應用六標準差改善 TFT LCD 偏貼製程因子之研究

The Six Sigma method for TFT LCD Polarizer Process Factor Research

徐世豐(Shih-Feng Hsu)

指導教授 ： 翁芳柏

元智大學/工程學院/機械工程學系/碩士(2012年)

摘要

玻璃面板貼附偏光板製程是生產液晶顯示器(Liquid Crystal Display； LCD)的重要製程之一，而「偏光板貼合製程」是在CELL段製程之最末端，也就是CELL段接近完成之階段。在面板上下兩面各貼上一片偏光板之目的，是要利用偏光板可吸收平行於其排列方向的光束電場分量之物理特性，藉由兩片偏光板相差約90度之排列方式，即可達到將面板下方背光源遮蔽之功能，再利用控制電場之強弱對液晶可產生偏轉及對光不同折射之特性，達到讓面板之顯示區部份透光部份不透光，如此即可達成顯像之功能。在面板與偏光板之貼合過程必須對面板全面性均勻施壓，以便將偏光板均勻、完整的貼著於TFT-LCD面板之兩面，因此偏光板貼合的品質會直接影響此液晶面板影像顯示的品質，再者此面板本體之製程到此亦將告一段落，若稍有閃失而造成面板損傷將導致前功盡棄，因此「偏光板貼合機」在TFT-LCD之CELL段製程中擔負一個攸關成敗之重要關鍵設備；偏光板貼合之完整製程共包含有：面板表面清潔、洗淨、偏光板貼合和檢查等，本研究藉由統計手法將偏光板製程之不良現象數據化，以期找出其中影響製程之關鍵因子並進行分析，其中實驗之步驟為利用六標準差手法之界定(Define)、衡量(Measure)、分析(Analyze)、改善(Improve)、控制(Control) 之實驗歩驟進行，而實驗設計與數據分析則利用分析軟體(Minitab)來進行實驗計劃的設計及統計分析。本實驗範圍則包括切裂玻璃方式（基板排版）、設備穩定性、製程參數等，以5因子(切裂玻璃方式/表清機sheet材/人員取放作業方式/ brush機毛刷/機台黏塵紙添加)與2水準以確保其交互作用關係。
經實驗玻璃基板切割製程的5個因子：切裂玻璃方式、表清機sheet材、人員取放作業方式、brush機毛刷、機台黏塵紙添加；進行2水準部份因子設計(2-Level Fractional Factorial Design)實驗。最後以分析軟體(Minitab)分析實驗數據與確認實驗結果，得到3個偏光板貼附製程重要因子：切裂玻璃方式(18面取排版)、表清機sheet材(MIP新式sheet材)、brush機毛刷(毛刷線徑0.2mm)。
綜合此研究可明確了解實驗結果與良率之關係與重要性。實現偏光板貼附製程因子最佳化，達到降低良率損失與提高產品品質之目的。

關鍵字

6標準差 ； DMAIC ； 偏光板貼附 ； LCD

並列摘要

The glass panel attached to the polarizer manufacturing process is the production of liquid crystal display (Liquid Crystal Display; LCDs), one of the important process, and the polarizer laminating process, which is the the CELL segment close to the stage of completion of the end of the CELL BEOL. The panel up and down both sides of the paste the purpose of a polarizer, the polarizer can absorb the physical characteristics of the beam electric field component parallel to its orientation by two polarizers, a difference of about 90 degrees arrangement can be achieved by shelter in the panel below the backlight function, re-use to control the strength of the electric field on the LCD can produce deflection and light refraction characteristics, reach the part of the panel display to some translucent to opaque, so you can reach the imaging the function. Must be comprehensive panel in the panel and polarizer fit even pressure, so that the polarizer uniform, close to both sides of the TFT-LCD panel, polarizer fit quality will directly affect this LCD panel image display quality, Moreover, this panel process of the body of this will come to an end if a little mishap caused panel damage will lead to naught, so polarizer laminating machine "responsible for a TFT-LCD CELL BEOL Yau off the success or failure of critical equipment; polarizer fit complete process consists of: panel surface is clean, wash, polarizers fit and inspection, this study of the negative phenomena of the polarizer process data by statistical methods to identify key factors of which affect the process and analyze the steps of the experiment for the use of Six Sigma practices of defined (Define), measure (Measure), analysis (the Analyze), improved (Improve), control (Control), experimental step steps, the experimental design and data analysis using analysis software (Minitab) to the design and statistical analysis of the experimental program. The scope of this experiment include the cut split the way of glass (substrate layout), the stability of the equipment, process parameters, split glass by five factors (cut / table Cleaner sheet material / personnel practices take place / brush brush machine / machine sticky paper dust added) to ensure that its interactions between the two standards.
Cut by the experimental glass substrate switching processes five factors: shear crack the glass the way the table clear machine sheet material, personnel take to put practices, brush machine brush, machine sticky paper dust to add; into Bank 2 level part of the factor design (2-the Level fractional Factorial Design) experiments. Finally, the analysis software (Minitab) to analyze experimental data to confirm the experimental results, the important factor of the three polarizer attachment process: cutting crack the glass (18 side to take the layout), Table Cleaner sheet material (MIP new sheet material), brush machine brush (brush diameter 0.2mm).
The combination of this study can be a clear understanding of the relationship and importance of the experimental results and yield. The polarizer attached to the process factor optimized to achieve the purpose to reduce yield losses and improve product quality.

並列關鍵字

Six Sigma ； DMAIC ； Polarizer ； LCD

參考文獻

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