訂單滿足流程與可允諾量分配模式-以TFT-LCD產業為例
摘要
Due to technology changes, the demands in the consumer electronics industry keep expanding, particularly in the Thin Film Transistor Liquid Crystal Display (TFT-LCD) panel industry. A firm may own several parallel production lines in different areas, where lines can not completely backup each other due to different technology levels. The manufacturing processes of TFT-LCD can be divided into three stages Array, Cell and Module. The production in Array and Cell is triggered by pre-defined production schedule because of their complicated production steps and long production lead time. Module begins to assemble panel and other components according to actual orders (assembly-to-order, ATO). In addition, we consider the transportation between different production stages because Module factories are usually built in areas with lower labor cost. The order fulfillment and available-to-promise (ATP) problems in TFT-LCD manufacturing are more complicated than other industries because of “alternative Bill of Material (BOM)” and “grade transformation” of final products. Alternative BOM means that one product may have several BOMs due to different raw materials from suppliers. Grade transformation causes the upgrade or downgrade of final products because of the alternative BOMs or different process capability. In this paper, a mixed integer linear programming model is developed for order fulfillment and ATP problems. This model considers customized BOMs, grades, and other realistic constrains. We conclude this paper with sensitivity analysis and the performance impacts of different ATP rules.