應用六標準差及限制理論改善在面板廠搬運流程

Application of Six Sigma and Theory of Constraints on TFT-LCD CELL Fabrication Automation Transportation Process Improvement

管育君(Yu-chun Kuan)

指導教授 ： 陳育欣

中原大學/電機資訊學院/工業與系統工程研究所/碩士(2011年)

https://doi.org/10.6840/cycu201100866

摘要

光電產業為我國兩兆雙星計畫的重點產業，其以液晶薄膜顯示器（Thin-Film Transistor and Liquid Crystal Display; TFT-LCD）產業最為注目的焦點。TFT-LCD產業的主戰場為亞洲地區，由日本、韓國與台灣廠商分庭抗衡。台灣TFT-LCD產業對外面臨韓國的規模經濟優勢與惡性競爭所導致的LCD售價不斷跌落，使得我方產業獲利空間受到嚴重的壓縮，對內則面臨多階多廠區的生產環境與龐大的設備折舊費用，在市場競爭愈形激烈的環境裡，企業皆致力於成本的降低、生產力的提高的方法，可透過六標準差管理手段改善方法及限制理論。可指出在生產的流程中，花費在運送、等待時間則佔有相當大的比例。本研究主要採個案研究法為例，將以國內某知名面板製造商的自動搬運（Automatic Guided Vehicle ;AGV）系統影響出貨產能作為研究個案。以現行搬送系統中浪費時間問題加以評估、驗證其改善成效，期透過此改善自動化生產設施搬送時間與減少產能損失。以顧客導向觀念希望貨能快速送達（速度）、沒有瑕疵（高品質），而且價格儘可能低廉（低成本），則運用六標差準的方法持續改善，並導入限制理論找出其問題點解決方式，加以改善流程及速度其改善效果顯著。

關鍵字

個案研究法 ； 限制理論 ； 六標準差

並列摘要

As one of the twin star trillion industry in Taiwan, TFT-LCD (Thin-Film Transistor and Liquid Crystal Display）gets a lot of attention. In fact, the major TFT-LCD manufacturers-the competitors of Taiwan all comes from Asia, which includes Japan & Korea.It shall be no surprise that, the competition of TFT-LCD industry is getting harder in this region.

Korean TFT-LCD manufacturers are among the biggest competitors of Taiwanese TFT-LCD industry because they have the biggest shares of the market. this kind of cost advantage reveals in product competitive and impacts Taiwan’s TFT-LCD manufacturers’ cost/price strategy and profits. As the hard situation that the Taiwan’s TFT-LCD manufacturers are facing, cost down policies becomes a critical issue for strengthening up their own competitive.

“Object transmission procedure is always the biggest part of total manufacturing cost” was indicate through announced Lean 6 sigma and TOC (Theory of Constrains) studies, which means the most of the manufacturing time was wasted on object’s temporarily storage & station to station transmission.

Base on this concept, we initialed this research through the method-“Case Study” on the biggest part of the automation transmission system- AGV（Automatic Guided Vehicle）, which research was based on the AGV transmission behavior at one of Taiwan’s Top#5 TFT-LCD manufacturer, through the transmission time wasting factor evaluation we expect to reduce the throughput loss because of a non-fine tuned transmission system.

“Faster delivery, zero defect quality and attractive prices” is always the first expectation from customers. Conducting the Lean 6 sigma- minimizes the wasting in production and TOC- to figure out and resolve the limitation from production turns popular in TFT-LCD business now, thanks to its well-known performance.

並列關鍵字

Automatic Guided Vehicle ； Theory of Constrains ； Six-Sigma ； Case Study ； TFT-LCD

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