印刷電路板製造廠主生產排程規劃系統之構建

Abstract

印刷電路板在製造過程中，存在著雙瓶頸工作站，分別為壓合站與鑽孔站。每一瓶頸工作站皆以批量機台進行加工，有多種機型，各機型生產訂單之加工時間不同，且加工一次之產出量亦不同。為提升競爭力，印刷電路板製造廠須適當規劃各週期之生產計劃，以解決產量配置問題，使訂單滿足交期。 承上所述，本文針對印刷電路板製造廠之接單式生產環境以及機台加工特性，建構一「印刷電路板製造廠主生產排程規劃系統」，此規劃系統包含「產能估算模組」與「壓合與鑽孔工作站排程模組」。 「產能估算模組」為在規劃幅度內，估算每一瓶頸工作站的產能是否足夠生產所有訂單。「壓合與鑽孔工作站排程模組」承接產能估算模組之結果，考量產能負荷、各筆訂單之到臨日與交期、整備時間、製程先後加工順序、各訂單需求量等限制，以訂單延遲數量最小化為目標，設計一整數規劃模式，求解各機台在各規劃週期加工各產品之最佳生產數量與加工順序，期望使訂單能在交期前完成生產。 經由案例分析結果顯示，藉由同時規劃壓合與鑽孔兩瓶頸工作站可達整體最佳解。此外，規劃時涵蓋多個規劃週期，可節省跨期間之整備時間。整體而言，本文所設計之模式可快速求得各訂單於各機台之配置數量，以及各機台於各規劃週期加工之產品順序，可提供現場規劃人員作為生產決策之依據。

The manufacturing of printed circuit board (PCB) includes two bottlenecks, named lamination workstation and drilling workstation. Each bottleneck workstation uses batch processing machines to process and owns multiple-type machines. The process time and throughput rate for an order is different if the machine type is not the same. To improve competitiveness, the PCB factory needs to make production plan for each period appropriately, with consideration of order allocation problem so as to deliver each order on time. Thus, this thesis develops a master production scheduling (MPS) system for the PCB factory for the make to order environment. The MPS system includes rough cut capacity planning module and bottleneck scheduling module. The rough cut capacity planning module is used to calculate the capacity supply of each bottleneck workstation and the time needed by all orders. Based on the result of rough cut capacity planning, the bottleneck scheduling module constructs the integer programming model, which considers the release time, due date and the quantity of each order, setup time, sequence between lamination and drilling, to generate the production schedule on each machine and the production amount for each order, with minimizing number of tardy orders as the objective. According to the result of cases analysis, this system attains optimal solution by planning lamination and drilling workstations simultaneously. Furthermore, the proposed system solves the scheduly for each planning period in a planning horizon and thus can reduce the setup time between periods. Consequently, the developed system can allocate the production quantity of each order on machines of two workstations, and solves the scheduly problems for the PCB factory.