧客的需求,因此投入擴建更大世代的製造廠,以應付市場各種尺寸的需求,也因此形成TFT-LCD產業存在多廠區的生產環境。

    TFT-LCD產能規劃層級依照規劃期間可分為長期、中期及短期。依照規劃議題可分為產能配置與產能擴充。大部分研究文獻針對TFT-LCD單一或前段製程產能規劃問題進行研究,過去較少發現針對TFT-LCD後段Cell及Module 兩個製程的整合式產能規劃議題進行討論。本研究根據產能規劃層級、產能規劃議題以及產能規劃技術,依照生產環境歸納現行研究之求解問題,目的在於提供Cell與Module製程產能規劃的概況探討,使產業新進者可藉由本文快速了解TFT-LCD產業後段製程的產能規劃概況。

    Cell廠單廠區產能規劃有投料派工問題及排程問題。投料派工問題以混合式及啟發式的規劃方法來縮短設置時間及縮短流程時間。排程問題規劃方法多以啟發式及混合式產能規劃技術,主要績效指標為達到最小化流程時間、最大化產出、最小化設置時間、最小化總延遲時間、最小化最大總延遲時間及訂單滿足。在多廠區產能規劃上,現行研究以產能配置的排程問題及產能擴充問題為主要研究,規劃技術多採啟發式、數學式及混合式,其績效指標以最大化利潤為最常用。

    Module廠單廠區產能規劃以排程及物料規劃問題研究為主要。排程問題較常採用啟發式、混合式、數學模式規劃技術。物料規劃多以混合式、啟發式、數學模式與模擬模式規劃技術,主要績效指標為最小化週期時間、訂單滿足、最小化總延遲時間及最大化產出。多廠區的產能規劃則以產能配置為主要來解決排程與物料規劃問題,規劃技術為數學模式與模擬模式。績效指標為達到最大化利潤、最小化總延遲時間及最小化週期時間為績效指標。


    TFT-LCD industry is categorized as capital and labor intensive, short product life cycle, and fast production skill development, thus how to optimize the capacity is considered as an important goal. The increasing trend on consumer electronic products demand and the products variety bring the significant effect to the material requirement planning for fulfilling the demand on medium-small size products and it’s variety. In order to increase the cutting ratio of medium-small size products and panel numbers which have already been overload in Cell process and shift the bottleneck from Array process to Cell process, so the Module process material requirement planning becomes an critical planning.

    TFT-LCD process is sequenced by Array process, Cell process, and Module process, consecutively. By following the customer demands in Module process, then those demands stimulate the backward scheduling to Cell process, Array process, and CF, respectively. It shows that the TFT-LCD is a multi-stage production environment. Because of the rising of the production skill level requirement and customer demand, the TFT-LCD industry eager to invest on the new generation factory.

    Based on the planning period, the capacity planning is divided by long-term, mid-term, and short-term. Based on planning issue, capacity planning is divided by capacity configuration and capacity expansion. Most of past studies show that they focus the discussion on preceding process (Array and Cell) instead of integrated capacity planning on Cell and Module process. This thesis considers planning period, planning issue, and skills of capacity planning and production environment to answer the questions of capacity planning. More over this paper provides the overview of capacity planning on Cell and Module factory.

    The capacity planning in Cell factory focuses on scheduling, lot releasing, and dispatching, by optimizing the three performance indexes that are cycle time, throughput and setup time. The capacity planning in Module factory focuses on scheduling and material planning, by optimizing the three performance indexes that profit, total tardiness, and cycle time.

    目 錄1 圖目錄3 表目錄5 第一章 緒論7 1.1 研究背景與動機7 1.2 研究目的與範疇9 1.3 研究範圍與限制9 1.4 研究流程10 第二章 TFT-LCD產業介紹11 2.1 TFT-LCD產業簡介11 2.1.1 TFT-LCD產業發展概況14 2.1.2 TFT-LCD生產流程19 2.2 TFT-LCD產能規劃25 2.2.1 TFT-LCD不同供應鏈結構之產能規劃31 2.3 TFT-LCD產能規劃方法與技術36 2.4 不同產業產能規劃方法41 2.5 小結45 第三章Cell廠產能規劃47 3.1 Cell廠生產型態與特性47 3.2 Cell廠生產管理議題47 3.3 Cell廠產能規劃文獻分析48 3.4 Cell廠產能規劃問題與分析57 3.5 小結59 第四章 Module廠產能規劃61 4.1 Module廠製程型態與特性61 4.2 Module廠生產管理議題63 4.3 Module廠產能規劃文獻分析64 4.4 Module廠物料規劃問題與分析74 4.5 小結76 第五章 結論與未來研究方向77 5.1 結論77 5.2 未來研究方向78 參考文獻79

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