TFT-LCD組立廠於製程可選擇情境下主生產排程系統與可允諾機制之構建

Abstract

薄膜液晶顯示器之組立廠將彩色濾光片與陣列廠所產出之玻璃基板進行一組立動作，並注入液晶而形成一液晶面板之半成品。在組立製程可選擇情境下，訂單需求包含指定HPS製程、指定ODF製程與不指定製程的類型。生產中小型產品之工廠，因而須以接單式與預測式生產方式，並保有可用產能來回應顧客多樣化的訂單需求。本文因而建構「主生產排程系統」，用以規劃出整備次數最小化之排程，並輔以「可允諾機制」，以便在短時間內因應顧客之訂單需求來修改排程。 承上所述，本文建構之「主生產排程系統」，將針對重點工作站進行排程求解。其先以「產能估算機制」來辨識出三個重點工作站，並將之區分為瓶頸與次瓶頸工作站。接著進行「重點工作站規劃機制」，以整備次數最小化為目標，考量HPS製程與ODF製程產量配置和跨期是否免整備，透過整數規劃模式同時進行三個重點工作站排程之求解。「可允諾機制」，用於實際訂單來臨時，規劃出可滿足實際訂單之排程。其透過「訂單允諾模組」檢視主生產排程之可允諾量與可允諾產能等資訊，與新到臨訂單進行沖銷，以在短時間內滿足新來臨之實際訂單。若未能滿足實際訂單，則透過「重排程模組」在凍結已接訂單之排程下，考量重排程後與重排程前工作站平均利用率之差異，以較小的排程更動幅度來重新對預測式產品與實際訂單做排程。 案例結果顯示，本文所發展之「主生產排程系統」，可快速計算出重點工作站跨期是否免整備，以在短時間內求解出重點工作站整備次數最小化之排程。而「可允諾機制」，則可在短於「主生產排程系統」之求解時間下，滿足新來臨之實際訂單。 關鍵字：薄膜液晶顯示器、重點工作站、產量配置、跨期是否免整備、實際訂單

The cell assembly factory assembles the color filter with the glass substrate produced from array factory, and filling with liquid crystal for making thin film transistor liquid crystal display (TFT-LCD). In the process selectable environment, each custom order can specify its required process such that orders can be classified as hot press (HPS) specified, one drop fill (ODF) specified, and unspecified. Factories that producing middle and small size products, thus take make-to-order (MTO) mixed with make-to-forecast (MTF) policy and try to keep some unused capacity to response the new arrived customer orders. As a result, this thesis proposes a master production scheduling system to plan a schedule with the most unused capacity, and develops the available-to-promise mechanism to response the new arrived customer orders in short time. The proposed master production scheduling system solves the schedule for all major workstations. At first, rough cut capacity planning mechanism is used to identify three major workstations and then distinguishes the bottleneck and sub-bottleneck among them. Then major workstation planning mechanism is used to determine the production quantity of HPS process and of ODF process. An integer programming model is built to solve the schedule for the three major workstations simultaneously with minimization of the bottleneck’s setup time as the objective function. The proposed available-to-promise mechanism is applied when the new orders arrives. It adopts the order promise module to check whether the quantity available to promise and the capacity to promise can fulfill the new arrived orders or not. If the new order can not be fulfilled, rescheduling module freezes the schedule of the firm orders and reschedule the make to forecast orders and new arrived orders, with consideration of minimizing the difference of the bottleneck’s average utilization rate before and after rescheduling. According to the result of cases analysis, the proposed master production scheduling system can solve the schedule of the three major workstations and minimize setup times for the bottleneck with efficiency. The proposed available-to-promise mechanism can make the new arrived orders fulfilled with the time faster than rerunning the proposed master production scheduling system. Key words：TFT-LCD, major workstations, production quantity, inter-period setup, actual order