TFT-LCD陣列製程設施規劃問題研究-以C公司為例

The Layout Planning Problem of Array Process at TFT-LCD Plant-The Case of C Company

黃國宏(Kuo-hon Huang,)

指導教授 ： 胡黃德

元智大學/工程學院/工業工程與管理學系/碩士(2009年)

摘要

TFT-LCD面板產業由於特有的景氣循環特性加上近期之全球金融海嘯衝擊，企業獲利能力大幅下降。因此，以往不斷朝新世代的建廠競賽已告一段落，取而代之的是各家業者審度自身現有廠房的優缺點發展出具利基之產品及銷售策略。以C公司第3代線廠房為例，期望進入中小尺寸市場來降低僅靠筆記型電腦、監視器及電視面板所帶來的風險。藉由在瓶頸製程增購新設備達到產能提升、降低產品單位成本以增加產品競爭力。因此，本研究之目的乃是思考如何在現有廠房空間限制下，以最少的費用支出為新增加之設備作妥適的佈置規劃並同步檢討現有生產設備設施規劃是否尚有優化之及調整之必要。在部份現有設施因變動佈置位置將造成鉅額費用列入固定設施 (不予調整) 的情況下，檢討現有設備佈置規劃待改善之處。本研究利用成對交換法發展出四個可行方案，最後以總搬運距離作為方案選擇的依據。經由實際驗證結果，將洗淨製程區及檢查製程區互換並同步執行產能提升計畫，可有效降低單位製造成本 (NTD 82.14/piece)，成本降幅百分比約10.79 %，可以有效增加產品的競爭力。在假設即產即銷之情況下，約2.4年即可回收。改善前總搬運距離約為1,865公尺，改善後為1,662公尺，約可節省約203公尺，總搬運距離節省幅度百分比可達到10.89 %。

關鍵字

TFT-LCD陣列製程 ； 程序式佈置 ； 成對交換法

並列摘要

Because of the unique life cycle of TFT-LCD industry and the impact of global financial crisis, the enterprise’s profitability decreases dramatically. Therefore, the competition of continuing building new generation plant is over. Instead, each company examines the advantages and disadvantages of exciting plants to develop its niche products and marketing strategies. Take C Company’s Generation 3 (G3) plant as an example, which hopes that it can decreases the risk of NB, monitor, and TV panels merely by entering the Medium and Small size market. By purchasing new equipments of bottle-neck processes to raise capacity, decreasing product unit cost, and enhancing product competitiveness, the company also thinks about how to make proper facility layout and review the necessity of adjusting the exciting facilities with limited spaces and minimum expenses. Because of the re-layout would result in huge fixed facility expenses (without adjusted), the company would also review the current facility layouts that need to be improved at the same time. In this study, we developed four feasible alternatives by using pairwise interchange method by measuring the total traveling distances. Through the analysis, we could exchange the location of clean process and inspection process and increased its capacity at the same time. It reduced efficiently the unit manufacturing cost of NTD 82.14 per piece, about 10.79%, and it also increased product competitiveness. At the situation of production-then-sale, the facility’s pay-back period could be reduced to 2.4 years. The total moving distance was reduced from 1,865 down to 1,662 meters (i.e., 10.89%).

並列關鍵字

TFT-LCD Array Process ； Process Layout ； Pairwise Interchange Method

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