LCD的技術一直在進步,而面板內部的製造是屬高精密的製作,只要有百分之一微米的不良就會降低面板品質。本研究依據個案公司的單項產品中,針對SS Short不良提出對策,降低該項不良率、提升該尺吋面板整體良率及降低報廢面板的浪費。個案是以六標準差(Six Sigma)管理手法的流程步驟(D-M-A-I-C)做逐步的了解及對策,並歸納出〝配向枚數〞及〝ITO膜厚〞是影響製程的主要關鍵因子,且運用實驗設計法(Design of Expriments, DOE)的3^2全因子實驗及主效用、交互作用圖找出最佳的參數組合。最終個案的研究結果為配向枚數控制在450枚時更換配向布且ITO膜厚設定在850埃,可將不良從3.83%降至0.69%且Cpk從0.35提升至1.12,確實有效抑止大部分不良的發生亦達到提升良率的效果。而整體效益使改善前後成本降低18%。
The technology of Liquid Crystal Display(LCD) keeps updating to improve yields. The product will be identified as a failure as long as a hundredth micron deviation in LCD’s panel due to high standard required. In this research, we use 6-sigma to find the solution of improving SS short in a production process. The goal is to decrease the defective rate as much as possible. In our case, we discover〝NO. of panel to pass rubbing〞and〝thickness of ITO〞are two critical factors in the process. Also, we apply the design of experiment method(DOE) to find the best combination of parameters. Through a 3^2 full factorial experiment、main effects plot and interaction plot, we determine the best setting of parameter values and the Cpk increases from 0.35 up to 1.12. Through this improvement study, not only the company cost for the product is reduced around 18%, but also a standard procedure to improve the production quality is documented.
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