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研究生: 吳立民
ChrisWu
論文名稱: 液晶注入之批次加工機台排程
The Scheduling of Batch Processing Machines of the Liquid Crystal Injection Process
指導教授: 洪一峰教授
Dr.Hung Yi-Feng
口試委員:
學位類別: 碩士
Master
系所名稱: 工學院 - 工業工程與工程管理學系
Department of Industrial Engineering and Engineering Management
論文出版年: 2004
畢業學年度: 92
語文別: 中文
論文頁數: 85
中文關鍵詞: 液晶顯示器批次加工機台隨機塔布搜尋法模擬退火法
外文關鍵詞: liquid crystal display, batch processing machine, stochastic tabu search, simulated annealing
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  • 「批次加工機台」在許多製造環境中扮演著相當重要的角色,例如液晶顯示器產業的液晶注入(liquid crystal injection)製程工作站中,是由許多相同的平行批次機台所組成,一部機台能同時加工某特定數目的面板。我們主要的排程問題是在含生產順序相關的裝設時間條件下,求得「批量在等候線中的期望延遲時間」及「批次機台的產能利用率」兩者之間的平衡。
    機台換線生產時需要很長的裝設時間,若能儘量減少機台換線的次數並增加加工的批次數,就可獲得更高的機台產能利用率。在此兩難下,本論文所設定的目標為最小化總成本。依照Weng and Leachman【1993】所提出「未來到達資訊」的觀念,我們可以利用到達批量時點的預測,做出是否值得立即載入生產的決策。生產決策是由存貨成本、欠貨成本及裝設成本加總的總成本函數來衡量決定。
    我們利用隨機塔布搜尋法(stochastic tabu <a href="http://www.ntsearch.com/search.php?q=search&v=56">search</a>, STS)及模擬退火法(simulated annealing, SA)求解此排程問題。最後,為了驗證求解品質並評估效能,我們進行實驗設計來比較兩種方法。結果顯示,隨機塔布搜尋法在最終求解品質的表現上優於模擬退火法;但在初期運算時間的表現上則劣於模擬退火法。


    Batch processing machine plays an important role in many manufacturing environments. For example, the workstation in the liquid crystal injecton(LC injection) process in LCD manufacturing consists of identical parallel batch processoing machines. Each machine can process a certain number of panels simultaneously. The objective of this scheduling problem is to balance “the expected delay of lots in queue” and “the capacity utilization of batch machines” under the constraints of sequence dependent setup times.
    Machines require different setups. That the less times the machines spend on setups and the larger batch sizes are processed can improve machine utilization. Therefore, to balance the trade-off, we set the objective of the problem is to minimize the total costs. By utilizing “the future arrivals information” as proposed by Weng and Leachman【1993】, we use the arrival <a href="http://www.ntsearch.com/search.php?q=time&v=56">time</a> prediction and make decisions whether we should start a batch or wait. The quality of production decision can be measured by a cost function that is the sum of inventory costs, backorder costs, and setup costs.
    Two heuristic <a href="http://www.ntsearch.com/search.php?q=search&v=56">search</a> algorithms, stochastic tabu <a href="http://www.ntsearch.com/search.php?q=search&v=56">search</a> (STS) and simulated annealing (SA), are used to solove the schedule problem. Finally, to validate the quality and to evaluate the speed of the two algorithms, extensive experiments were performed. The result shows that STS is better than SA in terms of the quality of final solutions, but STS is worse than SA at the early state of computation.

    目錄 第一章 緒論 ……………………….……….…………………………………...1 1.1 研究背景與動機 ……………..…………………………………….….1 1.2 研究目的 …..……………………………………………………….….4 1.3 研究範圍與特性 …..…………………………………………………..5 1.4 研究架構與流程 ……..………...……………………………….……..9 第二章 文獻回顧與探討 ……..…..……………………………………...…..10 2.1 液晶發展史 ……………………………………………………...…10 2.1.1 液晶的性質與分類 .…..….…………………………………….10 2.1.2 液晶的光電效應與顯像原理 …..……..……………………….11 2.1.3 總結 ……..…………………..………..………………………...13 2.2 TFT-LCD製程簡介 ………..…….…………………………………14 2.2.1 薄膜電晶體陣列製程(TFT Array) ….…………..……………...14 2.2.2 液晶顯示器面板組裝製程(LCD cell assembly) …………..…...18 2.2.3 液晶顯示器模組組裝製程(LCD module assembly) …………...22 2.2.4 總結 ……..…………………..………..………………………...23 2.3 彩色濾光片製程簡介 ……….…….…………………………………25 2.3.1 彩色濾光片製造方法 .…..….………………………………….25 2.3.2 彩色濾光片製造流程 .…..….……………………………….....26 2.4 結語 ……….…….……………………………………………………29 2.5 文獻回顧 ……….…….………………………………………………32 2.5.1 批量服務等候線系統(bulk service queueing systems)問題 …..32 2.5.2 批量排程問題 …..……..………………………….….….……..33 第三章 方法建構 …..…………...……………...………………….….……….38 3.1 問題定義及假設 ……….……………………….……………………38 3.2 問題的初始模型分析 ……………………..…………...……….……39 3.2.1 模型的理論依據 .…..….…………………………………….....39 3.2.2 起始解的建構 .…..….…………………………………..……...40 3.3 隨機塔布搜尋法求解平行批次機台生產模式的方法建構 ..……..43 3.3.1 前言 .…..….……………………………………..……………...43 3.3.2 基本元素設定 .…..….…………………………………..……...44 3.3.3 隨機塔布搜尋法之演算步驟 .…..…….……………………….47 3.4 模擬退火法求解平行批次機台生產模式的方法建構 …………….49 3.4.1 前言 .…..….……………………………………..……………...49 3.4.2 基本元素設定 .…..….…………………………………..……...50 3.4.3 模擬退火法之演算步驟 .…..…….……………………..……...52 3.5 計算總成本函數的方法建構 ………………………………………..54 3.6 求解流程架構 …………………………………………………….….60 第四章 實驗設計的方法與結果分析 ……..…..………………………....62 4.1 實驗問題設定與環境說明 ……………..……………..……….........62 4.1.1 實驗的問題設定 .…..…….……………………..……………...62 4.1.2 實驗的環境說明 .…..…….……………………..….……...…...63 4.2 問題參數設計 …………………………..…………..………….…....64 4.2.1 鄰近解的產生方式 .…..…….……………………..…….……..64 4.2.2 模擬退火法的參數設定 .…..…….……………………..……...65 4.2.3 隨機塔布搜尋法的參數設定 .…..…….……………..………...66 4.2.3.1 參數設計實驗的問題設定 .…..…….……………..…… 66 4.2.3.2 參數設計實驗的結果分析 .…..…….……………..…… 67 4.3 多因子混合模型分析 …………………..……………..……………..69 4.3.1 實驗的問題設定 .…..…….……………………..……………...69 4.3.2 對解改善幅度的因子分析實驗結果 .…..…….……...………..72 4.3.3 對演算法效能比較的因子分析實驗結果 .…..…….………….76 4.4 實驗結論 ….……………………………..……………..…………….78 第五章 結論與未來研究建議 …..…………...……………...……………...79 參考文獻 ……………………………………………………………….……….81 圖目錄 圖1-1 平面顯示器分類 ……...…….…………..……………..……………….2 圖1-2 液晶注入製程生產特性圖 ……………..……………………………...6 圖1-3 研究架構流程圖 …………..…………..……………………………….8 圖1-4 研究架構流程圖 …………..…………..……………………………….9 圖2-1 液晶分子配列的基本結構 ………..…....…………………………….11 圖2-2 未加電場前的TN效應動作原理 ……..….…….……………………12 圖2-3 施加電場後的TN效應動作原理 ...………...………………………..12 圖2-4 TFT-LCD顯像原理 …….…………….………………………...….....13 圖2-5 TFT-LCD組裝剖面圖 …….…………….……………………...….....14 圖2-6 薄膜電晶體陣列製程 …………..….……..…………………………..17 圖2-7 間隔材結構圖 …………..….……..…………………………………..19 圖2-8 液晶顯示器面板組裝製程 ……………………………..…………….21 圖2-9 液晶顯示器模組組裝製程 ….………………………………………..24 圖2-10 顏料分散法 ………………………………………..………………...26 圖2-11 彩色濾光片結構 ………..……………………………………….......27 圖2-12 彩色濾光片製造流程 ……………………...………………………..28 圖2-13 非晶矽TFT-LCD的製造流程 ………..…………………………....31 圖2-14 DBH的控制策略 ………………..…………………………….....…35 圖3-1 起始解之生產模式示意圖 …..…………………………………….....43 圖3-2 取代鄰近解示意圖 …………………………..……………………….44 圖3-3 刪除鄰近解示意圖 …………………………..……………………….45 圖3-4 插入鄰近解示意圖 …………………………..……………………….46 圖3-5 隨機塔布搜尋法流程圖 …………………………..………………….48 圖3-6 模擬退火法跳出局部最佳解示意圖 …………………………...……50 圖3-7 模擬退火法流程圖 …………………………..……………………….53 圖3-8 存欠貨數量時間示意圖 ……………………………………...………55 圖3-9 兩轉折時點的三種不同存欠貨狀態示意圖 …………...……………56 圖3-10 兩種啟發式演算法的流程架構圖 .…………………………………61 圖4-1 實驗設計(2)-問題大小 vs. 改善幅度分析圖 ……………………..73 圖4-2 實驗設計(2)-產能/需求比例 vs. 改善幅度分析圖 …………..…74 圖4-3 實驗設計(2)-到達量與需求量變異vs. 改善幅度分析圖 ……...…75 圖4-4 實驗設計(2)-演算法vs. 改善幅度分析圖 ………………………...76 圖4-5 演算法效能比較趨勢圖 ………..……………..……………………...77 表目錄 表4-1 實驗設計(1)-實驗因子水準設計值 ……...………………….…….67 表4-2 實驗設計(1)-參數實驗的因子檢定分析表 ...………………...…...68 表4-3 實驗設計(1)-鄰近解集合數的Duncan’s Test分析表 ………….68 表4-4 實驗設計(2)-實驗因子水準設計值 ………………………..….…..70 表4-5 實驗設計(2)-總成本改善幅度實驗的多因子檢定分析表 …..…...72 表4-6 實驗設計(2)-問題大小的Duncan’s Test分析表 ………………..73 表4-7 實驗設計(2)-產能/需求比例的Duncan’s Test分析表 ………..74 表4-8 實驗設計(2)-到達量與需求量變異的Duncan’s Test分析表 .….75

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