LED封裝試比例回饋系統之設計與實作

Abstract

LED製造流程一般分為上游磊晶、中游晶粒、下游封裝，而LED封裝廠為了取得符合客戶規格之色座標，因此需要進行試比例作業，以決定部分製程參數。本論文之研究，收集各系統資料統整成資訊，用來建置LED封裝廠的核心技術之「試比例回饋系統」平台，工程師除了方便掌握各項資訊外，並運用這些歷史資料預先模擬適當的製程處方，不僅可以加速產出也可以提升產出週期，省去不少人力來計算製程處方，也讓工程師和作業員之間溝通無障礙，避免資訊不及時或資訊傳遞有誤差，並可減少作業員因為抄寫錯誤參數而導致產品良率降低。 整體研究成果包含「物料系統」管理供應商、螢光粉和封裝膠等資訊；「點膠系統」提供試比例申請、生產資訊表、點膠資訊、產出分佈、放量等功能；「回饋系統」依據產品屬性，並參考歷史資料的各試比例資料，運用線性迴歸原理或Weight %調整模組，進行Weight %的模擬回饋計算後，產生分佈圖、線性方程式和各項數據指標回饋給工程師，讓工程師能更迅速做出適當的決定，而這些統整的技術知識，包含製程重要參數、指標、產出分佈圖等資訊，也有助於訓練新進工程師之輔助，讓新進者能快速掌握試比例流程和方法。 由實驗結果顯示，試比例次數和產品週期皆有降低的趨勢，以及CIE目標差距縮小，表示Weight %預估準確，整體產出分佈也很集中。過去工程師使用紙本或試算表的平均試比例次數約為6.53次，與系統上線後平均試比例次數為4.27次，降幅約為34.6%。 未來，期望能藉由本論文建置之「試比例回饋系統」，由系統定期訓練Weight %調整模組，並排除異常點以達到自動回饋的機制，更進一步擴充到雙粉試比例回饋系統，以便讓工廠運作更為自動有效率。

Light Emitting Diode (LED) manufacturing is generally divided into upstream Epitaxy, middle Chip, downstream Package. In the LED Package factory, it’s necessary to obtain the CIE coordinates in order to meet customer specifications. Therefore the factory does the try-run operations before mass-production which is the core technology of the LED Package. In this thesis, we created the Try-Run Feedback System to integrate information from various systems and to provide useful information for this operation. With this system, engineers are easy to master all kinds of information and use historical data to simulate the process recipe. Many advantages can be achieved such as speeding up the output, enhancing the output cycle by elimination the need for a lot of manpower to calculate the prescription of the process, providing better communication between the engineers and the operators, providing the precise and on-time information and increasing product yield by preventing from mistyping parameters. The overall system architecture consists of material management system, dispensing systems, feedback system, etc. The material management system is used to manage the information of the supplier, phosphor and glue. The dispensing system is used to manage the try-run requisition, run card of the process flow, dispensing process parameters, product color distribution and release control for mass-production, etc. Based on product attributes, and historical data of each try-run data, the feedback system uses the principle of linear regression or Weight% adjustment module to calculate the weight% of the phosphor to glue, generating the charts of product color distribution, linear equations and many useful indicators for engineers which help engineers to make appropriate decisions quickly. Thus the junior engineers will familiar with the processes of the try-run operations quickly with the systematize knowledge which including the important parameters of the process, indicators, color distribution and other information. From the experimental results, the times and cycle time of try-run are decreased, the gap between the CIE target and the result are also reduced, which reveals the precisely Weight% and the concentrated color distribution. The try-run times was enhanced for 34.6% from 6.53 to 4.27 times. In the future, the weight% module will be adjusted automatically by the Try-Run Feedback System in order to exclude the outliers and to achieve automatic feedback mechanism. The other application is to support double phosphors in Try-Run Feedback System, to improve manufacturing efficiency.