TFT - LCD模組廠於存貨式生產環境下物料配置機制之建構

Abstract

位於薄膜液晶顯示器供應鏈最末端之模組廠，規劃物料時須考量LCD面板半成品之符合率和零輝點率等問題，以滿足顧客對於產品品質規格之要求；此外，還須考慮關鍵物料之替代特性，使產品之產出量，不受限於主料之可用量。有鑑於此，本文擬建立一良好之物料配置機制，有效利用各物料，減少模組廠之物料庫存成本。 本論文建構一混合整數規劃模式，以利潤最大化為目標，同時考量「LCD面板半成品等級與降轉配置」、「關鍵物料群組替代與單一替代配置」和「瓶頸工作站排程」等三部分。首先，「LCD面板半成品之等級降轉配置」，針對各產品等級之需求量，考量降轉特性，進行LCD面板半成品投料等級和數量之規劃，以滿足各產品等級所設定之品質規格要求。再者「關鍵物料群組替代與單一替代配置」，考量每一產品有不同之物料群組可供選擇，每群組下每一關鍵物料又有數量不等之替代料可使用，來配置各物料之用料量，以搭配產品之產出量。最後「瓶頸工作站排程」，對瓶頸工作站進行排程與換線規劃，將各規劃週期內之用料規劃，轉換成產品可交付數量。 案例結果顯示，本文所發展之物料配置機制，採實際安排排程之方式，來確定各產品可加工之數量；其考量LCD面板半成品之降轉特性，可以較少之投料量，得到較大之產品產出量；加上考量關鍵物料之替代特性，使物料適當地被運用，有效降地低物料之庫存成本。

TFT-LCD module factory is located at the end of TFT-LCD supply chain. The material planning for module factory needs to consider that the product acceptance and zero-bad-defect rate of LCD panels so as to meet the quality and quantity requirement of products. It also needs to consider the characteristic of critical material substitution such that the production is not limited by the amount of main material. Thus, this thesis develops a material allocation system, which makes the use of material efficiently so as to increase the amount of products and decrease material cost. To maximize the profit, this thesis uses a mixed integer programming model to solve three problems simultaneously: LCD panels graded-panel allocation and downgrading, critical material allocation with grouping and single substitution, and bottleneck scheduling. First, “LCD panels graded-panel allocation and downgrading” considers the characteristic of LCD downgrading to plan the release amount of each grade of panels to satisfy quality qualification of products. Second, “critical material allocation with grouping and single substitution” allocates the amount of each material type so as to match the number of throughput units. It considers that each product has several types of bill of material, named group substitution, and that each material type can be substituted by other material types, named single substitution. Finally, “bottleneck scheduling” plans the sequence of production and set up times. The plan states transformation of released material into products at each planning period. The result of experiment shows that the proposed material allocation system determines the material units should be released by scheduling. With consideration of downgrading of LCD panels smaller amount of materials are needed to meet the product requirement, more product units are obtained with smaller number of released material. Moreover, the use of grouping and single substitution, makes materials are used efficiently and the holding cost is released.