結論與未來研究方向 - 彩色濾光片內製廠之主生產排程建構機制之設計

5.1、結論

隨著TFT-LCD 產業走向上下游垂直整合之趨勢，附帶提高彩色濾光片內製化之需求及比例。然而在內製廠環境中，須針對下游組立製程所開立之需求數量及交期，完善地考量瓶頸資源、附屬資源─光罩、以及外包之數量及種類限制下，制定出自製及外包之訂單最適配置種類及數量，及自製產能之最佳生產順序，用以回覆上層管理單位交貨時點及下層生產單位確切之生產目標。

有鑒於此，本文針對彩色濾光片內製廠之生產特性，建構一主生產排程機制。該機制包含兩個模組：

一、產能估算模組

本模組針對規劃幅度內之總需求數量，進行初步之產能估算；於估算過程中，依序判斷瓶頸機台產能與外包數量限制是否能滿足總需求量，以及「現有光罩數」及「總需求所推估出的預計光罩數」間之比對。藉由此模組過濾出不合理之需求，以利後續模組之進行。

二、主生產排程規劃模組

承接產能估算模組評估後之合理需求，依續對各筆訂單依交期時間序進行規劃。針對產能估算模組評估後的需求情境，分別以「產能充足排程模式」、「產能不足排程模式」執行最佳解之計算，並考量機台製程規格能力、光罩數量、機台產能、外包合約數量等限制，求解出該期之主生產排程結果。接續運用滾動排程及暫存排程之概念，以及外包縮減機制之執行，完成一個月之主生產排程。規劃結果囊括各期別採自製生產時，各機台之最佳生產順序、產品種類及數量、光罩調度結果、以及交予外包商生產之各期產品種類與數量。

藉由第四章之實例驗證結果分析，將本文之成效彙整如下：

1. 考量淡、旺季之情境，設計規劃機制提供管理者制定自製及外包種類與數量之決策依據。

2. 同時考量各機台製程規格能力及光罩數量限制，可明確得知各光罩於不同機台間之調度結果。再者，針對順序相依之排程問題求解出最適之生產順序；以利生產活動之進行。

3. 採用變動規劃週期之設計進行分段規劃，可大幅減少變數個數及瓶頸機台之排程複雜度。

4. 可假設所有訂單之備料完成時點皆為 0，對整個規劃幅度進行排程之求解，以推導出各訂單之產品別的最適備料完成時間，有助於成本最小化之追求。

5. 將求解結果經由撰寫 Excel VBA 自動產出甘特圖，提供管理者圖示化結果以供參考。

5.2、未來研究方向

綜觀本文所發展之主生產排程機制，在其過程中查覺仍有不足之處，

值得後續研究繼續深入探討，彙整如下：

1. 在彩色濾光片產業中，除了本文提及之換線規格外(光罩、光阻液、玻璃規格)，為節省換線時間，於實務環境中存在「不同玻璃規格間之替代」，即採用同一尺寸之玻璃用以生產不同尺寸之面板，但此舉動將會造成額外之成本花費。如何在「減少換線時間」與「增加成本」兩者中取捨為可探討議題。

2. 以往組立製程相關之研究，將薄膜電晶及彩色濾光片視為來料直接進行後續規劃。但陣列及彩色濾光片製程本身之生產型態、製程特性及目標皆不相同；再者，不同世代之陣列及彩色濾光片製程可互相支援，

因此協同兩製程進行生產規劃為當務之急。有鑑於此，若能考量「陣列及彩色濾光片」兩者進行生產規劃，將有助於TFT-LCD 產業制定出完善之生產排程結果。

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附錄

附錄A iLOG 求解結果

輸出結果與變數之對應為：w[i,m,t]=ωi,m,t、BG[i,m,t]=BGi,m,t、 FG[i,m,t]=FGi,m,t、alpha[i,m,t]=αi,m,t、beta[i,m,t]=βi,m,t、gamma[i,i’,m,t]=γi,i’,m,t、 O[i,t]=Oi,t、X[i,m,t]=Xi,m,t、delta[a,m,t] =δa,m,t、Y[i,t]=Yi,t、OY[i]=OYi，此外下列表格皆併除數值為0 之變數。

A-1. 求解範圍(1,1)之完整規劃結果

t=1

alpha[1,1,1] = 1 beta[0,8,2,1] = 1 FG[5,2,1] = 1 X[7,3,1] = 3312 alpha[3,1,1] = 1 gamma[1,3,1,1] = 1 FG[10,3,1] = 1 X[8,2,1] = 3499 alpha[5,2,1] = 1 gamma[7,5,2,1] = 1 w[1,1,1] = 1 X[9,3,1] = 2300 alpha[5,3,1] = 1 gamma[7,11,3,1] = 1 w[3,1,1] = 1 X[10,3,1] = 880 alpha[6,2,1] = 1 gamma[8,7,2,1] = 1 w[5,2,1] = 1 X[11,3,1] = 2696 alpha[6,3,1] = 1 gamma[9,10,3,1] = 1 w[7,2,1] = 1 O[8,1] = 1 alpha[7,2,1] = 1 gamma[11,9,3,1] = 1 w[7,3,1] = 1 O[10,1] = 2120 alpha[7,3,1] = 1 delta[1,1,1] = 1 w[8,2,1] = 1 O[11,1] = 4

alpha[8,2,1] = 1 delta[2,2,1] = 1 w[9,3,1] = 1 --

alpha[8,3,1] = 1 delta[2,3,1] = 1 w[10,3,1] = 1 --

alpha[9,3,1] = 1 delta[3,3,1] = 1 w[11,3,1] = 1 --

alpha[10,3,1] = 1 BG[1,1,1] = 1 X[1,1,1] = 5000 --

alpha[11,3,1] = 1 BG[7,3,1] = 1 X[3,1,1] = 4070 --

beta[0,1,1,1] = 1 BG[8,2,1] = 1 X[5,2,1] = 5100 --

beta[0,7,3,1] = 1 FG[3,1,1] = 1 X[7,2,1] = 288 --

求解結果

目標值 =155,580 (自製成本：117,338、外包成本 38,242)

；決策變數 = 1,120；限制式 = 17,405；求解時間 = 4.11 秒

A-2. 求解範圍(2,2)之完整規劃結果

t=2

alpha[2,1,2] = 1 beta[3,3,1,2] = 1 BG[10,3,2] = 1 X[5,2,2] = 2895 alpha[3,1,2] = 1 beta[5,5,2,2] = 1 FG[2,1,2] = 1 X[6,2,2] = 310 alpha[5,2,2] = 1 beta[10,10,3,2] = 1 FG[6,2,2] = 1 X[6,3,2] = 2313 alpha[5,3,2] = 1 gamma[3,2,1,2] = 1 FG[6,3,2] = 1 X[10,3,2] = 400 alpha[6,2,2] = 1 gamma[5,6,2,2] = 1 w[2,1,2] = 1 O[2,2] = 1849 alpha[6,3,2] = 1 gamma[10,6,3,2] = 1 w[3,1,2] = 1 O[3,2] = 5 alpha[7,2,2] = 1 delta[1,1,2] = 1 w[5,2,2] = 1 O[5,2] = 5 alpha[7,3,2] = 1 delta[2,2,2] = 1 w[6,2,2] = 1 O[6,2] = 477 alpha[8,2,2] = 1 delta[2,3,2] = 1 w[6,3,2] = 1 O[8,2] = 200 alpha[8,3,2] = 1 delta[3,3,2] = 1 w[10,3,2] = 1 O[11,2] = 400 alpha[10,3,2] = 1 BG[3,1,2] = 1 X[2,1,2] = 1151 O[12,2] = 500

alpha[11,3,2] = 1 BG[5,2,2] = 1 X[3,1,2] = 2295 --

求解結果

目標值 =106,832 (自製成本：45,804、外包成本 61,028)

；決策變數 = 1,120；限制式 = 17,369；求解時間 = 3.83 秒

A-3. 求解範圍(3,3)之完整規劃結果

t=3

alpha[1,2,3] = 1 beta[6,6,3,3] = 1 FG[2,2,3] = 1 X[5,2,3] = 14899 alpha[2,2,3] = 1 gamma[1,2,2,3] = 1 FG[7,3,3] = 1 X[6,2,3] = 7895 alpha[5,2,3] = 1 gamma[5,1,2,3] = 1 FG[11,1,3] = 1 X[6,3,3] = 9205 alpha[5,3,3] = 1 gamma[6,5,2,3] = 1 w[1,2,3] = 1 X[7,3,3] = 18499 alpha[6,2,3] = 1 gamma[6,8,3,3] = 1 w[2,2,3] = 1 X[8,3,3] = 8647 alpha[6,3,3] = 1 gamma[8,7,3,3] = 1 w[5,2,3] = 1 X[9,1,3] = 8200 alpha[7,2,3] = 1 gamma[9,10,1,3] = 1 w[6,2,3] = 1 X[10,1,3] = 8285 alpha[7,3,3] = 1 gamma[10,12,1,3] = 1 w[6,3,3] = 1 X[11,1,3] = 6500 alpha[8,2,3] = 1 gamma[12,11,1,3] = 1 w[7,3,3] = 1 X[12,1,3] = 12799 alpha[8,3,3] = 1 delta[1,2,3] = 1 w[8,3,3] = 1 O[4,3] = 10500 alpha[9,1,3] = 1 delta[2,2,3] = 1 w[9,1,3] = 1 O[5,3] = 1 alpha[10,1,3] = 1 delta[2,3,3] = 1 w[10,1,3] = 1 O[7,3] = 1 alpha[11,1,3] = 1 delta[3,1,3] = 1 w[11,1,3] = 1 O[8,3] = 1153 alpha[12,1,3] = 1 BG[6,2,3] = 1 w[12,1,3] = 1 O[10,3] = 3755 beta[1,9,1,3] = 1 BG[6,3,3] = 1 X[1,2,3] = 12900 O[12,3] = 1

beta[6,6,2,3] = 1 BG[9,1,3] = 1 X[2,2,3] = 2000 --

求解結果

目標值 =814,372 (自製成本：536,978、外包成本 277,394)

；決策變數 = 1,120；限制式 = 17,369；求解時間 = 4.78 秒

135

目標值 =814,384 (自製成本：536,988、外包成本 277,396)

；決策變數 = 1,144；限制式 = 17,431；求解時間 = 4.66 秒

目標值 =406,212 (自製成本：120,456、外包成本 136,782、未排入成本 148,974)

；決策變數 = 1,144；限制式 = 17,431；求解時間 = 4.73 秒

A-6. 求解範圍(4,4)之扣除未排入產品規劃結果

目標值 =257,238 (自製成本：120,456、外包成本 136,782)

；決策變數 = 1,144；限制式 = 17,431；求解時間 = 4.25 秒

目標值 =325,840 (自製成本：325,840)

；決策變數 = 1,144；限制式 = 17,431；求解時間 = 4.80 秒

137

A-9. Case6 求解範圍(4,5)之完整規劃結果

t=4

alpha[1,1,4] = 1 beta[1,5,2,4] = 1 BG[5,2,4] = 1 X[1,1,4] = 1319 alpha[2,1,4] = 1 beta[5,5,3,4] = 1 BG[5,3,4] = 1 X[2,1,4] = 4000 alpha[3,1,4] = 1 beta[10,2,1,4] = 1 FG[4,1,4] = 1 X[3,1,4] = 4980 alpha[4,1,4] = 1 gamma[1,3,1,4] = 1 FG[6,2,4] = 1 X[4,1,4] = 1700 alpha[5,2,4] = 1 gamma[2,1,1,4] = 1 FG[9,3,4] = 1 X[5,2,4] = 7246 alpha[5,3,4] = 1 gamma[3,4,1,4] = 1 w[1,1,4] = 1 X[5,3,4] = 54 alpha[6,2,4] = 1 gamma[5,6,2,4] = 1 w[2,1,4] = 1 X[6,2,4] = 5173 alpha[6,3,4] = 1 gamma[5,7,3,4] = 1 w[3,1,4] = 1 X[7,3,4] = 4900 alpha[7,2,4] = 1 gamma[7,11,3,4] = 1 w[4,1,4] = 1 X[9,3,4] = 4960 alpha[7,3,4] = 1 gamma[11,9,3,4] = 1 w[5,2,4] = 1 X[11,3,4] = 2900 alpha[8,2,4] = 1 delta[1,1,4] = 1 w[5,3,4] = 1 O[6,4] = 2327 alpha[8,3,4] = 1 delta[2,2,4] = 1 w[6,2,4] = 1 O[10,4] = 1000 alpha[9,3,4] = 1 delta[2,3,4] = 1 w[7,3,4] = 1 O[12,4] = 1300

alpha[10,3,4] = 1 delta[3,3,4] = 1 w[9,3,4] = 1 --

alpha[11,3,4] = 1 BG[2,1,4] = 1 w[11,3,4] = 1 --

t=5

alpha[1,1,5] = 1 alpha[12,3,5] = 1 delta[3,3,5] = 1 w[9,3,5] = 1 alpha[2,1,5] = 1 beta[4,4,1,5] = 1 BG[4,1,5] = 1 w[10,3,5] = 1 alpha[3,1,5] = 1 beta[6,6,2,5] = 1 BG[6,2,5] = 1 w[12,3,5] = 1 alpha[4,1,5] = 1 beta[9,9,3,5] = 1 BG[9,3,5] = 1 X[1,1,5] = 2981 alpha[5,2,5] = 1 gamma[1,2,1,5] = 1 FG[2,1,5] = 1 X[2,1,5] = 11550 alpha[5,3,5] = 1 gamma[3,1,1,5] = 1 FG[5,2,5] = 1 X[3,1,5] = 6270 alpha[6,2,5] = 1 gamma[4,3,1,5] = 1 FG[7,3,5] = 1 X[4,1,5] = 1100 alpha[6,3,5] = 1 gamma[6,5,2,5] = 1 w[1,1,5] = 1 X[5,2,5] = 9760 alpha[7,2,5] = 1 gamma[8,7,3,5] = 1 w[2,1,5] = 1 X[6,2,5] = 9520 alpha[7,3,5] = 1 gamma[9,10,3,5] = 1 w[3,1,5] = 1 X[7,3,5] = 5800 alpha[8,2,5] = 1 gamma[10,12,3,5] = 1 w[4,1,5] = 1 X[8,3,5] = 4700 alpha[8,3,5] = 1 gamma[12,8,3,5] = 1 w[5,2,5] = 1 X[9,3,5] = 3770 alpha[9,3,5] = 1 delta[1,1,5] = 1 w[6,2,5] = 1 X[10,3,5] = 2750 alpha[10,3,5] = 1 delta[2,2,5] = 1 w[7,3,5] = 1 X[12,3,5] = 5200

alpha[11,3,5] = 1 delta[2,3,5] = 1 w[8,3,5] = 1 --

求解結果

目標值 = 577,204 (自製成本：493,918、外包成本 83,286)

；決策變數 = 2,264；限制式 = 35,255；求解時間 =352.67 秒

139

A-10. 淡季情境：對

l=1

求解範圍(1,1)之完整規劃結果

t=1

alpha[1,2,1] = 1 alpha[10,1,1] = 1 BG[4,2,1] = 1 w[10,1,1] = 1 alpha[3,2,1] = 1 beta[0,4,2,1] = 1 BG[6,3,1] = 1 X[1,2,1] = 5300 alpha[4,2,1] = 1 beta[0,6,3,1] = 1 BG[9,1,1] = 1 X[3,2,1] = 4796 alpha[5,2,1] = 1 beta[0,9,1,1] = 1 FG[1,2,1] = 1 X[4,2,1] = 1000 alpha[5,3,1] = 1 gamma[3,1,2,1] = 1 FG[5,3,1] = 1 X[5,3,1] = 18000 alpha[6,2,1] = 1 gamma[4,3,2,1] = 1 FG[10,1,1] = 1 X[6,3,1] = 10500 alpha[6,3,1] = 1 gamma[6,5,3,1] = 1 w[1,2,1] = 1 X[9,1,1] = 6000 alpha[7,2,1] = 1 gamma[9,10,1,1] = 1 w[3,2,1] = 1 X[10,1,1] = 7500 alpha[7,3,1] = 1 delta[1,2,1] = 1 w[4,2,1] = 1 O[3,1] = 204 alpha[8,2,1] = 1 delta[2,2,1] = 1 w[5,3,1] = 1 O[11,1] = 4500

alpha[8,3,1] = 1 delta[2,3,1] = 1 w[6,3,1] = 1 --

alpha[9,1,1] = 1 delta[3,1,1] = 1 w[9,1,1] = 1 --

求解結果

目標值 =325,648 (自製成本：250,384、外包成本 75,264)

；決策變數 = 1,120；限制式 = 17,406；求解時間 =3.5 秒

A-11. 淡季情境：對

l=2

求解範圍(1,1)之完整規劃結果

t=1

alpha[1,2,1] = 1 beta[1,1,2,1] = 1 BG[1,2,1] = 1 w[11,1,1] = 1 alpha[2,2,1] = 1 beta[5,5,3,1] = 1 BG[5,3,1] = 1 w[12,1,1] = 1 alpha[4,2,1] = 1 beta[10,10,1,1] = 1 BG[10,1,1] = 1 X[1,2,1] = 4500 alpha[5,2,1] = 1 gamma[1,2,2,1] = 1 FG[6,3,1] = 1 X[2,2,1] = 4500 alpha[5,3,1] = 1 gamma[2,4,2,1] = 1 FG[7,2,1] = 1 X[4,2,1] = 2000 alpha[6,2,1] = 1 gamma[4,8,2,1] = 1 FG[11,1,1] = 1 X[5,3,1] = 18885 alpha[6,3,1] = 1 gamma[5,6,3,1] = 1 w[1,2,1] = 1 X[6,3,1] = 7500 alpha[7,2,1] = 1 gamma[8,7,2,1] = 1 w[2,2,1] = 1 X[7,2,1] = 6389 alpha[7,3,1] = 1 gamma[10,12,1,1] = 1 w[4,2,1] = 1 X[8,2,1] = 9300 alpha[8,2,1] = 1 gamma[12,11,1,1] = 1 w[5,3,1] = 1 X[10,1,1] = 5500 alpha[8,3,1] = 1 delta[1,2,1] = 1 w[6,3,1] = 1 X[11,1,1] = 4000 alpha[10,1,1] = 1 delta[2,2,1] = 1 w[7,2,1] = 1 X[12,1,1] = 5800 alpha[11,1,1] = 1 delta[2,3,1] = 1 w[8,2,1] = 1 O[5,1] = 1747 alpha[12,1,1] = 1 delta[3,1,1] = 1 w[10,1,1] = 1 O[7,1] = 3011

求解結果

目標值 =418,824 (自製成本：342,696、外包成本 76,128)

；決策變數 = 1,120；限制式 = 17,406；求解時間 =3.47 秒

A-12. 淡季情境：對

l=3 及 4

求解範圍(2,3)之完整規劃結果

t=2

alpha[1,2,2] = 1 alpha[11,1,2] = 1 delta[3,1,2] = 1 w[11,1,2] = 1 alpha[2,2,2] = 1 alpha[12,1,2] = 1 BG[6,3,2] = 1 w[12,1,2] = 1 alpha[3,2,2] = 1 beta[6,6,3,2] = 1 BG[7,2,2] = 1 X[2,2,2] = 3074 alpha[4,2,2] = 1 beta[7,7,2,2] = 1 BG[11,1,2] = 1 X[3,2,2] = 4080 alpha[5,2,2] = 1 beta[11,11,1,2] = 1 FG[2,2,2] = 1 X[4,2,2] = 1000 alpha[5,3,2] = 1 gamma[3,4,2,2] = 1 FG[8,3,2] = 1 X[6,3,2] = 7000 alpha[6,2,2] = 1 gamma[4,2,2,2] = 1 FG[9,1,2] = 1 X[7,2,2] = 5684 alpha[6,3,2] = 1 gamma[6,8,3,2] = 1 w[2,2,2] = 1 X[8,3,2] = 9805 alpha[7,2,2] = 1 gamma[7,3,2,2] = 1 w[3,2,2] = 1 X[9,1,2] = 9878 alpha[7,3,2] = 1 gamma[11,12,1,2] = 1 w[4,2,2] = 1 X[11,1,2] = 5700 alpha[8,2,2] = 1 gamma[12,9,1,2] = 1 w[6,3,2] = 1 X[12,1,2] = 3500 alpha[8,3,2] = 1 delta[1,2,2] = 1 w[7,2,2] = 1 O[7,2] = 3495

alpha[9,1,2] = 1 delta[2,2,2] = 1 w[8,3,2] = 1 --

alpha[10,1,2] = 1 delta[2,3,2] = 1 w[9,1,2] = 1 --

t=3

alpha[1,2,3] = 1 alpha[10,1,3] = 1 delta[3,1,3] = 1 w[10,1,3] = 1 alpha[2,2,3] = 1 alpha[12,1,3] = 1 BG[2,2,3] = 1 w[12,1,3] = 1 alpha[3,2,3] = 1 beta[2,2,2,3] = 1 BG[8,3,3] = 1 X[1,2,3] = 5000 alpha[4,2,3] = 1 beta[8,8,3,3] = 1 BG[10,1,3] = 1 X[2,2,3] = 1196 alpha[5,2,3] = 1 beta[9,10,1,3] = 1 FG[1,2,3] = 1 X[5,3,3] = 12000 alpha[5,3,3] = 1 gamma[2,1,2,3] = 1 FG[5,3,3] = 1 X[7,3,3] = 9321 alpha[6,2,3] = 1 gamma[7,5,3,3] = 1 FG[12,1,3] = 1 X[8,3,3] = 4194 alpha[6,3,3] = 1 gamma[8,7,3,3] = 1 w[1,2,3] = 1 X[10,1,3] = 8000 alpha[7,2,3] = 1 gamma[10,12,1,3] = 1 w[2,2,3] = 1 X[12,1,3] = 7000 alpha[7,3,3] = 1 delta[1,2,3] = 1 w[5,3,3] = 1 O[3,3] = 4420 alpha[8,2,3] = 1 delta[2,2,3] = 1 w[7,3,3] = 1 O[8,3] = 1 alpha[8,3,3] = 1 delta[2,3,3] = 1 w[8,3,3] = 1 O[9,3] = 622

求解結果

目標值 = 611,876 (自製成本：475,266、外包成本 136,610)

；決策變數 = 2,240；限制式 = 35,148；求解時間 =134.41 秒

在文檔中彩色濾光片內製廠之主生產排程建構機制之設計 (頁 143-156)