Capacity and Product Mix Planning Problem for TFT Array Multi-Plant

TFT Array多廠區之產能與產品組合規劃問題

10.29977/JCIIE.200711.0006

林則孟(James T. Lin)；陳子立(Tzu-Li Chen)；陳韋均(Wei-June Chen)

產品組合規劃 ； 產能規劃 ； 薄膜液晶顯示器 ； 多廠區規劃 ； product mix planning ； capacity planning ； TFT-LCD ； TFT Array ； multi-plant planning

工業工程學刊

24卷6期（2007 / 11 / 01）

489 - 504

英文

本研究針對薄膜液晶顯示器(TFT-LCD)面板業之策略層次的產能與產品組合規劃問題進行探討，提出一適用於目前TFT陣列(Array)多廠區的產能與產品組合規劃之決策模式，以解決目前業界所面臨之問題。TFT Array多廠區之產能與產品組合規劃問題，主要是根據各產品族的需求預測，考量各產品族於不同世代廠區生產的材料利用率、各世代廠區的產能與生產能力限制、生產變動成本、存貨驅動成本等，以最大化邊際貢獻(contribution margin)爲目標，決定TFT Array各世代廠區最適合生產的產品族集合，與各產品族於各世代廠區之生產數量。當供給產能與需求預測有差異時，將供給產能與需求預測進行平衡，若供給產能小於需求預測時，評估是否需要擴充各世代廠區之設備，以增加供給產能水準；若供給產能大於需求預測時，則必須有效利用已投資之廠區設備，決定投入生產的供給產能水準，以最小化產能損失成本。本研究針對TFT Array多廠區之產能與產品組合規劃問題，提出三階段之規劃方法論：(1)階段一：產能與產品組合分配，將需求預測與供給產能作最佳化的組合分配，以達到最大邊際貢獻；(2)階段二：產能擴充，當需求預測大於供給產能時，評估是否可擴充產能以滿足最大化需求；(3)階段三：產能填補，當各廠區仍有剩餘產能時，則建議額外投入之產品族與投入數量，以降低產能損失成本，創造最大化之利益。

This research focuses on the strategic capacity and product mix planning problems in Thin Film Transistor Liquid Crystal Display (TFT-LCD) Panel Industry. A capacity and product mix planning decision model for TFT Array multi-plant is proposed according to TFT-LCD panel industry environment. Capacity and product mix planning problems for TFT Array multi-plant are resource allocation problems. Product mix and production quantity for each product group produced in a specific plant are decided on capacity and product mix planning. In the planning, the objective is maximum contribution margin. And, we consider many constraints to obtain the capacity and product mix plan, such as material utilization, production capacity, production capability, production variable costs, and inventory-driven costs for each product group produced in a specific plant. Furthermore, we use capacity and product mix planning to balanced the difference between total supply capacity and total demand forecast. If total supply capacity is smaller than total demand forecast, we evaluate the feasibility to expand production capacity. On the other hand, we suggest increasing production quantity in over-supply plant. We propose a methodology to solve capacity and product mix planning problems for TFT Array multi-plant. There are three phases in the methodology, including (1) capacity configuration, (2) capacity expansion, and (3) capacity exploitation. In the first phase, we allocate production capacity in each plant to produce a suit product mix set. If demand forecast is greater than supply capacity for a specific product group, we evaluate the feasibility to expand production capacity in the second phase. In the third phase, we suggest best additional production quantity of the profitable product group to exploit the remained capacity adequately.

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