标题: TFT-LCD模组厂生产规划系统之构建
The Design of Production Planning System for the TFT-LCD Module Factory
作者: 许运达
Yun-Ta Hsu
钟淑馨
Shu-Hsing Chung
工业工程与管理学系
关键字: 薄膜电晶体液晶显示器;模组厂;生产规划系统;产能规划;生产周期时间估算;TFT-LCD;Module factory;Production planning system;Capacity planning;Cycle time estimation
公开日期: 2004
摘要:   薄膜电晶体液晶显示器(Thin Film Transistors Liquid Crystal Display;简称TFT-LCD)之制程步骤共分为三个主要阶段。其中,模组厂(Module Assembly)位于最终阶段且为最接近顾客的生产环境,其生产产品总类繁多,因此满足顾客需求为其经营策略;但模组厂之瓶颈工作站换线时间高达6个小时,所以如何建构ㄧ个良好的生产规划系统,来有效减少换线次数,使产出最大化。
  对于此课题,本系统共建构三个模组来加以因应,分别是“产能规划模组”、“物料规划模组”与“生产规划与排程模组”。首先,在“产能规划模组”中,考量模组厂瓶颈机台的最大可用产能与换线时间相当长等限制,建构ㄧ线性规划模式,用以求解各期产品加工数量与顺序表,使其充分利用瓶颈,达到产出最大化之目标。“物料规划模组”则是在求解出各期产出目标之后,对模组厂所需要之原物料进行备料,以防止机台无料生产,导致在制品上升与机台利用率下降。最后,在“生产规划与排程模组”里,由于混线生产比专线生产多考虑了换线因素,造成在进行估算生产周期时间时,有相当大的变异,因此分别运用Conway估计式与queueing Model M/M/s来求算各工作站混线与专线的生产周期时间。
  实验结果显示,本文的生产规划系统不仅可有效减少换线次数、充分利用瓶颈资源,且可达到产出最大化之目标;而在生产周期时间估算方面,亦有相当良好的成效。整体而言,本文建构的生产规划系统,可快速获知模组厂生产之产品别及数量,且提供一良好生产周期时间之依据。
  The manufacturing process of TFT-LCD mainly consists of three stages. Among them, module assembly is the final stage of the whole production process and is most close to customers. Since module assembly produces various products, its scheduling strategy is to meet customers’ demand. However, the setup time of bottleneck workstation is very long and is up to 6 hours. The key of such problem is to construct a good production planning system to reduce the number of setups and to maximize the throughput.
  To solve the problem, the proposed system comprises three modules: capacity planning module, material planning module, and production planning and scheduling module. In the capacity planning module, we construct a linear programming (LP) model which considers the constraints such as the maximum capacity of bottleneck machine and long setup time. The planning results contain the production quantity of each product type and the production sequence at each time period. With the throughput target for time period, material planning module is to get the material ready for dispatch in order to avoid the drop in machines’ utilization rate and the increase in WIP level. Finally, since the mix line needs to consider the set-up operation, variation in cycle time is very large and the estimation is more difficult. Therefore, the production planning and scheduling module applies queueing M/M/s Model and Conway estimation to calculate the production cycle time in both the mix line and the dedicate line of each workstation.
  Experimental result shows that our production planning system not only can reduce the number of setups efficiently and utilize the bottleneck effectively, it can also maximize the throughput and estimate the cycle time rather accurately. Overall, our production planning system can arrange product type and quantity of module factory quickly and provide a good reference of production cycle time.
URI: http://140.113.39.130/cdrfb3/record/nctu/#GT009233530
http://hdl.handle.net/11536/77102
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