以產品裝配為觀點探討 TFT-LCD 製造業資材規劃問題之研究

陳重佑

指導教授 ： 阮約翰 ； 呂俊德

國立清華大學/工學院/工業工程與工程管理學系/碩士(2006年)

摘要

全球薄膜電晶體液晶顯示器（Thin Film Transistor Liquid Crystal Display , TFT-LCD）產業隨著各項應用產品多元開發與推廣，需求逐年成長。各世代廠陸續開出產能的結果，使大型面板供應能力提升。但快速提升的產出量，卻造成產品庫存累積，以及關鍵零組件供應不足兩大問題。
　　TFT-LCD產業製程複雜而且差異性大，各階段製程中投入包括玻璃基板（Substrate）、彩色濾光片（Colorfilter）、偏光板（Polarizer）、背光模組（Backlight）、驅動IC（Driver IC）等關鍵零組件，以及其他多項重要資材。產業中資材成本佔總營運成本的60%，再加上各關鍵零組件的供應市場呈寡佔情形，使得零組件供應的穩定性與品質受到考驗。生產計劃與資材計畫的不當配合，會造成零組件或是成品的存貨量上升，侵蝕企業營運的績效。因此如何有效整合生產計畫以及資材計畫是決策上的重點。
　　本研究以產品裝配的觀點，藉由量化模型的發展，對TFT-LCD 產業中各階段製程與其資材投入做規劃，考量資材供應能力、製程能力、設備產能等限制因素，建構決策輔助模式。提供多階段裝配中生產計畫、資材計畫以及庫存控制的決策工具。本研究提出兩種決策方案，方案A以混合整數線性規劃（Mix Integer Linear Programming）為理論依據之決策方案。方案B為規則式演算法決策模型。兩方案皆以市場需求為考量起始點，進行各期各廠產能分配、各階段各品項零組件採購計畫、庫存價值控制的決策輔助。本研究並利用數據範例來探討兩決策方案的求解品質，以確認所發展之方案，足以做為產業各階段資材規劃的決策輔助工具。

關鍵字

TFT-LCD ； 資材規劃 ； 產品裝配 ； 數學規劃

並列摘要

The popularization of the application products impels the development of global TFT-LCD industry. The demand for the panel grows up year by year and the output of every factory increases. But the quantity of output improved causes two big problems: The stock of the finished product is accumulated, and the key spare part is insufficient in supply.
The manufacture procedure of TFT-LCD industry is complicated. Manufacture procedure at every stage needs different spare parts, such as substrate, colorfilter, polarizer, backlight, driver IC, etc. In this industry, the material cost accounts for 60% of the total cost. And the supplies market is controlled by just a few manufacturers.The stability and quality of material supplies are challenged. Improper coordination between production plan and materials plan will cause the stock amount of the spare part or the finished product to rise. To combine the production plan and materials plan effectively is the goal of this research.
In this thesis, we propose two models to efficiently adjust the production plan and materials plan and control the amount of stock. The proposed methods in this research are (a) the mix integer linear programming model, (b) the rule-base decision model. This research uses an example to verify the quality of solving of two models. The related results show that the quality of solving to be similar of two models, and as well as good tools for implementing in this industry.

並列關鍵字

TFT-LCD ； material planning ； production planning ； mathematical programming

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