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研究生:趙國榮
研究生(外文):Kuo-Jung Chao
論文名稱:TFT-LCD彩色濾光片廠有限產能規劃與投料策略之研究
論文名稱(外文):Finite Capacity Planning and Order Release Policy for TFT-LCD Color Filter Fab
指導教授:陳建良陳建良引用關係
指導教授(外文):James C. Chen
學位類別:碩士
校院名稱:中原大學
系所名稱:工業與系統工程研究所
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:2009
畢業學年度:97
語文別:英文
論文頁數:44
中文關鍵詞:實驗設計TFT-LCD彩色濾光片廠有限產能規劃系統模擬
外文關鍵詞:Experimental designTFT-LCDSimulationColor filter fabFinite capacity planning
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薄膜電晶體液晶顯示器 (Thin Film Transistor - Liquid Crystal Display, TFT-LCD) 產業為台灣推動國家科技發展政策「兩兆雙星」之重要產業,而彩色濾光片 (Color Filter, CF)為TFT-LCD的關鍵零組件之一,並佔其總成本相當大的比例。產能規劃對於彩色濾光片廠之生產績效有相當大的重要性。本研究針對彩色濾光片廠發展一套多廠之有限產能規劃系統 (Finite Capacity Planning System, FCPS)。FCPS藉由計算顧客訂單的各項資訊並規劃廠內有限的產能來分配訂單至各廠。FCPS包含訂單優先序模組 (Order Priority Module, OPM)、訂單投料模組 (Lot Release Module, LRM)、訂單選廠模組 (Fab Selection Module, FSM)、工作負荷堆疊模組 (Workload Accumulation Module, WAM)及在製品管制模組 (WIP-Controlling Module, WCM),由上述五個模組將決定訂單之開始時間及完成時間。
本研究利用Microsoft Visual Basic for Application (VBA)及AutoMod模擬軟體建置本研究之有限產能規劃策略。相關之彩色濾光片生產數據收集自實際工廠,並利用實驗設計探討FCPS之績效。模擬結果顯示本研究發展之FCPS可有效提高達交率及產出量,並提供管理者作為決策參考之依據,另外,本研究建構之模擬模型也可提供其他生產相關問題進行模擬分析。
Thin Film Transistor Liquid Crystal Display (TFT-LCD) industry is growing fast due to market demands and global competition. Color Filter (CF) is one of the key components of TFT-LCD, and capacity planning is crucial to the performance and competitiveness of CF fabs. This research develops a Finite Capacity Planning System (FCPS) for multiple CF fabs. FCPS assigns customer orders to multiple fabs by taking into account each fab’s available capacity, as well as each order’s batch size, product type, process routing, and processing time. Order’s assignment to fab, order release time and finished time are determined by the implementation of five FCPS modules: Order Priority, Lot Release, Fab Selection, Workload Accumulation, and WIP-Control.
FCPS was developed in Microsoft Visual Basic for Application, and an AutoMod simulation model was also developed. Industrial data from real CF fabs are collected and used to evaluate the performance of the proposed FCPS based on the design of experiments. Preliminary simulation results show that FCPS can effectively and efficiently improve the throughput and increase on-time delivery.
Contents
Abstract (in Chinese)
Abstract (in English)
Acknowledgement
Contents
List of Figures
List of Tables
1. Introduction
2. Literature Review
3. Finite Capacity Planning System
3.1 Order Priority Module (OPM)
3.2 Lot Release Module (LRM)
3.3 Fab Selection Module (FSM)
3.4 Workload Accumulation Module (WAM)
3.5 WIP-Control Module (WCM)
4. Case Study and Simulation
5. Results and Discussion
6. Conclusions and Future Research
References
Appendix A: The figure of the AutoMod Simulation model
Appendix B: The figure of the VBA program

List of Figures
Figure 1. The manufacturing processes of TFT-LCD
Figure 2. A typical CF process
Figure 3. The concept of Finite Capacity Planning System (FCPS)
Figure 4. The concept of Finite Capacity Requirements Planning
Figure 5. The flow of FCPS
Figure 6. An example of EDD, LBS and CR*
Figure 7. An example of backward and forward scheduling mechanisms in LRF
Figure 8. An example of LFL assigns order to fabs
Figure 9. An example of LLL policy
Figure 10. AutoMod simulation model
Figure 11. Model for simulation via fishbone analysis
Figure 12. Stocker’s shelves in AutoMod simulation model
Figure 13. The concept of CONWIP in this research
Figure 14. Inputs and outputs of FCPS
Figure 15. Product routine
Figure 16. Fab layout in Simulation
Figure 17. Main effects plot with respect to delivery
Figure 18. Two-factor interaction plot with respect to delivery
Figure 19. Main effects plot with respect to throughput
Figure 20. Two-factor interaction plot with respect to throughput
Figure 21. Main effects plot with respect to cycle time
Figure 22. Two-factor interaction plot with respect to cycle time

List of Tables
Table 1. Notation list
Table 2. The OPM policy
Table 3. Product data
Table 4. Experimental design used to evaluate the performance of FCPS
Table 5. Duncan’s test for combination of OP and FS
Table 6. Duncan’s test for combination of FS and CL
Chen, J. C., Chen, C. C., Mo, C. N., Peng, T. W., Chao, G. C., Sun, C. J., Chao, K. J., Chien, J. W., Wei, Y. Y., Feng, C. H., Liu, Y. C. and Chiang, M. T., 2009a. Effective order release and dispatching for color filter fabs. Society for Information Display International Symposium (SID), San Antonio, Texas, USA.
Chen, J. C., Dai, R. D. and Chen, C. W., 2008. A practical fab design procedure for wafer fabrication plants. International Journal of Production Research, 46 (10), 2565-2588.
Chen, J. C., Fan, Y. C. and Chen, C. W., 2009b. Capacity requirement planning for twin fabs of wafer fabrication. International Journal of Production Research, 46 (16), 4473-4496.
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Chen, W. L., Huang, C. Y. and Lai, Y. C., 2009c. Multi-tier and multi-site collaborative production: Illustrated by a case example of TF-LCD manufacturing. International Journal of Computers & Industrial Engineering, 57 (1), 61-72.
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Matsuura, H., Tsubone, H. and Kataoka, K., 1995. Comparison between simple infinite loading and loading considering a workload status under uncertainty in job operation times. International Journal of Production Economics, 40 (1), 45-55.
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Pillai, D. D., Bass, E. L., Dempsey, J. C., and Yelling, E. J., 2004. 300-mm full factory simulation for 90- and 65-nm IC manufacturing. IEEE Transactions on Semiconductor Manufacturing, 17 (3), 292-298.
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Spearman, M. L., Woodruff, D. L. and Hopp, W. J., 1990. CONWIP: a pull alternative to kanban. International Journal of Production Research, 28 (5), 879-894.
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