臺灣博碩士論文加值系統

近幾年來，面板(Thin Film Transistor Liquid Crystal Display, TFT-LCD)普遍的被應用在顯像產品上，如筆記型電腦、液晶監示器及液晶電視等等。不論其生產尺寸為何，製造流程皆包含三大部分，分別為前段陣列製程、中段組立製程及後段模組製程。由於在全球產能增加的激烈競爭環境下，國內面板廠已開始運用各種不同的方案來降低產品的生產週期時間以提升快速回應市場的製造管理能力。其中在組立製程內必須考量到兩物料在組裝時是否能成套到齊方能順利進行貼合，而組裝前各站之製程特性皆為多機台及換線時間長，若機台分配不均或換線次數過多時皆會造成兩物料產出不平均（不成套）而影響組裝的進行，甚致會影響整廠的產出，因此组立廠管理得當與否顯得格外重要。為了因應此課題本文提出一個客制化的限制驅導式現場排程系統(Drum-Buffer-Rope, DBR)來提升組立廠快速回應市場的製造管理能力。DBR排程方法是一套架構在限制理論基礎上而用來解生產製造問題的現場管理機制，現今已廣泛的被應用在不同的製造業上，並且相當成功。儘管如此，在應用這套方法時，仍必須根據製造廠的特性與需求來對方法進行客製化的修正才能適用於不同的製造環境上。因此本文提出客制化的DBR排程系統來改善組立廠的生產週期時間。首先依照組立廠的需求與特性提出客制化的限制驅導節奏演算法，其次再以一組立廠案例來說明這套演算法之應用，最後再以eM-Plant模擬語言開發一套雛形系統來說明本文所提出的面板組立廠客制化DBR排程系統的可行性。

Thin film transistor liquid crystal display (TFT-LCD) manufacturing process consists of three basic process stages: Array process, Cell process and Module process. Under stringent competition due to increasing global capacity, the TFT-LCD plants in Taiwan initiate different programs to enhance their market responsiveness by reducing the cycle time (CT). In this thesis, a customized Drum-Buffer-Rope (DBR) Systems for Cell plants is proposed to enhance their market responsiveness. The DBR method is the production application of Theory of Constraints, a global managerial methodology that helps the manager to concentrate on the most critical issues. The DBR methodology is now being implemented by a growing number of manufacturing organizations. Although the DBR system have been successfully implemented in some manufacturing plants, the detailed design rule or applications must be customized based on the special characteristics and requirement of different manufacturing environments. A customized DBR method for TFT-LCD Cell process is thus proposed in this thesis based on its specific domains to improve its CT. A detailed exploration of the required customization of drum design algorithm in this method is first presented. A Cell plant case is then utilized to explain this algorithm. A prototype is finally provided by using the eM-Plant simulation model to demonstrate the significance and feasibility of this proposed customized DBR scheduling system for TFT-LCD Cell process.

摘 要 i
Abstract ii
誌 謝 iii
目 錄 iv
圖目錄 vi
表目錄 viii
第一章 緒論 1
1.1研究背景與動機 1
1.2研究目的 2
1.3研究範圍與限制 3
1.4研究步驟 4
第二章 文獻探討 6
2.1面板製程簡介 6
2.2組立製程敘述 6
2.3組立製程特性 13
2.4組立廠生產型態 14
2.4.1生產計劃 15
2.4.2機台配置 17
2.4.3投料模式 18
2.4.4機台派工模式 19
2.4.5績效評估指標 19
2.5面板組立廠相關文獻 20
2.6限制驅導式排程方法DBR(Drum-Buffer-Rope) 21
2.7平行機台排程相關文獻 21
2.8緩衝時間(Buffer Time)的決定 26
第三章 模式構建 28
3.1問題定義與分析 28
3.2研究架構 28
3.3決定瓶頸與緩衝值的設定 29
3.4分批(batch)與Drum的設計 32
3.5投料計劃 38
3.6範例說明 38
第四章 排程系統實作 55
4.1排程系統環境說明 55
4.2系統限制與假設 55
4.3排程系統 57
4.3.1輸入資訊 58
4.3.2輸出資訊 59
第五章 結論與未來研究方向 65
5.1結論 65
5.2未來研究方向 65
參考文獻 67

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