六標準差DMAIC之實務應用方法研究-TFT LCD 亮點品質改善之個案研究

Abstract

六標準差方法是在 1980 年代初期所發展出來的，首先將這種方法運用於改革公司生產流程的是 Motorola 公司。並由奇異公司發揚光大，也因為奇異公司推行的成功案例，使得六標準差方法在國外較具競爭優勢的企業之經營中，佔有相當重要的地位，國內也有一些企業正準備推動並導入這個方法，以增加公司的競爭力。 本研究以國內某TFT LCD 廠，利基型22吋寬螢幕產品，零亮點問題作一探討，TFT-LCD 面板產業為近年來台灣發展最快速的產業之一，大尺寸TFT-LCD 產業為資本密集且具進入與退出障礙，面板廠商需持續投資擴充產能以維持其競爭力。持續降低生產成本、提升生產良率為面板製造商成功的關鍵因素。台灣目前的產業技術並不落後日、韓等大廠，隨著面板普及與大尺寸來臨，液晶顯示器技術也不斷再創新，如何進行品質改善，降低亮點發生比率與減少修補成本，已是首要要務。本研究以六標準差管理手法的流程步驟-DMAIC，搭配個案公司從其企業策略之擬訂、公司目標規劃與部門績效指標佈署出發，研究其如何利用六標準差品質改善方法之界定、衡量、分析、改善、控制五大改進循環，解決策略目標執行過程中所產生之問題，並針對其理論架構與實務應用方法進行TFT LCD無亮點(ZBD)品質提升的探討。找出關鍵品質特性，建立衡量量測系統及製程能力，歸納出影響的關鍵因子，再利用假設檢定進行實驗，期望能提升無亮點產出比率，達到客戶要求。

Six Sigma methods are developed in the early 1980s; the first company which applied this method to reform the production process is the Motorola Inc.And carried forward by GE. Also because of success case of GE, Therefore Six Sigma method possess a very important status in competitive foreign enterprises, some local enterprises are going to promote and introduce this method,to use as increasing the company's Competitiveness. It is the purpose of this research project into the zero bright issue of a niche 22-inch wide-screen product of a certain TFT-LCD company. In recent years, TFT-LCD panel industry is one of the fastest growing industries in Taiwan.Large-size TFT-LCD industry is capital-intensive and also possessing entry and exit barriers, panel makers need continuing invest on expanding capacity to keep their competitiveness. Continued reducing production costs and improving production yields are the critical factors of a successful panel maker. Taiwan's current industry technology is not lagging behind Japan, Korea and other manufacturers. As the advent of large-size, popularity of panel and liquid crystal display technology had also been constantly re-innovation, how to improve quality, reduce the occurrence rate and repair cost of the bright dot has been the primary task. In this research, using the management process of Six Sigma as DMAIC, with the strategy formulation, target planning, departmental performance indicators of the case company to study how to use the five improving cycle of Six Sigma, which is defining, measuring, analyzing, improving and controlling, to solve the problem of achieving the strategic objectives.And focus on TFT LCD zero bright dot (ZBD) quality improvement between the theory and practical application of method. To identify key quality characteristics, and build the measurement system to improve manufacture capability, summed up the key factors, use hypothesis experiment, hoping to raise the output ratio of ZBD, to meet customer requirements.