工業技術研究院於1990年開發出3吋至6吋薄膜電晶體型技術開始,自1994完成建廠開始生產小尺寸薄膜電晶體液晶顯示器。而大型薄膜電晶體自1997年投資建廠生產大尺寸TFT-LCD面板,短短十餘年間完全取代傳統映像管顯示器。TFT-LCD量產技術由三代廠一路開發至八代廠,期間不過二十餘年。需求端對面板規格與良率要求日趨嚴格,再加上材料面為了提升產品特性,不斷更新生產材料,許多生產設備量產後不到十年間,對於點狀類的缺陷已經無法滿足以6標準差的良率標準做出客戶所需。在此過度時期生產線會使用雷射修補方式,將有缺陷的成品修補成全良品,此時修補站點產能日趨重要。案例中產線過去提升修補站點產能的方法,僅聚焦在機台妥善率與縮短修補時間上,並搭配大量加班人力來提升產能,並未全面性的使用特定的改善手法來提升生產力。本研究針對TFT-LCD的雷射修補站點的生產力提升,使用六標準差的DMAIC(Define,Measure,Analyze,Improve,Control)改善手法,搭配精實生產的剃除浪費,使用團隊合作模式找到影響雷射修補站點的浪費主因,最終以標準手法訂定未來生產模式,以期望生產系統能持續保持流暢且精實狀態。
Since 1990, Industrial Technology Research Institute (ITRI) has developed from 3-inch to 6-inch Thin Film Transistor-Liquid Crystal Display, called TFT-LCD. From the completion of its establishing the factory in 1994, ITRI started producing monitor-sized TFT-LCD. After investing to expand the factory in 1997, ITRI started producing TV-sized TFT-LCD panels. Just within ten more years, its TV-sized TFT-LCD panels completely replaced Cathode Ray Tube (CRT). The mass production technology of TFT-LCD started from the third-generation factory to the eighth, which it’s only more than two decades. Demand side’s requirements of its panel specifications and yields were becoming stricter and stricter. What’s more, to raise the quality of its products, TFT – LCD industry continuously renewed its production materials. After the mass production less than ten years, about the point-type defects, lots of production equipment had been unable to meet the yield standard by Six Sigma, the accuracy that customers needed. During this transitional period, the production lines would use the method of laser repair to mend the defective products into the good ones. This study focuses on the productivity of TFT-LCD’s laser repair stations, using the improvement tactics of Six Sigma DMAIC(Define, Measure, Analyze, Improve, and Control) along with lean production to eliminate waste and teamwork pattern to find out the main reason which affected the waste of the laser repair stations. And ultimately, set up the future production mode by Standard Operation Procedure (SOP), and it’s expected that the production system will remain smooth and lean.