TFT-LCD模組廠物料配置問題求解模式之構建

Abstract

TFT-LCD模組廠位於液晶顯示器生產製造流程之最後階段，其生產型態類似電子組裝業，由LCD面板半成品與關鍵物料之搭配以滿足顧客需求。在進行物料規劃時，LCD面板半成品需考量不同等級之LCD面板半成品之符合率與零輝點率，以及是否需要降轉滿足產品需求之特殊情形；而關鍵物料部份則需考量物料之替代特性。在之前已經有學者將上述問題寫成數學限制式，並以利潤最大化為目標，用混整數規劃（mixed integer programming）的方法求解，雖可求出最佳解，但是所需耗費的時間過長。有鑑於此本文擬建立一物料配置模式，以啟發式演算法求解，使物料能夠有效利用且能提升求解之效率。 本文建立之物料配置模式分為兩個階段，分別為「LCD面板半成品之配料規劃模式」與「關鍵物料配置規劃模式」。在「LCD面板半成品之配料規劃模式」針對各產品等級各期之需求量，考量LCD降轉之特性，以利潤最大化為目標進行LCD面板半成品等級與數量之規劃。並在「關鍵物料配置規劃模式」中搭配「LCD面板半成品之配料規劃模式」之規劃結果，並考量關鍵物料之單一替代與群組替代特性以最小成本為目標進行求解。 經由案例結果驗證，本文所建立之物料配置模式，以使用啟發式演算法求解，可在短時間內求解，此乃表示本文所建立之物料配置模式能夠在短時間內有效的規劃TFT-LCD模組廠內，令各個等級LCD面板半成品與關鍵物料之配置量，使得利潤提高。

TFT-LCD (Thin Film Transistors- Liquid Crystal Display) module assembly is the final stage of the whole LCD manufacturing process. Its product type is similar to the electronics assembly industry. To meet customer’s demand, the semi-finished of LCD panels and critical materials are considered. For the material planning, the product acceptance rate, zero-bad-defect rate and the downgrade issues of LCD panels are considered in the thesis. In addition, the characteristics of the replacement parts for critical material are also considered. This problem has been formulated as a mixed integer programming model with objective of maximum profit in previous research. Although the optimal solution can be obtained by using the MIP model, the computational time is inefficient for moderate-scaled and large-scaled problems. Thus, in this thesis, we develop a material allocation model and construct algorithms to enhance the efficiency for the material planning. The material allocation model can be divided into two stages which are referred to as “The allocation planning model of LCD panels” and “The allocation planning model of critical materials”. In the first stage, we propose a model to plan the grade and required amounts of LCD panels with the objective of maximal profit with the consideration of the downgrade issue of LCD panels. In the second stage, in order to achieve the minimal critical materials cost based on the results obtained from the first stage, we solve the problem with consideration of single substitution and group substitution for critical materials. The results of experiments show that the material allocation model presented in this thesis can obtain the solutions efficiently. In addition, the allocated amounts of the various levels of LCD panels and critical materials to can be obtained to maximize the profit.