應用TRIZ手法於六標準差製程改善專案之研究-以面板廠CELL磨邊製程為例

現今的面板製造業(LCD-TFT)，正面臨著嚴苛的考驗，一般而言產品週期可分為四個階段，分別為1.萌芽期、2.成長期、3.成熟期、4.衰退期。而面板製造業便是屬於成熟期，成熟期所需面臨的是利潤被大量壓縮，進而造成成本壓力，因此精確進行設備改革提升良率，便是現今刻不容緩的課題。面對著求新求變的產品，且須配合客戶的需求不同而做調整，過去相同產品大量生產已無法滿足客戶的需求，未來的考驗勢必會比現今更複雜的多。因此，面對產品的多樣化及多功能的變化生產線上的機台如何對應，已成為企業製造與生產時，所需考慮的問題之ㄧ。在量產產品的生產過程中，透過六標準差(SIX SIGMA)去檢驗產品的差異性，再利用TRIZ的解決問題方法，不但可以有效的達到功能需求，並且可使成本降低及改善時間縮短。本研究結合這兩種方法，得出兼顧各方考量的設計概念與建議，幫助公司在產品良率提升0.503%，從改善前失敗成本一條產線約90萬/年到改善後無此類異常，成效相當顯著。

關鍵字

TRIZ ；六標準差； LCD-TFT

並列摘要

Nowadays, LCD-TFT industry is facing severe situation. Usually, there are four phases of product lifecycle: 1.Introduction 2. Growth 3. Maturity 4. Decline and LCD-TFT industry is in Maturity phases. What Maturity phase faces is low profit, causing high-pressure in cost structure. Accordingly, precisely equipment tuning and high yield-rate is the most important topic. However, with highly diversified product, it is required to adjust the product specification for different needs. It cannot satisfy customers by providing same product with mass production. In the future, the test should be more serious that what we face now. Therefore, the equipment which can adjust for different product and functionality spec is one of the concern point for a company to manufacture and produce. In the process of mass production products, by using SIX SIGMA to determine the differentiation of product and TRIZ to solve the problem, not only can it reach the functionality requirement but also lowers down cost and shortens the schedule. Using these two methodologies, this research comes out with thorough design concept and idea and helps to increase the yield rate by 0.503%. This achievement is remarkable compared with the failure cost of 900,000 NTD per year before to non-failure phenomenon after.

並列關鍵字

TRIZ ； LCD-TFT ； Six SIGMA

參考文獻

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[11]Bariani, P. F., Berti, G. A., and Lucchetta, G., “A Combined DFMA and TRIZ Approach to the Simplification of Product Structure,” Proceedings of the Institution of Mechanical Engineers, Volume 218, Number 8, pp. 1023-1027 (2004) 。

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