本研究運用六標準差改善流程,搭配全面生產保養 (Total Productive Maintenance, TPM)在設備異常前的訊息預測觀念為輔助,進行偏光片翹曲異常處理流程改善,先收集偏光片生產過程中可能會影響翹曲反應值的變異因子,藉由部分因子實驗設計,找出造成偏光片翹曲異常的關鍵參數條件,藉由分析原管理流程的缺點,進行流程改善,當關鍵因子出現不正常的趨勢變化時,預警系統即時發出預警信號,告知製程管理人員接下來可能發生的生產異常現象,提前進行因應措施,藉此減少生產過程中因機構異常所造成的生產損失。本研究有效降低了偏光片生產過程中的失敗成本,提高利潤,此先期監控與生產條件管理系統也為偏光片產業帶出了一套工業4.0 - 智慧化生產的系統藍圖。
This research applies the Six-Sigma process improvement and the predicted information before unit exception from TPM(Total Productive Maintenance) to enhance the process improvement of warping polarizers. First, the researcher collects the various factors of polarizer warping. Through fractional factorial experimental design, researcher lists out the key parameter factors of warping polarizers. Researcher also improves process management through analyzing the flaws of it. When key factors show abnormal activity, the precaution system sends out warning immediately to alarm process manager in order for them to response in time to avoid production loss due to machine malfunction and also increase profit. This advanced monitoring and production condition managing system is the blueprint of Industry4.0, intellectualized production system for the polarizer production industry.