應用實驗設計方法改善光學膠膠泡不良率-以面板材料公司為例

Application of Experimental Design to Decrease the Rate of the Optical Clear Adhesive Bubble Gum Defect Rate：Panel Material Company Case Study

林銘宗(Ming-Tsung Lin)

指導教授 ： 黃惠民

中原大學/電機資訊學院/工業與系統工程研究所/碩士(2015年)

https://doi.org/10.6840/cycu201500410

摘要

摘要
觸控面板產業的技術不斷的更新進步，需求在近年來亦不斷的提升，為提高競爭優勢，降低生產的成本及品質的提升已成為影響的關鍵。光學膠(Optically Clear Adhesive, OCA)主要用於觸控面板模組內Lens、ITO film及光學玻璃的黏接貼合工藝，貼合技術是觸控面板製程中相當重要的製程，要貼的準確、勻稱且無氣泡。
本研究運用六標準差之DMAIC五大步驟有效降低生產成本提高利潤，首先定義(Define)目標提升收率，再研究影響收率的主要因子為品質膠泡異常，衡量(Measure)量測系統的可靠性，進行重複性(Repeatability)及再現性(Reproducibility)評估，確認量測能力後使用特性要因圖進行流程分析，展列膠泡產生的影響程度較高的因子(真空消泡時間、靜置時間及真空攪拌)，由實驗設計（Design of Experiment, DOE）層別分析(Analyze)確認顯著因子(真空攪拌)，找出參數最佳化並逐步進行改善驗證(Improve)，導入後收率由74.39%上升至97.68%提高了23.29%，每年材料成本可省下150萬(Control)。

關鍵字

光學膠 ； 量測系統分析 ； 實驗設計 ； 六標準差

並列摘要

ABSTRACT
Techniques in the industry of Touch Panel are progressing continuously and demands are raising yearly. Reducing costs and improving qualities are the keys to acquire the competitive advantage. OCA optical glue is commonly used in laminating technology between lens and ITO films of touch panels. Lamination is a critical process of touch panel production; it requires accuracy, flat and without bubble.
The five procedures, DMAIC, in six-sigma, were applied in this study to reduce cost and increase benefits. Firstly, we DEFINED the target for “Raising the Yield Rate”. Then we investigated the main factors affecting the issue of bubbles and verify the MEASURING system; then we evaluated the Gage Repeatability & Reproducibility. After verifying the MEASURING system, we analyzed the process with cause-and-effect diagrams to explore the associated factor that influence bubbles occurrence. They are: time of vacuumed bubbling, time of waiting and time or parameter when stirring in vacuum. Using the Design of Experiment (DOE) method, we ANALYZED and ensured the significant factor such as the time or parameter when stirring in vacuum. Fine tuning the parameters and IMPROVE progressively. In our study, the yield rate was raised by 23.29%, from 74.39% to 97.68% after we implemented the new method. A total of 1.5 million NT$ in material cost was saved.

並列關鍵字

Design of Experiment ； Measurement System Analysis ； Six-Sigma ； Optically Clear Adhesive

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