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作者(中文):洪子晏
作者(外文):Hong, Tzu-Yen
論文名稱(中文):工業3.5之智慧製造系統-以TFT-LCD陣列製造動態排程與派工為實證研究
論文名稱(外文):Smart Manufacturing System Based on Industry 3.5 – The Empirical Study of TFT-LCD Array Dynamic Scheduling and Dispatching
指導教授(中文):簡禎富
指導教授(外文):Chien, Chen-Fu
口試委員(中文):王孔政
莊寶鵰
郭財吉
張國浩
褚志鵬
口試委員(外文):Wang, Kung-Jeng
Chuang, Pao-Tiao
Kuo, Tsai-Chi
Chang, Kuo-Hao
Chu, Chih-Peng
學位類別:博士
校院名稱:國立清華大學
系所名稱:工業工程與工程管理學系
學號:103034804
出版年(民國):108
畢業學年度:107
語文別:英文
論文頁數:108
中文關鍵詞:智慧製造系統模擬基因演算法TFT-LCD陣列製造動態排程問題
外文關鍵詞:smart manufacturingsystem simulationgenetic algorithmTFT-LCD array manufacturingdynamic scheduling problem
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自德國提出工業4.0提出後,智能製造已成為全世界重要的議題。諸如美國、中國皆提出先進製造夥伴2.0、中國製造2025等國家型計畫以因應智慧製造之發展。然而,台灣及其他新興國家的產業結構與德國或美國等領先國家不同,產業的升級與相關政策的推動亦需要長期累積,智慧製造的發展並未能一步到位,因此如何結合工業3.0自動化之基礎、製造管理的經驗、以及生產製造現場調度能力發展智慧製造,並逐步往工業4.0邁進,是對於台灣等新興國家關鍵的問題。
本研究提出基於工業3.5的智慧製造系統架構,旨在提出可於目前製造環境下發展智慧製造之藍圖。本架構整合製造端資訊,藉以串連製造子系統、資料庫以及相關支援技術。根據本研究提出之架構,產線可逐步由自動化邁向彈性決策支援,並最終升級為工業4.0之智慧工廠。
本研究以薄膜液晶顯示器之陣列製造動態排程為實證研究。作者提出以模擬為基準的動態排程與派工模型求解陣列製造排程。研究結果顯示,本研究提出之混合基因演算法可有效減少瓶頸站點之產能損失,同時可降低因工件延誤所造成的缺陷及報廢。此外,陣列廠之生產績效如延誤工件數量及總延誤時間,亦能藉由於非瓶頸站點導入組合派工法則而有效改善。本研究發展之模型亦能導入實際產線中,並嵌入其決策支援系統。
Smart manufacturing has become a crucial issue since the propose of Industry 4.0 by Germany. Similar proposals, including the Advanced Manufacturing Partnership 2.0 (AMP2.0) by the United States and Made in China 2025, are also national plans to achieve the smart manufacturing. There are many developed or developing countries also try to step into the field of smart manufacturing. However, most of the emerging countries may not be ready for the migration of Industry 4.0 directly since their industrial infrastructures are different from that of the leading countries. It is crucial to have a transitional plan to make up the gap and maintain competiveness in the transitional stage between Industry 3.0 and to-be Industry 4.0. This study proposes a framework of smart manufacturing system based on Industry 3.5, which aims to achieve smart manufacturing under the existing environments. The framework is constructed by three subsystems, database, supporting technologies, as well as the integration of information. Based on the proposed framework, it provides a blueprint from the existing manufacturing systems towards the smart factory.
An empirical study was conducted at a leading TFT-LCD company. This study proposed a simulation-based dynamic scheduling and dispatching model for TFT-LCD array manufacturing. Results show that the capacity loss of bottleneck workstation and delivery tardiness can be significantly improved by the proposed hybrid genetic algorithm (HGA). Besides, the overall array performances, such as mean value of tardy jobs and total tardiness, can be improved by employing combinatorial dispatching rules at non-bottleneck workstations. Finally, this model can be embedded in the practical production lines to support the decisions of practical manufacturing systems.
Table of Contents vi
List of Figures ix
List of Tables xii
List of Abbreviations xiv
Nomenclature xv
Chapter 1 Introduction 1
1.1 Background 1
1.2 Motivation 3
1.3 Research aims 5
1.4 Dissertation organization 6
Chapter 2 Literature review 7
2.1 Manufacturing strategies 7
2.1.1 Evolution of manufacturing system 7
2.1.2 Industry 4.0 9
2.1.3 Industry 3.5 13
2.1.4 Smart factory 15
2.2 Scheduling problems 18
2.2.1 Classification of scheduling problem 18
2.2.2 TFT-LCD scheduling problem 21
2.3 Methodologies for scheduling problem 23
2.3.1 Dispatching rules 23
2.3.2 Mathematical models 24
2.3.3 Meta-heuristics 25
2.3.4 Discrete-event simulation 27
Chapter 3 The framework of smart manufacturing system for Industry 3.5
29
3.1 Research framework 29
3.2 Simulation-based smart manufacturing system 32
3.2.2 Production planning system 34
3.2.3 Dynamic scheduling and dispatching system 36
3.2.4 Control and monitoring system 39
Chapter 4 TFT-LCD array photolithography stages scheduling problem 41
4.1 Problem structuring 41
4.1.1 Limited waiting time constraints 42
4.1.2 Scheduling period 42
4.1.3 Photo mask availability 42
4.1.4 Photo mask transportation time 43
4.1.5 Available machines with different processing for jobs 43
4.1.6 Different arrival time of jobs 43
4.2 Problem formulation 44
4.3 Simulation-based photo stages scheduling model 49
4.3.1. Chromosome representation and initialization 52
4.3.2. Decoding and evaluation 53
4.3.3. Crossover, mutation and selection 55
4.3.4. Local search 57
4.3.5. Randomized local search 57
4.4 Experimental design 58
4.4.1 Small cases 58
4.4.2 Practical experiments 59
4.5 Validation 61
4.5.2 Result of small cases 62
4.5.3 Result of practical experiments 63
4.6 Discussion 69
Chapter 5 TFT-LCD array photolithography stages scheduling problem 72
5.1 Problem background 72
5.2 Dispatching decision for simulation-based DSDS 74
5.2.2 Candidate dispatching rules 76
5.2.3 Min-max normalization and performance evaluation 78
5.2.4 TOPSIS 79
5.3 Empirical experiments 81
5.3.1 Identifying critical workstations and reducing candidate rules
81
5.3.2 Results of experiments 86
5.4 Discussion 91
Chapter 6 Conclusions 94
References 98
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