本計畫針對薄膜電晶體液晶顯示器（Thin Film Transistor - Liquid Crystal Display, TFT-LCD）彩色濾光片製程（Color Filter）建構模擬系統，並提出改善方案及建議。
首先以模擬應用軟體- AutoMod架構彩色濾光片6代廠的雛形。建模時需輸入機台特性和產品資料，蒐集並彙整各製程的特性與限制，將之轉換為基本參數輸入到模擬系統。資料依序輸入到系統後，模擬案例廠一個月份的生產狀況，依據現場生產狀況調整參數並做投產資料比對，驗證此模擬系統是否具代表性。經由敏感度分析與模擬系統的驗證與測試，此模組之模擬現場實際產出差異在 ± 1%之內，表示此模擬模組具有相當代表性。
本研究提出的改善方案為前瞻式投料（Look-ahead release planning），利用即將到來的排程資訊預測主製程稼動率，並將適合的批量做排程調度。將改善方案套用到已驗證的模型中，比對改善前後的績效。決策者可依據What-if分析選擇較佳的生產方案並實際應用至工廠。在不干擾廠區運作的情況下先確認改善績效，選擇最佳的生產投料方式，可有效降低風險並確保改善結果。

This study develops look-ahead release planning on the basis of AutoMod simulation of 6th-generation Thin Film Transistor - Liquid Crystal Display, (TFT-LCD) color filter (CF) fab.
The conceptual model is built by AutoMod simulation application software, then collect data from fab as input parameters for modeling. The data include layout facility, logic, and production characteristic. After monthly data input, a series of sensitivity analysis, verification and validation processes are conducted to ensure the correct assumptions and representation. The model is representative with less than 10% difference of each process and 1% difference of total output between simulation model and the real CF fab.
Furthermore, a look-ahead release planning is implemented in the model to evaluate the key performance index of productivity and equipment capacity. The experimental design investigates the impact of throughput and main significant factors of the experimental results show that look-ahead release planning is effective in improving throughput. Decision makers can use what-if analysis to evaluate better production alternatives to ensure the success and reduce risks by simulation results before implemented.

[1] Chen, S. H., Chang, C. K. and Kuo, C. L., Optimal scheduling in color filter manufacturing, Journal of Chinese Institute of Industrial Engineers, Vol.22, No.4, pp 301-308, 2005.
[2] Chen, J. C., Chen, C. C., Mo, C. N., Peng, T. W., Chao, G. C., Sun, C. J., Chao, K. J., Chien, J. W., Wei, Y. Y., Feng, C. H., Liu, Y. C., and Chiang, M. T., Effective order release and dispatching for color filter fabs. Society for Information Display International Symposium (SID), San Antonio, Texas, USA , 2009.
[3] Chen, W. L., Huang, C. Y., and Lai, Y. C., Multi-tier and multi-site collaborative production: Illustrated by a case example of TF-LCD manufacturing. International Journal of Computers & Industrial Engineering, Vol.57, No.1, pp 61-72. 2009.
[4] Chen, J. C., Huang, P. B., Sun, C. J., Chao, K. J., Chao, G. C., Chien, J. W., Chen, C. C., Mo, C. N., Peng, T. W., Wei, Y. Y., Feng, C. H., Liu, Y. C., and Chiang, M. T., Simulation Modeling of TFT-LCD Color Filter Fab, The 16th International Display Workshops (IDW 2009), Miyazaki, Japan, December 9 - 11, 2009.
[5] Cigolini, R., Perona, M., Portioli, A., and Zambelli, T., A New Dynamic Look-ahead Scheduling Procedure for Batching Machines, Journal of Scheduling, Vol.5, No.2, pp.185-204, 2002.
[6] Chen, J. C., Su, L. H., Chen, C. C., Peng, T. W., and Chao, G. C., Release planning for color filter fabs based on iterative simulation, Journal of the Society for Information Display, Vol.19, No.7, pp 480-487. 2011.
[7] Gupta, A. K., and Sivakumar, A.I., Optimization of due-date objectives in scheduling semiconductor batch manufacturing, International Journal of Machine Tools & Manufacture, Vol.5, No.12-13, pp1671-1679, 2006.
[8] Gupta, A. K., and Sivakumar, A.I., Controlling delivery performance in semiconductor manufacturing using look ahead batching. International Journal of Production Research, Vol.45, No.3, pp 591-613, 2007.
[9] Hung, Y. F. and Leachman, R. C., A production planning methodology for semiconductor manufacturing based on iterative simulation and linear programming calculations. IEEE Transactions on Semiconductor Manufacturing, Vol.9, No.2, pp 257-269, 1996.
[10] Kim, B., Jeong, S., Shin, J., Koo, J., Chae, J. and Lee, S., A layout- and data-driven generic simulation model for semiconductor fabs. IEEE Transactions on Semiconductor Manufacturing, Vol.22, No.2, pp225-231, 2009.
[11] Kutanoglu, E., and Sabuncuoglu, I., Experimental investigation of iterative simulation-based scheduling in a dynamic and stochastic job shop. Journal of Manufacturing Systems, Vol.20, No.4, pp 264-279, 2001.
[12] Law, A. M., Designing a simulation study: how to conduct a successful simulation study, Winter Simulation Conference 2003: 66-70, 2003.
[13] Law, A. M., How to build valid and credible simulation models, Proceedings of the 2009 Winter Simulation Conference: 24-33, 2009.
[14] Lin, J. T., Wang, F. K., and Peng, C. C., Lot release times and dispatching rule for a TFT-LCD cell process. Robotics and Computer-Integrated Manufacturing, Vol.24, No.5, pp 228-238, 2008.
[15] Pillai, D. D., Bass, E. L., Dempsey, J. C. and Yelling, E. J., 300-mm full factory simulation for 90- and 65-nm IC manufacturing. IEEE Transactions on Semiconductor Manufacturing, Vol.17, No.3, pp 292-298, 2004.
[16] Park, B. C., Park, E. S., Choi, B. K., Kim, B. H., Lee, J. H., Simulation based planning and scheduling system for TFT-LCD fab, Simulation Conference, WSC2008, Austin, Winter, 7-10 Dec. 2008.
[17] Sargent, R. G., Verification and validation of simulation models, Proceedings of the 2009 Winter Simulation Conference, pp. 162-176, 2009.
[18] Sha, D. Y., Hsu, S. Y., Lai, X. D. Design of due-date oriented look-ahead batching rule in wafer fabrication, International Journal of Advanced Manufacturing Technology, Vol. 35, No.5-6, pp596-609, 2007.
[19] Van Der Zee, D. J., Dynamic Scheduling of Batch-processing Machines with Non-identical Product Sizes, International Journal of Production Research, Vol. 45, No. 10, pp. 2327 – 2349, 2007.
[20] Wang, F. K., Du, T., and Wen, F. C., Product mix in the TFT-LCD industry. Production Planning and Control, Vol.18, No.7, pp 584-591, 2007.