TFT-LCD產業設計鏈作業參考模式

Design Chain Operations Reference Model of TFT-LCD Industry

陳鑑文(Chien-Wen Chen)

指導教授 ： 陸元平

國立臺北科技大學/機電學院/機電整合研究所/碩士(2010年)

摘要

持續的進行研究發展活動是任何企業永續經營的命脈，而縮短產品上市的時間與成本的降低更是企業生存的不二法則，新產品不斷的進步改善與推陳出新以及產品生命週期循環的加快是現今產業普遍的現象，因此產業設計鏈變為現在企業活動中重要的環節。單靠追求製造效率的提升，並不足以滿足企業永續經營的目標，必須在產品研發流程上做最好的管理，以達到縮短產品上市的時間與成本的降低。尤其是政府力捧的兩兆雙星產業中的面板產業，其設計鏈的流程建置與有效管理是提升國內TFT-LCD產業未來的競爭力的重要工作。本研究在探討「設計鏈作業參考模式」(DCOR) 在TFT-LCD產業導入之研究，此模版提供TFT-LCD產業設計鏈的基本定義與績效衡量指標，預期可協助TFT-LCD產業進行設計鏈流程整合與促進研發團隊成員溝通，並對新產品設計的縮短研發時程、降低研發成本做出貢獻。
為了印證D-DCOR之有效性，本研究將選定一個案公司，以所提之D-DCOR與其傳統設計流程同步執行驗證比較。從最後的結果來看D-DCOR的最明顯的效益就是縮短了較C公司原來的設計流程的schedule將近一個月。歸納個案公司以D-DCOR執行新產品開發會提昇整體績效的主要原因如下：
1.D-DCOR定義嚴謹、流程清楚，個案驗證中在設計開發過程中都遵循著正確的步驟而較少出現設計或生產製造過程的失誤，因而都會按照PM當初所規劃的schedule來走，delay的情形也較為輕微。
2.傳統流程中，製造生產單位在設計初期沒有與設計單位好好溝通製程的生產極限，讓設計人員了解到目前之生產設備或參數的極限。D-DCOR在LEVEL1中整合(Integration)這個主流程所展開的各項子流程中有充分的提到設計與生產的溝通以確認設計出來的產品的生產性是否符合目前設備與技術能力所及。
3.D-DCOR在輸入及輸出文件部分需要上傳至系統才能進行下一階段活動，避免重要新產品設計相關資訊傳遞之遺漏，而傳統設計流程雖也有類似工作項，但卻無強制性。
4.D-DCOR之新產品設計開發總成本因為試做次數較少，且無二次開發新光罩，因而成本較低。
5.D-DCOR之新產品設計開發資產利用率也因為試做次數較少因而利用率較高。
雖然個案公司的現有的設計開發流程能夠持續的開發出新產品，但是其效率卻是不及本研究提出的D-DCOR model，在目前面板產業處境艱困的情況下，若能適時有效的導入D-DCOR model或許能夠降低設計、生產等成本，進而提高利潤並增進股東權益，增強個案公司在面板產業的競爭力。

關鍵字

設計鏈 ； 新產品設計開發 ； 協同設計 ； 設計鏈作業參考模式

並列摘要

The ongoing conduct of research and development activities is the lifeblood of sustainable development for every business, and shortening product launch time and reducing cost are the only rules for business survival. In today’s industry, the continuous improvement and introduction of new products and the acceleration of product life cycle are common phenomena, therefore the design chain now becomes an important part in business activities. The pursuit of increasing manufacturing efficiency alone is not sufficient for the goal of business sustainability, hence the best management must be executed during the product development process in order to shorten the time of product launch and reduce costs. In the panel industry which is particularly promoted and fully supported by government in the" Two Trillion & Twin Star" plan, the process building and effective management of its design chains are the major tasks to enhance the future competitiveness in the TFT-LCD industry. This study attempts to explore the introduction of "Design Chain Operations Reference" (DCOR) model to the TFT-LCD industry. The template resulted from the study provides the basic definition and the indicators of performance evaluation to design chains in the TFT-LCD industry, is expected to assist in the process integration and to foster the communication among research and development team members, and contributes to the reduction in both the research and development schedule and the cost of new product design.
In order to verify the effectiveness of D-DCOR, a certain company was selected to conduct a case study, and the proposed D-DCOR was simultaneously verified and compared with the traditional design process of the studied company. The final results show that the most obvious benefit of D-DCOR is to shorten the design process schedule by nearly one month compared to the original one of the C company. In summary, the reasons why the overall performance of the studied company will be raised by using D-DCOR to implement the new product development are as follows:
1.D-DCOR has rigorous definitions and a clear process. The design development process followed the correct steps all the time, and fewer design or manufacturing errors occurred in the verification of the case study; as a result, everything would follow the product manager’s schedule, and the delay situation was relatively minor.
2.In the traditional process, because manufacturing and design units do not have proper communication regarding the production limit in process at the early stage of product design, designers have no idea about the limit of current production equipment or parameters. In LEVEL1 of D-DCOR, the communication between design and production units are completely mentioned in the sub-processes under the main process of “Integration”, and the purpose of the communication is to confirm whether the existing equipment and techniques can meet the production demand of design products.
3.In D-DCOR, the input and output of documents have to be uploaded to the system so that the next step can be proceeded, and the measure avoids missing important and relevant information of new product designs during information transfer. Although the traditional design process has a similar work items, it is not mandatory.
4.In D-DCOR, the total cost of new product design development is lower due to fewer trials and no secondary development of new masks.
5.In D-DCOR, the asset utilization ratio of new product design development is higher due to fewer trials.
Although the current design development process can sustain the new product development in the studied company, the D-DCOR model proposed in this study has more efficiency. The panel industry is in a plight today, and if the D -DCOR model can be effectively introduced in time, maybe the design and production costs can be reduced, the profits and shareholders’ interests can be increased, and the competitiveness of the studied company can be enhanced in the industry.

並列關鍵字

Design chain ； Product research and develop ； Collaborative Product Design ； DCOR(Design Chain Operation Reference Model )

參考文獻

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