臺灣博碩士論文加值系統

平面顯示器(Flat Panel Display:FPD)的製程，以 TFT-LCD產業佔大部分，不論是在陣列（Array）製程、組立（Cell）製程或模組（Module）製程都相當複雜，然而過去許多文獻中時常探討LCD面板的製程所遇到的瓶頸都出至於製程機台，然而實際上瓶頸卻出現在搬送面板的機器手臂(Robot Station)上，因此本研究將新設備(PHS)導入Cell段製程中，幫助決策者進行製程導入及擴充產能的成本與效益分析，針對製程進行產能規劃，以達最大總利潤的目標，並考量cycle time與投資資金等相關限制條件及考慮生產成本、耗能成本、維修成本、存貨持有成本等，決定Cell廠最適合機台汰換之時程。最後透過線性規劃法（Linear Programming，LP）建構模式分析導入PHS效益，並且規劃取得最佳的長、中、短期導入的時間點。

FPD(Flat Panel Display) manufacturing in which TFT-LCD taking the majority, no matter in array, cell, or module process, is quite complex. As noted in literature, the bottleneck occurred in the machinery station during the manufacturing process. However, the bottleneck station could appear in material handling Robot Station that used for moving panel during the processes. Therefore this paper will utilize the robust high-tech facility, Panel Handling Station (PHS), developed by Gthink Tech to substitute for Robot Station in Cell process of TFT-LCD manufacturing and an effectiveness analysis model by using mathematical programming will be proposed to evaluate the long term investment project. This research inducts new equipment (PHS) in Cell process and helps the decision-maker to carry on the necessary feasibility analysis, including capacity planning, yield rate and grade proportion of production line, the production cost, the inventory cost, work in process stock, the production cycle time, the system bottleneck and so on. The objective is to maximize total profit under the relative constraints and to suggest the optimal long-term investment timetable about the substitution for robot-stations.

摘 要 II
Abstract II
誌謝 III
目錄 IV
表目錄 VII
第一章 研究背景與目的 1
1.1 研究背景 1
1.2 研究動機及目的 4
1.3 研究步驟 5
1.4研究架構 6
第二章 文獻探討 8
2.1薄膜液晶顯示器Cell段製程簡介 8
2.2設施購置與汰換規劃問題 10
2.3 PHS與Robot比較分析 15
第三章 研究方法與架構 19
3.1 研究問題 19
3.2 研究架構 23
3.3假設條件與研究限制 24
3.4規劃模式 25
第四章 實驗模式及結果分析 30
4.1 案例背景 30
4.2情境說明 32
4.3 實驗目的 36
4.4實驗架構 36
4.5實驗因子 37
4.6實驗結果與分析 38
4.7本章小結 49
第五章 結論及建議 50
5.1結論 50
5.2 建議 51
參考文獻 52

1. 白健二、陳文華、郭瑞祥、蔣明晃，生產與作業管理，1997。
2. 林則孟，生產計畫與管理，2006。
3. 高仲顯原著、洪騰岳編譯，生產計劃的方法，書泉出版，1996。
4. 張益菁，考量需求不確定之單階多廠產能規劃問題—以TFT LCD 產業為例，國立清華大學工業工程與工程管理學系碩士論文，2007。
5. 曾建淞，TFT-LCD 之多廠區需求管理與產能規劃，明新科技大學工程管理研究所碩士論文，2008。
6. 熊雅意，晶圓代工廠考慮週期時間限制之機台規劃研究，國立交通大學工業工程與管理學系博士論文，2004。
7. 賴明材，隨機過程方法應用於系統最佳置換策略之研究，國立清華大學，博士論文，1996。
8. 譚紹榮，「技術突破下機具重置模式之研究」，國防管理學院，碩士論文，1994。
9. Ahmed S. and Sahinidis N. V, “Robust capacity planning under uncertainty”, Ind. Eng. Chem. Res., Vol. 37 (5), pp. 1883‐1892, 1998.
10. Aghezzaf E, “Capacity planning and warehouse location in supply chains withuncertain demands”, Journal of the Operational Research Society, Vol. 56, pp.453–462, 2005.
11. Bellman, R. “Equipment Replacement Policy”, Journal of the Society for Industrial and Applied Mathematics, Vol. 3, No. 3, 133-136,1995.
12. Bard J. F, Srinivasan K, and Tirupati D, “An Optimization Approach to Capacity Expansion in Semiconductor Manufacturing Facilities”, International Journal of Production Research, Vol. 37, No. 15, pp. 3359-3382, 1999.
13. Bretthauer K. M., “Capacity planning in manufacturing and computer networks”,European Journal of Operations Research, Vol. 19,1996, pp. 386-394.
14. Catay, B., Erenguc S. S., Vakharia A. J., “Tool capacity planning in semiconductormanufacturing”, Computers &; Operations Research, Vol. 30, pp.1349–1366, 2003.
15. Connors, D. P., Feigin G. E., and Yao, D. “A Queueing Network Model for Semiconductor Manufacturing”, IEEE Transactions on Semiconductor Manufacturing, Vol. 9, No. 3, pp. 412-427, 1996.
16. Chou Y.‐C., “Configuration Design of Complex Integrated Manufacturing Systems”, International Journal of Advanced Manufacturing Technology, Vol. 15, pp.907‐913, 1999.
17. Chou Y.‐C. and You R. C., “Resource Portfolio Planning Methodology for Semiconductor Wafer Manufacturing”, International Journal of Advanced Manufacturing Technology, Vol.18, pp. 12‐19, 2001.
18. Donohue K. L, Hopp W. J. and Spearman M. L., “Optimal Design of Stochastic Production Lines: A Dynamic Programming Approach”, IIE Transactions, Vol.34, 2002, pp. 891-903.
19. Grewal N. S, Bruska A. C, Wulf T. M, and Robinson J. K, “Integrating Targeted Cycle-Time Reduction into the Capital Planning Process”, Proceeding of the Winter Simulation Conference, pp. 1005-1010, 1998.
20. Geng N, Jiang Z, and Chen F, “Stochastic programming based capacity planning for semiconductor wafer fab with uncertain demand and capacity”, European Journal of Operational Research, 2008.
21. Hartman, J. C., “An Economic Replacement Model with Probabilistic Asset Utilization”, IIE Transactions, Vol. 33, No.9, pp.717-727,2001.
22. Hopp Wallace J, Mark L. Spearman, Sergio Chayet, Karen L. Donohue, Esma S. Gel. “Using an optimized queuing network model to support wafer fab design.” IIE Transactions, Vol.34, pp.119‐130, 2002.
23. Hood S. J, Bermon S, and Barahona F., “Capacity planning under demand uncertainty for semiconductor manufacturing”, IEEE TRANSACTIONS ON SEMICONDUCTOR MANUFACTURING, VOL. 16, NO. 2, MAY 2003.
24. Kang J.‐S, Suh M.‐H, and Lee T.‐Y, “Robust economic optimization of process design under uncertainty”, Engineering Optimization, Vol. 36, No. 1, pp. 51–75, 2004.
25. Mollaghsemi and Evans G. W., “Multi-criteria design of manufacturing systems through simulation optimization”, IEEE Transactions on Systems, Man, and Cybernetics, Vol. 24, No. 9, pp. 1407‐1411, 1994.
26. Neacy. E, Abt. N, Brown. S, McDavid M, Robinson J, Srodes S, and Stanley T,“Cost Analysis for a Multiple Product / Multiple Process Factory: Application of SEMATECH’s Future Factory Design Methodology”, IEEE/SEMI Advanced Semiconductor Manufacturing Conference, pp. 212‐219, 1993.
27. Swaminathan J. M. “Tool Capacity planning for Semiconductor Fabrication Facilities under Demand Uncertainty”, European of Operational Research, Vol. 120,pp. 545‐558, 2000.
28. Swaminathan J. M., “Tool Procurement planning for wafer Fabrication Facilities:A Scenario‐Based Approach”, IIE Transactions, Vol. 34, pp. 145‐155, 2002.
29. Stephen C.H. Leung, Sally O.S. Tsang, W.L. Ng, and Yue Wu, “A robust　optimization model for multi‐site production planning problem in an uncertain　environment”, European Journal of Operational Research, Vol.181, pp. 224–238,　2007.
30. Chou Y. C. and Wu C. S, “Economic Analysis and Optimization of Tool Portfolio in Semiconductor Manufacturing”, IEEE Transactions on Semiconductor Manufacturing, Vol. 15, No.4, 2002 ,pp.447-453.