臺灣博碩士論文加值系統

隨著高科技產業的蓬勃發展，顧客對於品質的要求日益增加，在製品之檢驗已成為確保品質必備的基本程序之一。另外，在昂貴的生產系統中，企業所能提供之檢測資源有限；因此要如何將適當之檢驗資源指派到適當之地點進行檢測，藉以提昇產品品質，降低生產不良率，並為企業帶來最大的效益，實為一值得深入探討的課題。

本研究以彩色濾光片生產系統為對象建立數學模式，因其獨特的多品質製程特性，除了需考慮檢驗站的設置外，還要決定哪些品質特性需要檢驗，以期求得在最大利潤下的最佳檢驗設置方案。在生產系統中相關之成本可分為製造成本、品質檢驗成本、內部失敗成本及外部失敗成本等四類。在彩色濾光片生產系統中對瑕疵品的處理模式，可分為修理後重工以及報廢，重工產品將至當下製程重工。

本研究除利用窮舉法求出最佳解外，另以基因演算法求解，其不但求解品質不錯，求解時間也較短。本研究亦針對檢驗政策進行敏感性分析，分別對合格品比例、每單位營收、每單位外部損失、設備折舊攤提期限及檢驗設備成本等五類進行分析，探討在不同條件下其檢驗設置政策。相信本研究成果可以提供給彩色濾光片工廠實際運作時解決檢驗設置問題的參考，以提昇產業之競爭力。

With the prosperous development in the high technology industry, the quality requirement from customers increases day by day. Meanwhile, in order to ensure product quality, the inspection of work-in-process products has become one of basic procedures. In addition, enterprises can only provide limited inspection resources in their very expensive production systems. Therefore, how to assign the limited inspection resources to the right locations is an essential issue in order to promote product quality, reduce production defect rate, and increase enterprise profit.

This thesis takes color filter production systems as the study subject to develop a mathematical model. Due to its unique multi-quality-characteristics, we need to consider not only to set up inspection stations but also to determine which characteristics to be inspected in order to obtain the inspection policy with the optimal profit. The cost considered in this model consists of process cost, inspection cost, internal failure cost and external failure cost. The defect treatment for the color filter production system has two kinds: rework after repair and scrap. The product needed to rework will return to the current workstation.

This study uses not only the complete enumeration method but also the genetic algorithm method to find the optimal solution; the latter has very similar results as the former, but uses less computation time. A sensitivity analysis of inspection policy is performed with respect to each factor of the proportion of qualified products, revenue per unit, external loss per unit, equipment depreciation and inspection equipment cost to explore the inspection policy under various conditions. We believe that the results of this study can serve as a production planning tool to solve the inspection allocation problem in color filter production systems and increase their productivity.

中文摘要
英文摘要
誌謝
目錄
圖目錄
表目錄

第一章 緒論
1.1 研究背景與動機
1.2 研究目的
1.3 研究流程
1.4 論文大綱

第二章 文獻探討
2.1 產業介紹
2.1.1 彩色濾光片產業概述
2.1.2 彩色濾光片製程簡介
2.2 文獻探討
2.2.1 品質成本
2.2.2 檢驗站設置問題
2.3 文獻探討結論

第三章 彩色濾光片生產系統多品質特性檢驗站設置問題
3.1 研究假設
3.2 符號說明
3.3 數學模式建立
3.3.1 生產系統模式建立
3.3.2 檢驗模式建立
3.3.3 檢驗模式範例
3.3.4 成本模式建立

第四章 彩色濾光片生產系統檢驗站設置最佳化求解
4.1 生產系統參數
4.2 不合格品處理參數
4.3 工作站參數
4.4 檢驗站參數
4.5 工作站和檢驗站相關生產成本
4.6 總成本及總利潤
4.7 最佳解
4.8 差異化說明
4.9 敏感性分析
4.9.1 合格品比例對檢驗站設置政策之影響
4.9.2 每單位營收與外部損失相對調整下對檢驗站設置政策之影響
4.9.3 每單位營收在外部損失固定下對檢驗站設置政策之影響
4.9.4 每單位外部損失對檢驗站設置政策之影響
4.9.5 設備折舊攤提期限對檢驗站設置政策之影響
4.9.6 各抽樣模式下檢驗設備成本對檢驗站設置政策之影響
4.10基因演算法

第五章 結論與未來發展
5.1 結論
5.2 未來發展

參考文獻

圖2.1 TFT-LCD 結構示意圖
圖2.2 TFT-LCD產品基本構成元件
圖2.3 TFT-LCD顯示原理
圖2.4 TFT-LCD顯示動作
圖2.5 TFT-LCD 驅動原理
圖2.6 彩色濾光片材料成本狀況
圖2.7 彩色濾光片構造簡圖
圖2.8 CF Process-Cr Process
圖2.9 CF Process-BM Process
圖2.10 CF Process-G/R/B Process
圖2.11 CF Process -ITO Process
圖2.12 彩色濾光片彩色層示意圖
圖3.1 彩色濾光片多品質特性序列式生產系統
圖3.2 生產系統模式
圖3.3 在wsi工作站後設置insi檢驗站的狀況
圖3.4 累計當站檢驗的品質特性合格品通過比例狀況
圖3.5 累計前站相同品質特性未進行檢驗的合格品比例狀況
圖4.1 各檢驗站不需檢驗之合格品比例差異趨勢圖
圖4.2 各品質特性不需檢驗之合格品比例差異趨勢圖
圖4.3 每單位營收在外部損失相對調整下對檢驗站設置政策之影響趨勢圖
圖4.4 每單位營收在外部損失固定下對檢驗站設置之影響趨勢圖
圖4.5 每單位外部損失對檢驗站設置政策之影響趨勢圖
圖4.6 設備折舊攤提期限對最佳檢驗站設置之影響分析圖
圖4.7 GA三世代執行演算之檢驗政策累計統計趨勢圖

表3.1 彩色濾光片生產系統品質特性檢驗站說明
表4.1 CF生產系統參數設定
表4.2 CF生產系統中各站之品質特性檢驗設定狀況
表4.3 CF生產系統中各站之品質特性合格品比例
表4.4 CF生產系統中工作站不合格品重工或報廢處理設定
表4.5 CF生產系統中可進行修理再重工站點之修理材料成本
表4.6 CF生產系統中各工作站之參數設定
表4.7 CF生產系統中各站之品質特性檢驗設備成本設定
表4.8 各檢驗站合格品比例下的各工作站相關參數運算結果
表4.9 各檢驗站相關參數運算結果
表4.10 實例檢驗政策下的總利潤結果
表4.11 在實例參數設定下的最佳檢驗政策
表4.12 在實例參數設定下的最佳檢驗政策前30名
表4.13 各品質特性與實例檢驗站對照表
表4.14 最佳解和案例解的差異化比較
表4.15 合格品比例對檢驗站設置政策之影響
表4.16 合格品比例對檢驗站設置政策之影響(續)
表4.17 合格品比例調整對檢驗站設置成本之影響
表4.18 各檢驗站不需檢驗之合格品比例差異
表4.19 各品質特性不需檢驗之合格品比例差異
表4.20 每單位營收在外部損失相對調整下對檢驗站設置政策之影響
表4.21 每單位營收在外部損失固定下對檢驗站設置政策之影響
表4.22 每單位外部損失對檢驗站設置政策之影響
表4.23 設備折舊攤提期限對檢驗站設置政策之影響
表4.24 各折舊攤提期限的最佳檢驗政策前10名
表4.25 各折舊攤提期限的最佳檢驗政策前10名(續)
表4.26 各折舊攤提期限的最佳檢驗政策前10名(續)
表4.27 各抽樣模式下的檢驗站之平均檢驗數和平均每日需求產能
表4.28 各抽樣模式下的檢驗設備之成本及產能狀況
表4.29 各抽樣模式下設備成本變更對檢驗站設置政策之影響
表4.30 單項品質特性設備成本變更時對檢驗站設置政策之影響
表4.31 單一檢驗站檢驗機台成本變更對檢驗站設置政策之影響
表4.32 GA三世代執行演算之檢驗政策結果及執行時間
表4.33 GA三世代執行演算之檢驗政策累計統計表
表4.34 窮舉法與GA的執行時間比較

Barad, M., “A Break-Even Quality Level Approach to Location of Inspection Station in a Multi-Stage Production Process,” International Journal of Production Research, Vol. 28, No. 1, 1990, pp. 29-45.

Ballou, D. P. and Pazer, H. L., “The Impact of Inspector Fallibility on the Inspection Policy in Serial Production Systems” Management Science, Vol. 28, No. 4, 1982, pp. 387-399.

Chevalier, P. B., and Wein L. M., “Inspection for Circuit Board Assembly,” Management Science, Vol. 43, No. 9, 1997, pp. 1198-1213.

Eppen, G. D., and Hurst, E. G., “Optimal Location of Inspection Stations in a Multistage Production Process,” Management Science, Vol. 20, No. 8, 1974, pp. 1194-1200.

Feigenbaum, A.V., “Total Quality Control,” McGraw-Hill Companies, Inc., 1991.

Evans, J. R., and Lindsay, W. M., “The Management and Control of Quality–Fourth Edition,” South-Western College Publishing, 1999.

Hurst, E.G. Jr., “Imperfect Inspection in a Multistage production Process,” Management Science, Vol. 20, No. 3, 1973.

Juran, J.M., “Juran’s Quality Handbook,” McGraw-Hill, New York, 1998.


Kang, K.S., Ebeling, K.A., and La, S.H., “The Optimal Location of Inspection Stations Using a Rule-Based Methodology,” Computers and Industrial Engineering, Vol. 19, 1990, pp.272-275.

Kaspi, M. and Raz, T., “Optimal Sequencing of Production and Inspection Operations,” International Journal of Production Research, Vol. 32, No. 1, 1994, pp. 209-221.

Lee, J. and Unnikrishnan, S., “Planning Quality Inspection Operations in Multistage Manufacturing Systems with Inspection Errors,” International Journal of Production Research, Vol. 36, No. 1, 1998, pp. 141-155.


Lindsay, G.F. and Bishop, A.B., “Allocation of Screening Inspection Effort Dynamic-Programming Approach,” Management Science, Vol. 10, No. 2, 1964, pp. 343-352.

Mandroll, S.S., Shrivastava A.K., and Ding, Y., “A survey of inspection strategy and sensor distribution studies in discrete-part manufacturing processes,” IIE Transactions, Vol. 38, 2006, pp.309-328.

Montgomery, D.C., “Introduction to Statistical Quality Control”, 4th Edition. John Wiley and Sons, New York, 2001.

Peters, M.H. and Williams, W.W., “Location of Quality Inspection Stations: An Experimental Assessment of Five Normative Heuristics,” Decision Sciences, Vol. 15, No. 3, 1984, pp. 389-408.

Rau, H., and Chu, Y.H., “Inspection Allocation Planning with Two Types of Workstations: WVD and WAD, ” International Journal of Advanced Manufacturing Technology, Vol. 25, 2005, pp. 947-953.

Raz, T. and Kaspi, M., “Location and Sequencing of Imperfect Inspection Operations in Serial Multi-Stage Production Systems,” International journal of Production Research, Vol. 29, No. 8, 1991, pp. 1645-1659.

Raz, T., “A survey of Model for Allocation Inspection Effort in Multistage Production Systems,” Journal of Quality Technology, Vol. 18, No. 4, 1986, pp. 239-247.

Shiau, Y.R., “Inspection Resource Assignment in a Multistage Manufacturing System with an Inspection Error Model” International Journal of Production Research, Vol. 40, No. 8, 2002, pp. 1787-1806.

Tang, K. and Tang, J., “Design of Screening Procedures: A Review”, Journal of Quality Technology, Vol.26, No.3 , 1994, pp.209-226.

Trippi, R. R., “An On-Line Computational Model for Inspection Resource Allocation,” Journal of Quality Technology, Vol. 6, No. 4, 1974, pp. 167-174.

White, L. S., “The Analysis of a Simple Class of Multistage Inspection Plans,” Management Science, Vol. 12, No. 9, 1966, pp. 685-693.

White, L. S., “Shortest Route Models for the Allocation of Inspection Effort on a Production Line,” Management Science, Vol. 15, No. 5, 1969, pp. 249-259.
Yum, B. J. and McDowell, E. D., “Optimal Inspection Policies in a Serial
Production System Including Scrap Rework and Repair: An MILP Approach,” International Journal of Production Research, Vol. 25, No. 10, 1987,pp.1451-1464.

林成益，1998，「品質管制」，楊智出版社，台北市

陳耀茂，1995，「品質保證」，五南圖書出版社，台北市

杜志峰，2004，「彩色濾光片產業概況」，台灣凸版國際彩光(股)公司

瀚宇彩晶，2005，「Introduction of Color Filter Process」

瀚宇彩晶，2002，「LCD原理簡介」

友達光電網頁，http://auo.com/auoDEV/index.php

拓璞產業研究所，LCD產業市場研究，http://www.topology.com.tw/tri/

經濟部工業局，http://www.moeaidb.gov.tw/

ITIS產業資訊網，http://www.itis.org.tw/