薄膜電晶體液晶顯示器已廣泛應用於日常生活中的電子商品。所有面板製造商都在盡一切努力生產高品質的產品以增加市佔率與營業額。在這項研究中，本研究提出了一個整合六標準差與萃思的改善架構。此架構可適用於各種改善專案和新產品開發專案的相關問題之解決。本研究使用兩個實際案例來說明所提出架構之有效性。案例一是運用一簡單的問題解決的程序，透過歷史數據的分析與TRIZ的質場分析提出了最創新的優化改善計劃；結果顯示，彩色濾光片製程的良率得到了提升，並節省了370多萬美元。案例二是應用DFSS來提高LCD轉換為IPS面板的高對比度，經由品質工具和TRIZ之分析提出改善方案，LCD面板的超高對比度可提高到1000000：1，改善的效益超過了950萬美元，這也推動了TFT IPS LCD的市場訂單。

TFT-LCD has been widely applied to electronic merchandises in daily lives. All panel makers are trying everything possible to produce high quality products to fight for market share. In this study, we propose a continual improvement framework with integration of Six Sigma and TRIZ. This framework can be applied to address issues related to various improvement projects and new product development projects. Two cases are shown to demonstrate the effectiveness of the proposed framework. Case 1 utilized a simple problem-solving procedure , through the analysis of historical data and TRIZ's substance-field analysis to propose the most innovative optimization and improvement plan; implementation results show that the Color Filter process yield has been improved, and saved more than $3.7 million. Case 2 involved applying the DFSS methodology to improve the high contrast ratio of an LCD in-plane switching (IPS) panel, through the quality tool and TRIZ analysis. With the proposed improvement solution, LCD panel high contrast can be increased to 1000000:1 and the benefits of the improvement exceeded $9.5 million. This has also driven market orders for TFT IPS LCDs.

摘要 i
ABSTRACT ii
誌 謝 iii
TABLES vi
FIGURES viii
1 INTRODUCTION 1
1.1 Overview and Motivations 1
1.2 Objectives 3
1.3 Organization 3
2 RELATED WORKS 4
2.1 LCD 4
2.2 OLED AND IPS LCD 5
2.3 Color filter 7
2.4 Six Sigma 9
2.4.1 Define phase 9
2.4.2 Measure phase 10
2.4.3 Analyze phase 10
2.4.4 Improve phase 10
2.4.5 Control phase 11
2.5 DFSS 11
2.6 QFD 13
2.7 TRIZ 14
2.8 Taguchi Methods 17
3 PROPOSED APPROACH 21
3.1 Proposed framework 21
3.2 Problem solving procedure for Kaizen projects 24
3.3 DFSS methodology: DMADV 24
4 CASE STUDY: YIELD IMPROVEMENT IN COLOR FILTER MANUFACTURING 28
4.1 The Problem 28
4.2 Implementation 28
4.2.1 Identify the crucial factors that cause the occurrence of defect 28
4.2.2 Improve the process 31
4.2.3 Confirm and maintain the process 42
4.3 Summary 45
5 CASE STUDY: TFT-LCD CONTRAST RATIO IMPROVEMENT 46
5.1 The Problem 46
5.2 DMADV Implementation 47
5.2.1 Define Phase 47
5.2.2 Measure Phase 48
5.2.3 Analyze Phase 51
5.2.4 Design Phase 54
5.2.5 Verify Phase 57
5.3 Evaluation of the Effectiveness of Improvement and Performance Benefits 63
6 CONCLUSIONS 64
6.1 Summary 64
6.2 Future Research 65
REFERENCES 66

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