應用精實六標準差於改善面板廠自動無人搬運車傳送系統之研究
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2015
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Abstract
行動時代來臨更加強了市場對顯示器規格的要求，因此廣視角與高解析，將成為行動裝置應用的未來趨勢技術。為了因應行動裝置面板市場已走向高解析度與廣視角的高階規格發展，所以全球各面板廠也將以多樣的技術平台發展，包括薄膜電晶體液晶顯示器技術(Thin film transistor liquid crystal display, TFT-LCD)、低溫多晶矽技術(Low Temperature Poly-silicon, LTPS)、有機發光二極體技術(Organic Light-Emitting Diode, OLED)、先進超廣角技術(Advanced Hyper-Viewing Angle, AHVA)及半穿透半反射廣視角技術 (Multi-Domain Vertical Alignment, MVA)等來爭奪市場。但是能否投入量產與產能能否提高至獲利的水準，這仍然是各大廠最關心的問題。
本研究主要是依據公司3.5代廠區為案例，當工廠導入新技術製程時，新的機台會使工廠中的配置圖(Layout)變更與製程數變多，將影響工廠自動化系統(Factory Automation, FA)搬運時間變長之問題，此問題為本論文研究之重點，研究內容主要是透過精實六標準差管理手法界定、量測、分析、控制(Define、Measure、Analyze、Improve、Control, DMAIC)，來分析與解決傳送時間之問題，所以既有的工廠自動化傳送系統，可能產生搬運時成效性差異或影響產品生產問題時，我們希望透過資料分析來找出影響搬運能力因子，並進行對策改善來提升工廠自動化傳送系統之搬運能力。
最後，從結果顯示，透過精實六標準差實際運用找出該案例公司的工廠自動化傳送系統中自動無人搬運車系統(Automatic Guided Vehicle System, AGV)的影響搬運能力因子進行對策改善，將每筆傳送時間由351秒下降到330秒，這不但將自動無人搬運車系統效能提高，且後續進行水平展開至廠區內的其它自動化搬運系統，對該公司多元化製程產品(TFT-LCD、LTPS、OLED)產能亦獲得提升，其改善效益預估分析可減少公司成本支出。證明此次研究能夠有效的改善自動化搬運效能的問題。
The coming of mobile generation enhances the requirement for superior specifications of commercial display. Hence, features with wide visual angle and high resolution gradually become the tendency of mobile devices in the future. To keep up with the rapid development on aforementioned features and grasp the market share of prosperous mobile device market, all panel manufacturers over the world try to keep the share rate by developing kinds of technology platforms such as TFT-LCD(Thin film transistor liquid crystal display),LTPS((Low Temperature Poly-silicon), OLED(Organic Light-Emitting Diode), AHVA(Advanced Hyper-Viewing Angle), and MVA(Multi-Domain Vertical Alignment). However, the capability of mass production and sufficient production capacity to earn profit are still the most concerned issues. This research focuses on the topic sourced from an exemplified company whose transporting time of FA(Factory Automation) systems is prolonged by altered layout and additional processes after the 3.5 generation factories bring in new processes and purchase new machines. With the help of DMAIC(Define, Measure, Analyze, Improve, Control), the proposed research step by step analyzes and solves the potential problems while manufacturing and transporting by FA systems, and then detailed experimental analysis is present to find out the root cause that affects transporting performance so as to draw up strategies for improving the transporting capability of FA systems. Consequently, the experimental results indicate the overall transporting time of AGV system in the exemplified case decreases from 351s to 330s by means of DMAIC, which benefits the AGV system performance as well as other similar FA systems. Production capacity of products by diversified processes such as TFT-LCD, LTPS, OLED are also expanded. Analysis of the progress for yearly production capacity indeed proves the proposed research effectively improves the issues of FA systems.
The coming of mobile generation enhances the requirement for superior specifications of commercial display. Hence, features with wide visual angle and high resolution gradually become the tendency of mobile devices in the future. To keep up with the rapid development on aforementioned features and grasp the market share of prosperous mobile device market, all panel manufacturers over the world try to keep the share rate by developing kinds of technology platforms such as TFT-LCD(Thin film transistor liquid crystal display),LTPS((Low Temperature Poly-silicon), OLED(Organic Light-Emitting Diode), AHVA(Advanced Hyper-Viewing Angle), and MVA(Multi-Domain Vertical Alignment). However, the capability of mass production and sufficient production capacity to earn profit are still the most concerned issues. This research focuses on the topic sourced from an exemplified company whose transporting time of FA(Factory Automation) systems is prolonged by altered layout and additional processes after the 3.5 generation factories bring in new processes and purchase new machines. With the help of DMAIC(Define, Measure, Analyze, Improve, Control), the proposed research step by step analyzes and solves the potential problems while manufacturing and transporting by FA systems, and then detailed experimental analysis is present to find out the root cause that affects transporting performance so as to draw up strategies for improving the transporting capability of FA systems. Consequently, the experimental results indicate the overall transporting time of AGV system in the exemplified case decreases from 351s to 330s by means of DMAIC, which benefits the AGV system performance as well as other similar FA systems. Production capacity of products by diversified processes such as TFT-LCD, LTPS, OLED are also expanded. Analysis of the progress for yearly production capacity indeed proves the proposed research effectively improves the issues of FA systems.
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界定, 量測, 分析, 控制, 工廠自動化系統, 自動無人搬運車系統, Define, Measure, Analyze, Improve, Control, Factory Automation, Automatic Guided Vehicle System