建構滿足客戶需求品質水準與最大產出之產能調配模型於TFT-LCD製造

Abstract

TFT-LCD面板製程產品應用廣，從大尺寸的電視，中小尺寸電腦螢幕、觸控面板，以及智慧型的手機等；這些產品主要是由LCD及LCM 兩大製程段所組成。前段包含有 TFT Array Panel (TFT Array)、彩色濾光片 (Color Filter)、液晶面板組立 (LC Cell Assembly)；而後段則是TABLIC & PCB接著與背光元件BLU(Back Light Unit)模組組立 (Module Assembly)。製造工廠為提高產出達成客戶交期，常以加速製程速度或是犧牲產品的品質來做因應，然而衍生性的風險是複雜且廣的；風險小時，為人員或機台的漏篩，LCM後段製程會對LCD前段製程作反饋與要求改善，風險大時，即為客戶抱怨，若影響客戶的品質、交期甚至會被客戶要求賠償的；現實的工廠生產作業問題多為複合性關聯的問題，不是改善單一影響因子下就可解決。本研究以TFT-LCD工廠製造流程中重要關鍵製程Cell 段檢測站作業情境來做探討，以FlexSim 建構一個快速且貼近實務模型，符合客戶品質水準與最大產出之產能的調配模型，其中把工廠生產條件產品別、點燈機台配置的畫面數、OP檢查人員手法的情境模擬，結果發現，條件一產品別(量產品與新產品)模擬，量產品的產出量16,693pcs，是符合客戶需求，而新產品因在製造初期因各項生產條件尚未最佳化，產品缺陷較多需多花時間進行檢驗，是無法符合客戶需求。改善作法，以調配模型 (Source)平均投料時間變更為4個單位時間及標準差為2來因應，結果可提高產出量22.95%。於條件二點燈機配置畫面數差異(17與10個)模擬，點燈畫面數配置10個產出量是不符合客戶需求且還可能會客訴，其中工站(APIviwer)的使用率最低僅21.8%，表示工廠生產未滿載。條件三 OP站檢驗手法(加嚴與常規)模擬，結果發現兩者OK品產出數量差異了12,966 (pcs)，加嚴檢產出量少了78%，且多數工站使用率皆已達100%，表示工廠檢測能力已無法負荷此品質異常的客訴對應。綜合以上情境模擬得知，製造工廠基本配置站點大宗為投入、加工、產出，故可運用此方法快速讓工廠得到結果，進而能提高企業產品的獲利。

The TFT-LCD panels are widely applied to electronic products of large-size TV, small and medium-size computer screen, touch panel, and smart phones. The TFT-LCD manufacturing process composes of LCD and LCM, in which TFT Array, Color Filter, and LC Cell Assembly are in the front-end process and TABLIC & PCB lamination and backlight element module assembly are in the back-end process. In order to raise the throughput and meet the schedule customers requested, the manufactories usually attempt to sacrifice product quality or shorten the process time in favor of expedited delivery. However the consequence is complex and pervasive. The minor impacts include miss- sorting issues made by workers or machines, and front-end of line has to improve according to the feedback from back-end of line. The serious impacts are customer complaint on the defective material and penalties due to the delivery delays. In reality, there are compound factors associated with manufacturing and operational issues, and most problems cannot be solved by just improving from a signal element. This study is to investigate the situational of Cell-Line which is a key process in TFT-LCD manufactories. We develop a ready-to-use and accurate simulation model by FlexSim to access to the interactions between throughput and quality levels. The simulation is reacted by following conditions : the different product types, the number of light-on machine patterns, and the methods of OP inspector. The result of the simulation by product type is 16,693pcswhich could meet customers required. However the throughput of patterns reduced simulation (shorten the process time)is not only unreached customers requested but also might lead customer complaint. Besides the utilization of this step is the worse only 21.8%. But if the average input time of Source model has been modified to 4 unitswithin2 sigma with the new product, the result of throughput could be raised up 22.95%. As for the methods changed of OP inspectors (enhanced/ general), the output gap is 12,966pcs and throughput is less 78% due to enhanced inspecting. Besides the utilization of most steps is almost 100% that means the factory is no more capacity to handle quality issue and customer complain. Based on the above scenarios of simulations, the basic elements of manufacturing factory are input, process and output. Therefore by using the current resources is capable to get the results effectively and furthermore improve product profitability.