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研究生(外文):Bing-Yuan Cheng
論文名稱(外文):The use of simulation optimization to implement lean system design of TFT-LCD automated material handling systems
指導教授(外文):Taho Yang
外文關鍵詞:SimulationPull StrategyLean ProductionAMHSVSMTFT-LCD
  • 被引用被引用:6
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隨著TFT-LCD面板尺寸日趨增大,製程中所需的存放空間也就跟著增加,伴隨而來的是在製品(Work-in-process,WIP)所佔據的儲位空間以及面板本身的成本就跟著提高。本論文以共用資源(Shared Resources)的觀點,針對TFT-LCD廠Array製程之迴流特性,提出結合超級市場(Supermarket)與CONWIP(Constant Work-in-process)之精實後拉策略,藉由模擬最佳化之方法求解自動物料搬運系統(Automated Material Handling Systems,AMHS)之最佳儲位設計,用以改善製程中WIP過多而導致空間的浪費,並且以生產週期時間(Cycle Time)反應出WIP與存放空間浪費的改善。
本篇論文同時提出結合精實思考法與精實價值流指導原則的程序,用以導入此精實後拉策略。此程序從定義產品價值開始,經由現況價值流圖(Current-state Map)的繪製找到改善的契機,一直到利用模擬最佳化求解最佳方案,並繪製未來理想狀態價值流圖(Future-state Map)作為改善方案的依據。
此外,套用導入精實後拉策略的流程至一個實際的案例,比較現況價值流圖與未來價值流圖發現,在無額外投資且不變更任何實體設施的前提下,平均Cycle Time從原先的5.08天縮小至3.32天,改善了34.57%。而在自動化倉儲系統(Stocker)內的總儲位空間,由原先的最大利用率62.13%縮小至18.49%。而對每日產出需求進行敏感度分析時發現,改善後的系統目前每日的產能上限為4500片玻璃,這樣的資訊可提供管理者當作增加資源時的參考。
More store space is due to the increase of panal’s size in TFT-LCD manufacturing, that means increasing necessity of stocker space and cost from accumulated WIP. This paper proposes a lean pull strategy, combining supermarket with CONWIP, which is applying a viewpoint of shared resources to a re-entrant process in TFT-LCD manufacturing. By using simulation optimization to solve stockers design problem to find more efficient ways of utilizing stocker. Furthermore, using cycle time.to be an appropriate performance measure for answering the improvement of WIP and stocker utilization.
This paper also proposes to use Womack’s lean thinking and Rother’s 7 guiding principles procedure as applying the lean pull strategy. The proposed procedure is illustrated to begin defining value, to address the critical improvement point through the current value stream mapping, to solve the optimal problem by using simulation optimization, and to draw the future value stream mapping for implementing the improved alternative.
Besides, we implemented the proposed procedure to a real-world TFT-LCD Array process. After we compared current-state map and future-state map, the results indicated that the optimal solution could reduce the average cycle time from 5.08 days to 3.32 days as well as the maximum stocker utilization could be reduced from 62.13% to 18.49% without any extra investment or facilities shifting. In terms of sensitivity analysis, we had found the maximum daily throughput that would be 4500 glasses. It is important to extend capacities for reference.
摘要 i
Abstract ii
誌謝 iii
目錄 iv
圖目錄 vi
表目錄 ix
1. 緒論 1
1.1 研究背景與動機 1
1.2 研究目的 2
1.3 研究流程 3
1.4 論文架構 3
2. 文獻探討 4
2.1 精實生產系統 4
2.2 精實系統思考法 12
2.3 TFT-LCD產業簡介 22
2.4 模擬最佳化 39
3. 研究方法 44
3.1 現況分析與導入精實後拉策略 44
3.2 建立現況模擬模式與未來理想狀態模擬模式 54
3.3 尋找最佳解 58
3.4 敏感度分析 60
4. 實例說明 61
4.1 現況分析與導入精實後拉策略 61
4.2 建立模擬模式 70
4.3 尋找最佳解 92
4.4 敏感度分析 100
4.5 結果與討論 104
5. 結論與建議 105
5.1 結論 105
5.2 未來研究與建議 106
參考文獻 108
附錄A 機台相關資訊 112
附錄B 實驗參數設定 115
附錄C 模擬最佳化模型 118
附錄D 敏感度分析相關資訊 120
附錄E 價值溪流符號說明 121
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