偏光板(Polarizing Film)產業已進入一個全新時代,昔日少數大廠寡占的局面已悄悄被打破,將面對眾多新興產業競爭者的崛起,以及TFT-LCD面板廠自行投入偏光板生產的嚴峻挑戰,偏光板產業已步入戰國時代。若不能短時間大幅度提昇產品品質以及降低產品的變異性,則有機會在短時間之內被市場所淘汰。 本文依據案例公司被客戶訴怨最多的偏光板翹曲作為改善重點,期盼以六標準差(Six Sigma)管理手法的流程步驟(DMAIC),針對偏光板製程翹曲品質改善,首先找出關鍵品質特性,求得量測數據之可靠性,並對量測儀器進行量具重現性與再現性之能力分析,在確認製程能力後,歸納找出影響製程的關鍵因子,再利用實驗設計(Design of Experiments, DOE)來進行實驗,找出最適參數組合。 最後,實際驗證的結果得到翹曲改善達 54.6%,而製程能力指標Cpk由0.94提升至1.36,不良ppm已由改善前11053.02ppm大幅下降至1267.37ppm,且相關製程檢驗中均無產生其它品質副作用,改善效益預估分析年節省約台幣1127.8萬元生產的內部失敗成本,證明此次個案研究能夠有效改善偏光板連續機製程翹曲品質。
Polarizer industry has entered a new era and the situation that a small number of large companies monopolized the market in the past have quietly been broken. It will face many competitors of new Emerging industries, as well as the challenges from TFT LCD panel plant in self-production of polarizer. However, polarizer industry has already entered the Warring States era. If it can't be improved significantly to enhance the quality and reduce the variability, it will have the opportunity to be out of the market in a short time. This article was based on the cases to take curl of polarizer that customers complained most as a key point. We look forward to finding the key quality characteristic first by DMAIC of Six Sigma management technique to get the reliability of measuring data and the analysis of reappearance ability to the measuring equipment for the quality improvment of curl in polarizer process.After confirming the ability of process, we can find the key factor that affects the process and use the DOE to experiment and find the best parameter combination. At last, the result of real test is that the height of curl reduces averagely to 54.6% and Cpk increases from 0.94 to 1.36. The NG ppm drops off apparently before improvement from 11053.02ppm to 1267.37ppm and it doesn’t' result any other side effect of quality under relative process inspection. The benefit of improvement is estimated to save the inner failure cost of production about NT 1127.8 thousand dollars. It proves that this research case can improve effectively the curl quality of polarizer in LSG process.