生產系統考慮多品質特性檢驗設置及抽樣計畫之研究

A Study of Inspection Allocation Problem with Consideration of Multi-characteristics and Sampling Plans in Production Systems

卓國華(Kuo-Hua Cho)

指導教授 ： 饒忻

中原大學/電機資訊學院/工業與系統工程研究所/博士(2010年)

https://doi.org/10.6840/cycu201000754

摘要

隨著高科技產業的蓬勃發展及消費型態的改變，產品生命週期越來越短，產品上市後能為企業帶來利潤的時間也變短，一旦品質不良則企業可能立刻失去市場。因此在生產系統中，企業如何在有限的檢驗資源下，決定檢驗站的設置或使用何種檢驗政策，藉以提昇產品品質，是值得深入探討的課題。在半導體晶圓及面板製造中，生產型態除了傳統之序列式生產系統外，也有更為複雜的再回流式生產系統及多品質特性因素；同時檢驗站設置問題以再回流式生產系統並考慮抽樣計畫為研究範圍的也不多見。另外在生產系統中對不合格品的處理方式，大多數的文獻採取修理、當站重工或報廢等方式來建置模式，沒有考量對不合格品的處理採取回到前製程重工的方式，因此本研究分別對序列式及再回流式生產系統，探討檢驗站設置問題時考量多品質特性、抽樣計畫及重工。
本研究對檢驗站設置問題分為三個方向探討，首先針對再回流生產系統檢驗站設置問題的模式，使用基因演算法方法來改善求解時間及績效。第二，針對序列式及再回流式生產系統中，考量多品質特性及重工流程特性，建立利潤模式，模式的成本中包含生產成本、檢驗成本、重工成本、修理成本、報廢成本及外部失敗的懲罰成本等，期望於利潤最大下決定檢驗站設置及品質特性選擇政策，並發展出啟發式及基因演算法的求解方法。最後研究為考量重工及抽樣計畫檢驗，建構出序列式及再回流式生產系統的成本模式，在最小總成本為決策考量下，決定生產系統中的抽樣計畫，並發展出啟發式及基因演算法求解方法。本研究的多項成果相信可以提供相關產業在制訂檢驗政策時的參考。

關鍵字

多品質特性 ； 檢驗站設置 ； 抽樣計畫 ； 序列式生產系統 ； 再回流式生產系統 ； 基因演算法

並列摘要

Along with the high-tech industry’s blooming development and the consumption type’s change, the product life cycle is getting short more and more, as well as the time of bringing the profit to the enterprises after their products going on the market. Once the quality of product is bad, then the enterprise may lose the market rapidly. Therefore, how to allocate inspections or use which inspection policy is worth studying thoroughly in order to promote the quality of product in the production system for the enterprise under limited inspection resources. In the semiconductor wafer and TFT-LCD manufacturing, the serial production system used traditionally is not enough, the complicated reentrant production system is introduced with multi-characteristics inspection. Meanwhile, it’s not many researches found to consider sampling plan in the reentrant production system. On the other side, for most of the studies in the literature, possibilities of treatment of detected nonconforming units are repair, rework at the current workstation and they did not take the product to be reworked at the previous workstation. The above-mentioned facts motivate this dissertation to study the inspection allocation problem with consideration of multi-characteristics inspection, sampling plan and rework for serial and reentrant production systems.
This study explores the inspection allocation problem with three directions. First of all, we use a genetic algorithm to solve the inspection allocation problem for reentrant production systems in order to improve execution time and solution efficiency. Secondly, we solve the inspection allocation problem with consideration of multi-characteristics inspection and rework for serial and reentrant production systems. We develop a profit model, in which costs of production, inspection, rework, repair, scrap and penalty due to external failure are included. This study would like to find the best inspection allocation of stations and characteristics with the maximal profit. Two different solution approaches: heuristic algorithm and genetic algorithm are introduced. Finally, we develop a total cost model to solve the inspection allocation problem with consideration of sampling plan and rework for serial and reentrant production systems. This study will find the best sampling plans in production systems with the minimal cost. We believe that the results developed in this study can serve as a reference for the related industries when they are making inspection policies for the similar inspection allocation problems.

並列關鍵字

multi-characteristics ； sampling plan ； genetic algorithm ； serial production system ； inspection allocation ； reentrant production system

參考文獻

Bai, D. S., and Yun, J. H., “Optimal allocation of inspection effort in a serial multi-stage production,” Computers and Industrial Engineering, Vol. 30, No. 3, 1996 , pp. 387-396.

Ballou, D. P. and Pazer, H. L., “The Impact of Inspector Fallibility on the Inspection Policy in Serial Production Systems” Management Science, Vol. 28, No. 4, 1982, pp. 387-399.

Briteney, R.R., “Optimal screening plans for non-serial production systems,” Management Science, Vol. 18, No. 9, 1972, pp. 551-559.

Chakravart, A. K., “Strategic allocation of inspection effort in a serial, multi-product production system,” IIE Transactions,Vol 19, No. 1, 1987, pp. 13-22.

Crosby, P.B. “Quality is Free,” McGraw-Hill Co, New York, 1979.