Six Sigma 應用於貼合良率製程改善分析 ~以電漿顯示器材料濾光玻璃為個案分析

The research of Six Sigma methodology in lamination process improve~A case study for PDP’s Glass Filter

陳昆暉(Kun-Hui Chen)

指導教授 ： 陳雲岫

元智大學/工程學院/工業工程與管理學系/碩士(2006年)

https://doi.org/10.6838/YZU.2006.00259

摘要

隨著平面顯示器的技術快速發展，品質不斷精進，價格持續下滑，使得平面顯示器的競爭逐漸加劇。電漿顯示器中須利用濾光玻璃進行阻隔才能達到產品的功能性，然在貼合製程中易發生瑕疵降低良率，因此本研究以Six Sigma 管理手法的流程步驟-界定、衡量、分析、改善、控制五大改進步驟，進行貼合製程良率的改善。

首先確認膠粒及異物不良率為關鍵品質特性，衡量量測系統，而分析階段以 SIPOC進行解釋分析；再由柏拉圖找出24個可能因子，加以應用 C & E MATRIX 歸納出影響製程的12個比較可能影響製程的因子。接著改善階段中利用實驗設計中的 212-8 部分因子實驗篩選出顯著因子項目，以其反映設計進行確認實驗，找出最佳的製程條件組合，再以部分反映設計將交互作用的顯著因子確認，經cube plot分析顯示各主要因子在低水準時為最佳製程條件，並且將最佳條件標準化。

該公司個案以此方式進行研究分析和驗證結果，期望使該個案案例順利得以掌控品質，並且也能獲得良率的提昇，相對的也期待製程更為穩定。因此以Six Sigma 進行研究管理手法而讓顯著因子得以突顯，進而加以防範和最佳化，視為本個案最大的重點目標和要求。

關鍵字

六標準差；部分因子；反映設計；電漿顯示器

並列摘要

The technique in manufacturing Flat Monitors develops very fast in this decade, while the retail prices are declining gradually, thus the competition in flat monitor market is vigorous and rapid. For the plasma monitors, the target functionality of the products reveals after a filter glass is attached to the surface of the monitor. However, it can cause higher defective rate in the optical film lamination process. Thus, in this thesis, we implement Six Sigma (Define、Measure、Analyze、Improve and Control) to improve the defective rate of optical film lamination process.

The first step of the procedure in Six Sigma is to determine Colloidal Particle and DOT in the process as two key factors in the quality and measurement system. Then SIPOC is used to make analysis. First, 24 possible factors are sorted out by the Pareto chart and 12 potential factors are concluded which may influence procedure workflow potentially by the method of C & E MATRIX.

A partial factorial design, , is applied to executive design of experiment for the first time and then a reflected design of is performed to distinguish main from interaction effects. A partial reflected design of can confirm the significant effects between two interaction effects. Finally, a cubic plot shows the best combination of the levels of active factors in the manufacturing which is the combination of all low levels.

A Six Sigma method is implemented successfully to the target company for increasing the yield in the optical film lamination process. Our experimental results and procedures can be contributed to the company in improving the quality, increasing the stability of the yield rate and production procedure. From this study, we can understand and determine the active factors which affect the yield rate in the process by a systematic way- Six Sigma. We expect our research results can be applied to other manufacturing processes in the company to increase the yield rates significantly.

並列關鍵字

Six Sigma；partial factorial design；partial reflected design；PDP display

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