- 學位論文
RFID應用之標示防呆：太陽能電池廠個案研究
Error Proofing of labeling in RFID Application：A Case Study of Solar Cell Manufacturer
摘要
太陽能電池製造技術近似於半導體技術，但由於製程時間短，且原料成本較低，故一般太陽能電池製造商對自動化設備投入普遍不高。由於生產作業中的運送、識別及相關判斷作業都必須要倚賴作業員的狀況下，常常容易因為人員的輕忽、疏忽而導致工作缺失，輕則造成廠內異常事件發生；重則出貨至客戶端產生客戶抱怨，影響商譽。 本研究以國內某太陽能電池製造商的實際案例狀況為例，主要目的是希望能夠透過無線射頻技術在生產終端的成品標籤貼附作業部分來建置防呆系統，使得第一線的作業人員不至於因為作業中的疏忽而造成產品的異常。 文中將以依據防呆法導入流程依序進行；找出最容易發生標籤貼附錯誤的工作站點，並利用要因分析圖得出錯誤發生的癥結點在於「標籤無確實依附在產品上」。接著透過作業流程及成本關係圖來評估不同導入工具之優、缺點，評比之後取自行研發的無線射頻模組來取代現有的barcode作業模式。另外也在系統開發過程中，透過錯誤發生階段及防呆功能效力相關矩陣圖來確定此次系統開發確實具有高度防呆效力。 根據最後資料結果，在無線射頻技術導入後，錯誤發生的狀況大幅度改善，從原先每月平均約五件品質異常下降至零件，原先六個作業工序減少至五個，耗材費用則節省約383,137.6(NT$)。
並列摘要
Solar cell manufacturing technology is similar to semiconductor technology, however, its level of automation in production is not as high as semiconductor technology due to its shorter processing time and lower material cost. Operations, identification, and transportation in the production process of solar cells traditionally depend on manual labors. On account of negligence from labors, it is considerably easy to lead failures or defects which cause abnormal occurrences in the factory and further influence on company reputation. This study took a solar cell manufacturer in Taiwan as an example. It introduced error proofing methodologies and processes to figure out the workstation which was the most frequent to label incorrectly on products. It employed cause-and-effect diagrams to identify the main cause of wrong labeling, “Product labels are not attached surly on products.” Furthermore, it evaluated various identification systems and considered pros and cons of each system according to the relationship between operations and cost. It applied a self-developed RFID system to replace the traditional barcode system in the end. During the development of the RFID system, it was based on the relationship between periods of error occurrence and effectiveness of error proofing functions to verify performance and reliability of this system. Owing to the introduction of RFID system in the case company, failures or defects in the operations have been significantly improved by automatic reading and writing. This system reduces the dependence on manual labors in production and avoids the inaccuracy and unreliability caused by the damage of configuration labels. It also has effectively decreased operation time and material cost