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研究生:陳子立
研究生(外文):Tzu-Li Chen
論文名稱:以模擬為基礎之先進規劃排程法-以TFT-LCD模組廠為例
論文名稱(外文):Simulation-Based Advanced Planning and Scheduling for TFT-LCD Module Site
指導教授:林則孟林則孟引用關係
指導教授(外文):James T. Lin
學位類別:碩士
校院名稱:國立清華大學
系所名稱:工業工程與工程管理學系
學門:工程學門
學類:工業工程學類
論文種類:學術論文
論文出版年:2003
畢業學年度:91
語文別:中文
論文頁數:175
中文關鍵詞:先進規劃與排程模擬TFT-LCD
相關次數:
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TFT-LCD模組廠是以物料為主的組裝生產環境,也是最後成品組裝的階段,隨著TFT-LCD顧客要求多樣性與客製化的趨勢下,過去模組廠以存貨式生產(Make to Stock)模式已經無法滿足顧客需求,甚至會造成模組廠生產排程大幅度的變動以及呆成品庫存的增加,因此如何解決此問題是相當重要的議題。
本研究將探討在TFT-LCD產業中模組廠的範圍下,首先對於模組廠生產系統特徵與限制進行了解,再針對現有模組廠存貨式生產(MTS)的生產模式與生產規劃流程進行探討與分析,歸納出現有模式的特點與缺失。發現現行生產模式不適用於模組廠的生產環境,常常會造成訂單延遲、高存貨水準與過多呆料呆成品。因此,本研究建議未來TFT-LCD產業改變為接單後組裝生產(Assembly to Order)生產模式,即模組廠則改變為接單後生產(Build to Order)生產模式與規劃流程。接著在此未來生產模式下,對於模組廠在已知確定性訂單與各物料的供給狀況下,考慮產能限制,要如何排定出滿足顧客需求與減少庫存的最終組裝生產排程之問題,提出一個以限制為基礎模擬方法論(Constraint based Simulation;CBS)來解決之,此方法論結合了限制與離散式模擬的概念,同時考量多重限制包括物料限制、產能限制或交期限制等,透過前推式模擬與後推式模擬,決定出可行投料時窗,再根據兩大目標:(1)滿足訂單交期和(2)減少存貨水準包括在製品與成品存貨,在可行投料時窗中,尋找滿足目標理想投料時間點。然後,藉由案例探討,將此CBS方法論套用至案例生產規劃流程上,並用手動進行計算,確認此CBS方法論的可行性。
最後透過模擬軟體為工具,將案例與CBS演算法規劃方式建構成模擬模式,並透過三個單因子實驗,藉由實驗結果分析比較過去規劃方式MRP/FS(EDD)、MRP/FS(SPT)與CBS演算法規劃方式所造成的績效值的差異。經由實驗分析結果發現本研究提出的CBS演算法規劃方式,在模組廠環境甚至因子變動大的環境下,對於整體績效有著較佳的表現,尤其是在存貨水準的指標上。
第一章 緒論 1
1.1研究背景與動機 1
1.2研究目的 4
1.3研究範圍 4
1.4研究步驟與方法 5
第二章 TFT-LCD產業描述 7
2.1 TFT-LCD產業與生產製程 7
2.1.1 TFT-LCD生產製程介紹~列陣製程(Array Process) 8
2.1.2 TFT-LCD生產製程介紹~面板製程(Cell Process) 10
2.1.3 TFT-LCD生產製程介紹~模組製程(Module Process) 10
2.2 TFT-LCD模組廠生產特徵與限制 11
2.3 TFT-LCD現在(As-Is)生產規劃分析 16
2.3.1現有生產模式 16
2.3.2 現有生產規劃架構 17
2.3.3現有生產規劃方式 18
2.3.4現有生產規劃缺失 21
2.4 TFT-LCD未來(To-Be)生產規劃 22
2.4.1生產模式轉變 22
2.4.2未來生產規劃架構 24
2.5問題定義與假設 25
第三章 文獻回顧 29
3.1傳統生產計劃與管制 29
3.1.1傳統生產計劃與管制架構 29
3.1.2物料需求規劃缺失文獻 29
3.2整合物料與途程之產品結構 34
3.3生產規劃與排程模式分類 37
3.3.1物料導向規劃模式(Material-Oriented Planning) 38
3.3.2產能導向規劃模式(Capacity-Oriented Planning) 38
3.4生產規劃與排程方法分類 39
3.4.1啟發式規劃法 40
3.4.2數學規劃法 47
3.4.3模擬規劃法 47
3.4.4混和式規劃法(模擬規劃與數學規劃) 51
3.5現有軟體系統相關文獻 51
3.5.1物料導向規劃軟體 52
3.5.1.1 AcePilot 52
3.5.1.2 i2 54
3.5.2產能導向規劃軟體 55
3.5.2.1 Adexa 55
3.5.2.2 Asprova 57
第四章 以物料為主之CBS方法論 59
4.1 Bucket與Bucketless 現有規劃方法 59
4.2 CBS 63
4.2.1限制與限制分類 63
4.2.2 CBS之概念 65
4.3 CBS與Simulation Based Scheduling的比較 69
4.4方法論分析 71
4.4.1分析架構 71
4.4.2符號說明與定義 74
4.4.3績效評估指標 76
4.4.4單機排程 78
4.4.5多機排程 96
4.5演算法概念與描述 103
4.5.1演算法概念 104
4.5.2以符號描述演算法 109
第五章 案例探討 115
5.1 案例描述 115
5.1.1背景說明 115
5.1.2模組廠之產品結構與製造流程 116
5.1.3模組廠之生產排程 117
5.1.4生產排程在TFT-LCD生產規劃架構之角色 119
5.2 模組廠生產排程流程 122
5.2.1 Phase I:模組廠最終生產排程流程 122
5.2.2 Phase II:急單滿足流程 125
5.3 模組廠生產排程範例 128
5.3.1範例情境 128
5.3.2 Phase I:模組廠最終生產排程流程範例 132
5.3.3 Phase II:急單滿足流程範例 142
第六章 模式構建與實驗分析 145
6.1 模擬模式構建 145
6.1.1系統模式已知條件 146
6.1.2模擬模式細緻度 146
6.1.3模擬模式建構 146
6.1.4模式驗證與確認 150
6.2 實驗分析 151
6.2.1實驗目的 151
6.2.2實驗架構 152
6.2.3實驗結果與分析─訂單需求數量 156
6.2.4實驗結果與分析─訂單需求變異 159
6.2.5實驗結果與分析─物料延遲率 162
6.2.6結論 166
第七章 結論與建議 168
7.1結論 168
7.2建議 169
參考文獻 170
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