應用限制理論提升工廠生產力 －以I公司為例

隨著面板的普及，電視、手機市場已趨於飽和，但汽車產業對於面板應用與需求，卻日益增加，是各大面板廠眼裡的新藍海且具有長約效益，像是儀表板、抬頭顯示器、後照鏡、後座娛樂系統等，車用面板也逐漸成為新車的標準配備。全球汽車顯示器總體產值預估到2021年將達186億美元，其中薄膜電晶體液晶顯示器（TFT-LCD）在汽車顯示面板市場出貨量預估到2022年將達到2億片。液晶顯示器市場在近幾年出現了局勢變化，2019年日廠松下宣布2021年液晶顯示器終止生產，韓廠三星和LG Display也因營運策略，全面轉換OLED新製程，積極調降液晶顯示器產能，甚至關閉生產線，然而大陸廠京東方與華星光電也宣布暫緩TFT-LCD投資計畫。至於台廠華映，則是因財務操作不甚，宣布破產，退出市場。在整體供給面大幅減少與車載毛利又高於電視/手機等產品之下，對於維持生產TFT-LCD的公司是一大利多，因此各公司將重新檢視如何快速提升工廠產能，降低成本，來搶進新藍海並提升市占率，是非常最重要的議題，因此也是本研究的主要目的。本研究是以台灣某一面板公司，運用限制理論五聚焦步驟與關鍵要因圖方法來提升工廠生產力，其績效顯著。整體產能由75,132片/月提升至91,832片/月，提升16,700片/月，改善幅度22.2%。

關鍵字

薄膜電晶體液晶顯示器；限制理論；關鍵要因圖

並列摘要

With the popularity of panels, the TV and mobile phone markets are close to saturation, but the automotive industry is increasing its application and demand for panels. It is a new market in the eyes of major panel manufacturers and has long-term contract benefits. Dashboard, Head Up Display, Rearview mirror, Rear-Seat Entertainment, etc., car panels have gradually become the standard equipment for new cars. The global output value of automotive displays is estimated to reach US $ 18.6 billion in 2021. Among them, the shipment of thin-film transistor liquid crystal display (TFT-LCD) in the automotive display panel market is expected to reach 200 million in 2022. The LCD market has changed in recent years. In 2019, the Japanese factory Panasonic announced the termination of LCD production in 2021. The Korean factories Samsung and LG Display also gradually switched to new OLED products due to business strategies, and actively reduced LCD production, or even closed The production line, however, BOE and TCL of the china factories also announced to postpone the TFT-LCD investment plan. As for the Taiwan factory CPT, due to poor financial operations, it declared bankruptcy and withdrew from the market. Under the situation that the overall supply surface is greatly reduced and the gross profit of car panels is higher than that of TVs / mobile phones, it is a great benefit for companies that maintain TFT-LCD production. Therefore, companies will re-examine how to quickly increase factory capacity and reduce costs Grabbing into new markets and increasing market share is a very important issue, so it is also the main purpose of this study. A Case Study on a panel company in Taiwan, using the Theory of Constraints and Ishikawa Diagram method to improve the productivity of the factory, its performance is remarkable. Overall capacity improvement improved from 75,132 pieces / month to 91,832 pieces / month, an increase of 16,700 pieces / month, an improvement of 22.2%.