以精實六標準差改善TFT-LCD供應鏈零件品質－以電源轉換器關鍵零組件為例

Abstract

全面品質管理(Total Quality Management ; TQM)的精神在於強調包括供應商與顧客在內的組織全體承諾，其中供應鏈之競爭力需考量在每一鍊條環節中之品質成本與採購成本，亦即總成本(Total Costs)觀念。由於電子產品生命週期與可靠度及壽命有關，一般會呈現浴缸曲線(Bathtub Curve)三階段分佈，依次為故障率最高之早么期(Early failure period)、故障率偶發之使用期(Useful period)及損耗期(Wear-Out period)，因此源頭之材料品質可靠度及耐用性將影響供應鏈下游客戶甚至終端消費者的產品失效故障率。 個案選用新開發之變壓器為研究對象，本著全面品質管理的精神，以六個標準差(Six Sigma)與精實供應鏈(Lean Supply Chain)為主軸，透過可靠度驗證(Reliability Test)，於上游變壓器廠將早夭期不良有效篩檢，以縮短製程工時，進而減少個案公司於製程中多餘預燒時間的浪費，不僅降低製造工時、品質成本、降低碳排放，更能有效控制供應鏈下游客戶甚至終端消費者的產品失效故障率，整個供應鏈也因優良的變壓器品質及較低製造成本，使得TFT-LCD供應鏈更加有競爭力。

The spirit of “Total Quality Management” (TQM) is the emphasis on commitment of the entire organization which includes suppliers and customers. The quality cost and procurement cost in each sector of the supply chain must be taken into consideration for the competitiveness of the chain. The life cycle of electronic products usually depends on reliability and lifetime, and it is usually presented in the form of three-stage distribution of Bathtub curve in the sequence of the early failure period with the highest failure rate, the useful period with occasional failure rate, and the wear-out period. Therefore, the quality reliability and durability of materials at the source will affect the product failure rate at downstream customers and even end consumers. In this case the newly developed transformer will be the research object. Based on the spirit of total quality management and the principles of Six Sigma and Lean Supply Chain, the defects in early failure period of the upstream transformer factory will be effectively screened through reliability test in order to shorten the process working hours and reduce the extra waste of pre-burning time by the company in this case. This will not only lead to reduction of manufacturing working hours, quality cost, and carbon emission, but also result in effective control over the product failure rates among downstream customers or even end customers in the supply chain. The entire supply chain of TFT-LCD will become more competitive due to superior transformer quality and lower manufacturing cost.