臺灣博碩士論文加值系統

TFT-LCD產業具有三大製程―列陣、組立以及模組製程，各自位於不同的廠區。以往規劃方式採用各自獨立規劃，造成許多缺失。為了解決此缺失，本研究首先彙整TFT-LCD產業的生產製程、生產規劃上的限制、產業特性以期能了解該產業。而後，分析現有的生產模式、規劃流程以及規劃流程的演算法，並將現行缺失區分為三個層次，分別為生產模式、流程以及規劃方式的問題。有鑑於此，本研究提出以接單後組裝（Assemble-to-Order，ATO）為生產模式的規劃流程，以解決現行缺失。然而，其衍生在ATO生產模式下，如何將現有各種資源，包含物料資源、廠區產能，分配供給於各種需求，並同時排定需求在各廠區的投入產出排程的多廠區規劃排程問題。
在此問題下，本研究提出可同時規劃多廠區，同步考量將物料分配與各廠區主排程規劃的演算法―以限制為基礎的模擬（Constraint-Based Simulation，CBS），以期能解決此生產規劃問題。以限制為基礎的模擬是將限制與時間推進機構加以整合，利用限制的不可違背性，透過時間推進機構的計算，將不合理的時窗加以去除。最後，在剩餘的時窗內，根據目標，透過派工法則，搜尋較佳的解。
經由案例的驗證，確認CBS演算法的可行性。並將此案例及演算法建構於模擬軟體，比較不同的規劃方法，是否在不同環境下會有不同的績效值。從分析結果可以得知，CBS規劃演算法均具有一定的效益。

第一章 緒論 1
1.1研究背景與動機 1
1.2研究目的 3
1.3研究範圍 3
1.4研究步驟與方法 4
第二章 TFT-LCD產業描述 6
2.1 TFT-LCD生產製程 6
2.2 TFT-LCD生產限制與特色 9
2.3 TFT-LCD現有(As-Is)生產規劃分析 14
2.3.1 TFT-LCD現有(As-Is)生產規劃模式 14
2.3.2 TFT-LCD現有(As-Is)生產規劃流程 15
2.3.3 TFT-LCD現有(As-Is)生產規劃方式 16
2.3.4 TFT-LCD現有(As-Is)生產規劃下的缺失 18
2.4 TFT-LCD未來(To-Be)生產規劃分析 18
2.4.1生產模式的轉變以及未來(To-Be)生產模式 19
2.4.2 TFT-LCD未來(To-Be)生產規劃流程 22
2.5 問題定義與假設 23
2.5.1問題定義 23
2.5.3假設條件 25
2.5.4績效指標 26
第三章 文獻回顧 27
3.1 供應鏈定義與分類 27
3.2 多廠區生產規劃系統 32
3.2.1 多廠區生產規劃架構 32
3.2.2以Bucket為基礎的多廠區規劃 37
3.2.3.以Buckless為基礎的多廠區規劃 42
3.3 TFT-LCD產業相關規劃與排程研究 47
3.4 現有供應鏈軟體規劃方式 48
3.4.1 i2 48
3.4.2 Adexa 49
第四章 以產能為主之CBS方法論 52
4.1 Bucket Based與Bucketless Based方法的差異 52
4.2 CBS 56
4.2.1限制與限制分類 56
4.2.2 CBS之概念 58
4.2.3 CBS與Simulation Based Scheduling的比較 62
4.3方法論分析 64
4.3.1分析架構 64
4.3.2符號說明與定義 67
4.3.3績效評估指標 69
4.3.4單機排程 70
4.3.5多廠排程 80
4.4方法論演算法描述 87
第五章 案例探討 95
5.1案例描述 95
5.1.1背景說明 95
5.1.2多廠區生產規劃的目的與意義 96
5.1.3多廠區生產規劃與其他模組之關聯性 97
5.2生產規劃流程 99
5.3生產規劃範例 104
第六章 模式構建與實驗分析 118
6.1模擬模式構建 118
6.1.1系統模式已知條件 118
6.1.2模擬模式細緻度 119
6.1.3模擬模式建構步驟 119
6.1.4模擬模式構建 120
6.1.5模擬確認與驗證 122
6.1.6 Web端介面建置 123
6.2實驗分析 124
6.2.1目的 124
6.2.2實驗架構 125
6.2.3實驗結果與分析─需求數量 127
6.2.4實驗結果與分析─需求變異 129
6.2.5實驗結果與分析─物料變異 131
6.2.6小結 134
第七章 結論與建議 135
7.1結論 135
7.2建議 136
參考文獻 137

1.林則孟，系統模擬理論與應用，滄海書局，2001
2.王世欽，”多廠區生產系統之訂單分配模式─以液晶顯示器產業為例”，東海大學工業工程與經營資訊研究所論文，2002
3.陳子立， ”以模擬為基礎之先進規劃與排程法―以TFT-LCD模組廠為例”， 清華大學工業工程研究所碩士論文，2003
4.盧雲春，” IC設計公司之生產規劃系統”，國立清華大學工業工程與工程管理學系論文，1999
5.謝仲為，”先進規劃與排程系統應用於TFT-LCD產業之研究”，東海大學工業工程與經營資訊研究所論文，2002
6.Adexa, Training Menu
7.AMR, “Advanced planning and scheduling systems：Just a for or a breakthrough in manufacturing and supply chain management”, 1996
8.Barker, J. R., “SBM — Schedule Based Manufacturing：The Advantages of an Integrated Solution of Materials and Resources for Manufacturers”, Working Paper 1993-3-.008B, School of Information Technology, Bond Unversity, Gold Coast, Australis, 1993.
9.Barker, J. R., “MRPII, Real-Time Scheduling and SBM”, Assembly Automation, 14(2), pp.22-28, 1994.
10.Beamon, B. M., ”Supply chain design and analysis: Models and methods”, International Journal of Production Research, 55, pp.281-294, 1998
11.Bhatnagar, R., Chandra, P., and Goyal, S. K., “Models for Multi-Plant Coordination”, European Journal of Operational Research, 67, pp.141-160, 1993
12.Bruns, R. and Sauer, J., ”Knowledge-Based Multi-Site Coordination and Scheduling”, Flexible Automation and Intelligent Manufacturing, pp.115-123, 1995
13.Carrie, A., Simulation of Manufacturing Systems, Wiley Press, 1986.
14.Christian, H. T. and Kallrath J., ”Optimal Planning in Large Multi-Site Production Networks”, European Journal of Operational Research, 126, pp.422-435, 2000
15.Cox, J. F. and Blackstone, J. H., APICS Dictionary Ninth Edition,1998
16.Gupta, A. K. and Sivakumar, A. I., “Simulation based multiobjective scheduling optimization in semiconductor manufacturing”, Proceedings of the 2002 Winter Simulation Conference, 2002.
17.Harland, C., ”Supply chain operational performance roles”, Integrated Manufacturing System, 8(2), pp.70-78, 1997
18.i2, Rhythm Supply Chain Planner Concept Manual , 1997
19.i2, Training Menu , 2000
20.Jeong, B., Kim, S.-W. and Lee, Y. -J., ”An assembly scheduler for TFT LCD manufacturing”, Computers & Industrial Engineering, 41, pp.37-88, 2001
21.Jeong, B., Sim, S.-B., Jeong, H. -S. and Kim S.-W., ”An available-to-promise system for TFT LCD manufacturing in supply chain”, Computers & Industrial Engineering, 43, pp.191-212, 2002
22.Kehoe, D. and Boughton, N., ”Internet based supply chain management ─ A classification of approaches to manufacturing planning and control”, International Journal of Operations & Production Management, 21(4), pp.516-524, 2001
23.Kelleher, G.., “Scheduling and Rescheduling”, The institution of Electrical Engineers, 1997
24.Koh, K. H., Souza, R. D. and Ho, N. C., “Database driven simulation/simulation-based scheduling of a job-shop”, Simulation Practice and Theory, pp.31-45, 1996.
25.Leachman, R. C., ”Preliminary Design and Development of a Corporate-Level Production Planning System for the Semiconductor Industry”, Operations Research Center University of California, Berkeley,1987
26.Leachman, R. C., ”Modeling Techniques for Automated Production Planning in the Semiconductor Industry”, Engineering Systems Research Center, University of California at Berkeley, Berkeley California,1992
27.Leachman et al., ”IMPReSS：An Automated Production-Planning and Delivery-Quotation System at Harris Corporation ─ Semiconductor Sector”, Institute for Operation Research and the Management Sciences,1996
28.Lee, Y. H. and Kim, S. H., “Production-distribution planning in supply chain considering capacity constraints”, Computers & Industrial Engineering, Vol 43, pp. 169-190, 2002
29.Metaxiotis, K., Psarras, J. and Askounis, D., “Building ontologies for production scheduling systems：towards a unified methodology”, Information Management and Computer Security, pp.44-50, 2001.
30.Murty, S. V. and Bienvenu, J. W., ”Global Planning at Harris Semiconductor”, International Symposium on Semiconductor Manufacturing, 1995 International Symposium on Semiconductor Manufacturing, IEEE, 1995
31.Pagh, J. D. and Cooper, M. C., “Supply chain postponement and speculation strategies ：how to choose the right strategy”, Journal of Business Logistics, Vol. 19, No 2, pp.13-33, 1998
32.Pape, C., “Classification of scheduling problems and selection of corresponding constraint-based techniques”, The institution of Electrical Engineers, 1993.
33.Pape, C., “Constraint based scheduling：principles and application”, The institution of Electrical Engineers, 1996.
34.Parsons, D. J. and Phelps, R. A., “Production scheduling validity in high level supply chain models”, Proceedings of the 2001 Winter Simulation Conference, 2001
35.Roux, W., Dauzere-Peres, S., Lasserre, J. B. ,”Planning and scheduling in a multi-site environment”, Production Planning & Control, 10(1), pp.19-28, 1999
36.Sabath, R., “Volatile demand calls for quick response The integrated supply chain”, International Journal of Physical Distribution & Logistics Management, Vol. 28, No 9/10, 1998
37.Sambasivan, M. and Schmidt, C. P., “A heuristic procedure for solving multi-plant, multi-item, multi-period capacitated lot-sizing problems”, Asia-Pacific Journal of Operational Research, 19,pp. 87-105, 2002
38.Sauer, J., ”A Multi-Site Scheduling System”, AAAI''s Special Interest Group in Manufacturing Workshop on Artificial Intelligence and Manufacturing: State of the Art and State of Practice, pp.161-168, AAAI Press, Menlo Park, 1998
39.Sauer, J., Suelmann, G. and Apperlrath, H.-J., ”Multi-site scheduling with fuzzy concepts”, International Journal of Approximate Reasoning, 19, pp.145-160, 1998
40.Sauer, J. and Appelrath, H.-J., ”Integrating Transportation in a Multi-Site Scheduling Environment”, Proceedings of the 33rd Hawaii International Conference on System Sciences, 2000
41.Sauer, J. ,”Modeling and Solving Multi-Site Scheduling Problems”,2001
42.Sheikh, K., Manufaturing Resource Planning（MRP II）with introduction to ERP,SCM, and CRM, McGrawHill Press, 2001
43.Smith, S., Fox, M. and OW, P., ”Constructing and maintaining detailed production plan：investigations into development of knowledge-based factory scheduling system ”, AI Magazine, pp.45-61, 1986
44.Stadtlet, H. and Kilger, C., Supply Chain Management and Advanced Planning, Second Edition,Springer ,2002
45.Towill, D. R., Naim, M. M. and Wikner, J., ”Industrial Dynamics Simulation Models in the Design of Supply Chains”, International Journal of Physical Distribution & Logistics Management, 22(5), pp.3-13, 1992
46.Vollmann, T. E., Berry, W. L. and Whybark, D. C., Manufacturing Planning and Control Systems, Fourth Edition, McGrawHill Press, 1997
47.Wyman, F. P., “Common features of simulation based scheduling”, Proceedings of the 1991 Winter Simulation Conference, pp.341-347, 1993.