應用限制理論改善面板工廠控片庫存-以I公司為例

近年來TFT LCD面板產業蓬勃發展，隨這面板世代演進，造成舊世代舊廠逐漸缺乏競爭力，而舊世代廠房也並非全無生存利基，新技術的演進如 Mini LED、Touch Sensor等等，都是老廠的轉型契機，然而轉型研發期間生產成本勢必逐步升高，因此期間成本的管控即顯得極為重要。個案公司之面板工廠同樣面臨轉型期間所遭遇的問題，該廠之控片庫存使用量一直居高不下，控片成本管控亦也是管理高層極欲重視的問題。個案工廠控片管理所面臨的最大問題乃是庫存過高、變異過大週轉不及的問題，這些問題皆為導致庫存成本居高不下的原因。本研究主要以限制理論(TOC)的庫存管理思維來改善庫存成本過高的問題。運用TOC所提出的『需求拉動補貨』以及『動態緩衝管理』來改善庫存，驗證此方法是否亦適用於面板工廠之控片庫存管理。經由模擬結果得知，使用TOC之需求拉動補貨及動態緩衝管理方法，模擬的三種控片庫存量分別有效下降了66%、67%、55%，且無缺貨周轉不及的情形發生，證明此方法有效可應用於面板工廠的控片庫存管理上。

關鍵字

限制理論；需求拉動補貨；緩衝管理

並列摘要

In recent years, the TFT LCD panel industry has developed rapidly. With the evolution of different generations of panels, the old generation plants are gradually lacking in competitiveness, and the old generation plants are not without a foundation for survival. The evolution of new technologies such as Mini LED, Touch Sensors, etc., are opportunities for the transformation of old-generation factories. However, the production costs during the transformation R & D are bound to gradually increase, so the cost control during the period becomes extremely important. The panel factory of the case company also faced the problems encountered during the transition period. The factory's dummy inventory usage has been high, and the cost control of the control film is also a problem that the company's management supervisor attaches great importance to. The biggest problem faced by the dummy management of the case factory is the problem of too high inventory, too large variation and insufficient turnover. These problems are the reasons for the high inventory cost. This research mainly uses the inventory management thinking of theory of constraints (TOC) to improve the problem of excessive inventory cost. Use the "Demand Pull" and "Dynamic Buffer Management" proposed by TOC to improve inventory and verify whether this method is also applicable to the dummy inventory management of panel factories. According to the simulation results, using TOC's demand-driven replenishment and dynamic buffer management methods, the simulated three dummy stocks have effectively decreased by 66%, 67%, and 55%, respectively, and no shortage of stocks has occurred, which proves this The method can be effectively applied to the dummy inventory management of the panel factory.