本研究結合精實生產與六標準差的概念,以D2MAIC模式為架構,針對TFT-LCD業者所生產的薄型面板製程,由顧客的聲音為出發點,進行診斷與界定(Diagnose & Define)、衡量(Measure)、分析(Analyze)、改善(Improve)及控制(Control)各階段的行動步驟,於各階段中應用各種精實六標準差的工具與手法,在過程中發掘問題並進行分析,尋求最佳流程與製程參數。 經過個案實際驗證,客戶端線上不良率(VLRR)從3,628 dppm降低至814 dppm,Cell廠破片率從0.4%降低至0.15%,證明精實六標準差應用於薄型面板製程的可行性與效益。
This research is using the concept of the combination with Lean Production and Six Sigma and basing on the D2MAIC model to progress the improvement in slim panel process of a TFT-LCD manufacturer. The improvement is triggered by the voice of customer and following the five steps which are “diagnose and define”, “measure”, “analyze”, “improve” and “control”. There are many quality tools and methods applied in each step. After finding the root cause and doing the analysis, the better process and manufacturing parameters of slim panel are acquired. Through the validation of the case study, the VLRR is reduced from 3,628 dppm to 814 dppm and the cell crack rate is reduced from 0.4% to 0.15%. This research proves the feasibility and benefit of Lean Six Sigma, which can be implemented in slim panel manufacturing successfully.