要在市場上具有競爭優勢,不斷的提高產品品質與可靠度外,另外一個關鍵是降低成本。除了降低採購成本,最好的方式就是良率的提升,還需要利用分析技術找出產品的最佳製程能力,以期望能創造顧客滿意並具有競爭優勢。 本文所探討的是針對偏光板後段貼合機製程之不良項目保護面異物,做製程不良率的改善,利用六標準差中DMAIC方法,針對產品在貼合機製程中導致偏光板有保護面異物不良的要因,找出製程的變異,以六標準差的手法步驟進行探討作持續改善。 用實驗設計(Design of Experiments, DOE)來進行保護面異物改善實驗,找出最佳條件組合。改善前偏光板保護面異物不良DPPM為3992 DPPM,期望改善效益20%為目標,保護面異物不良降為3194 DPPM。 實際驗證的結果得到偏光板保護面異物有減少1049 DPPM,改善達26.2%,且檢驗相關製程中均無產生其它品質上的問題。 最後,改善後偏光板保護面異物不良為2943 DPPM,改善效益預估分析年節省約台幣587萬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貼合機製程產出不良項目保護面異物。
To have a competitive advantage in the market, continuously improve product quality and reliability, another key is reducing costs. In addition to procurement cost down, the best way is yield improvement, also need to use analytical techniques to identify the best process capability, to hope to create customer satisfaction and competitive advantage. In this study, we are based on DMAIC improvement procedure in 6 Sigma to perform defect item of protect film particle in the polarizer back process. Find out the process variability; explore the Six Sigma method steps for continuous improvement. Use Design of Experiments (DOE) to conduct protect film particle to improve the experiment, find out the optimal conditions. To improve before the polarizer defect of protect film particle was 3992 DPPM, Expect the target to improve the effectiveness 20%, to make of the protect film particle defect reduced to 3194 DPPM. The actual verification results polarizer protect film particle to reduce 1049 DPPM, improvements of up 26.2%, and test related process no other quality problems. Finally, to improve after the polarizer defect of protect film particle was 2943 DPPM. Improve the effectiveness estimates, to reduce the production internal failure costs about NT $ 587 million of year. As results as the experiments through step-by-step procedure in the study, case company obtained an effective improvement and approval which can be improving defect of polarizer film particle in the lamination process.