多廠區多階製程生產規劃—以TFT-LCD產業為例

Multi-Plant and Multi-Stage Manufacturing Process Production Planning for TFT-LCD Industry

張文龍(Wen-Lung Chang)

指導教授 ： 鄭元杰

元智大學/工程學院/工業工程與管理學系/碩士(2005年)

摘要

隨著TFT-LCD產業市場需求持續成長，促使企業以擴建新廠區的方式，滿足市場需求；且TFT-LCD各廠區內具有多階製程段，形成多廠區多階製程的生產環境。由於各廠區各製程段具有不同的生產限制與特性，在進行生產規劃時，需考量多廠間生產資源的整合及廠區內上下游製程供給的平衡，在滿足市場需求的前提下，提升各廠的產能利用率，達到最小化的生產規劃成本。故本研究欲探討如何在多廠多階製程的生產環境下，考量各廠區各製程段不同的生產限制與成本，進行多廠區多階製程生產規劃。
本研究以TFT-LCD多廠區之Array及Cell製程段為規劃範圍，利用線性規劃法建構多廠區多階製程生產規劃模式：以最小化多廠區多階製程生產製造、半成品存貨、最終成品存貨與缺貨總成本為目標，考量各廠區各製程段最大產能、各種產品生產上限、上下游製程間半成品供給、生產良率及最終成品分級率等限制，將最終成品需求分配至各廠區進行生產，並求得各廠區各製程段之最佳生產計畫。
最後，透過實例驗證本研究之多廠區多階製程生產規劃模式的可行性，在最小生產規劃成本總和下，取得最佳的生產計畫。所求得的結果可提供企業管理者進行規劃決策判斷及各廠區生管人員進行短期現場作業排程的依據。

關鍵字

多廠區 ； 多階製程 ； 生產規劃 ； TFT-LCD產業

並列摘要

As the marketing demand of TFT-LCD industry grows up continuously, an enterprise may expand the numbers of plants to meet the marketing demand. Each plant of TFT-LCD industry contains many stages of manufacturing process. Therefore, the production environment of TFT-LCD industry is multi-plant and multi-stage manufacturing process. Because each stage of manufacturing process in each plant has different restriction and characteristics of production, production planners must integrate the resources of all plants and balance the supply of up-stream and down-stream manufacturing process to meet the demand and increase the average utilization of capacity to make the production planning cost minimum. Under these considerations, it is important to develop a production planning and assign the demand properly to each plant in multi-plant and multi-stage manufacturing process environment.
In this research, a multi-plant and multi-stage manufacturing process production planning model is presented. This model is formulated by linear programming and applied to the Array and Cell manufacturing process of multi-plant of TFT-LCD industry. And it is to assign the demand to each plant and obtain the optimal production plan of each stage manufacturing process of each plant according to the constraints which are capacity limitation, production limitation, the supply between up-stream and down-stream manufacturing process, production yield rate and product grading rate etc., and achieve the objective that is to minimize the total production cost, holding cost and storage cost.
Finally, this research uses three real examples to verify the feasibility of the model. The result could help a company to enhance the decision support of detail production scheduling.

並列關鍵字

Multi-Plant ； Multi-Stage Manufacturing Process ； Production Planning ； TFT-LCD Industry

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