太陽能廠電池段製程主生產排程規劃系統之構建

Abstract

太陽能廠電池段製程中，存在著雙瓶頸工作站，分別為磷擴散站與鑽孔站。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，太陽能廠須適當規劃廠內之生產計劃，以解決產量配置問題，使訂單滿足交期。 本文針對太陽能廠之接單式生產環境以及機台加工特性，建構一「太陽能廠電池段製程主生產排程規劃系統」，此規劃系統包含「粗估產能規劃模組」與「主生產排程規劃模組」。 「粗估產能規劃模組」是在規劃幅度內，估算每一瓶頸工作站的產能是否足夠生產所有訂單。「主生產排程規劃模組」承接粗估產能規劃模組之結果，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、特殊訂單規格等限制，以訂單未達交數量最小化為目標，設計一整數規劃模式，求解各機台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，針對較大問題時，整數規劃求解時間將十分冗長。故吾人使用兩階段排程方法，利用派工法則初排後，將大問題分為數個子問題，接著針對各個子問題進行求解，最後將各個子問題之最佳解整合成最終排程結果。整體而言，本文所設計之模式可求得各訂單於各機台之配置數量以及其加工順序，可提供現場規劃人員作為生產決策之依據。

The manufacturing of cell line in solar energy factory includes two bottlenecks, named diffusion workstation and AR coating 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 solar energy needs to make production plan 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 solar energy 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, we constructs the integer programming model for the bottleneck scheduling module, which considers the release time, due date and the quantity of each order, setup time, sequence between diffusion and AR coating, 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, it is takes a lot of time to solve large-scale problem, so a two-phase scheduling approach is developed to solve this problem. In the first phase, a initial sequence of jobs by a dispatching rule is developed. In second phase, preliminary job sequence obtained from the first phase is divided into subsequence. Each subsequence is considered as a subproblem which is solved by a Integer Programming model. Consequently, the developed system can allocate the production quantity of each order on machines of two workstations, and solves the schedule problems for the solar energy factory.