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研究生: 王祥安
Wang, Hsiang-An
論文名稱: 利用線性規劃法求解LCD光學膜切割問題
A Study on Solving Cutting Stock Problem for Optical Films of LCD
指導教授: 黃宇翔
Huang, Yeu-Shiang
學位類別: 碩士
Master
系所名稱: 管理學院 - 工業與資訊管理學系碩士在職專班
Department of Industrial and Information Management (on the job class)
論文出版年: 2011
畢業學年度: 99
語文別: 中文
論文頁數: 52
中文關鍵詞: 平面切割問題數學規劃法角度限制材料成本
外文關鍵詞: Cutting Stock Problem, Mathematical method, Bias, Cost
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  • 切割問題廣泛的存在各種產業之中,一維切割問題如鋼筋、水管、電纜…等,二維切割問題如木板、玻璃、紙、液晶面板、薄膜…等,三維切割問題如鑽石切割,只要解決切割問題,就可以在既有的設備生產條件下,得到較佳的原物料利用率。平面切割的配置策略與成本競爭力有絕對的關聯性,若無法以較好的切割配置來得到較高的材料利用率,就會直接影響到生產成本,使得製造商在獲利能力與價格競爭力上受到影響。
    本研究以最低成本的概念考量製程中的原料成本、加工成本及報廢成本,發展有角度光學膜片兩階段切割模式,並以線性規劃的方法建構數學模型,使用 Lingo 做為求解的工具軟體,最後將研究結果與膜片切割廠歷史數據比對驗證。本研究提出的規劃法相較於切割廠所使用的固定角度分配法,原料成本降低了3.1%,加工成本降低了3.6%,而廢料成本下降了78.5%,總成本共降低了6.2%,成本減少主要因素在於材料利用率的提高,降低了母材的使用量及報廢成本,加工成本也因為加工面積的減少而得到節省。

    Cutting problems exist in every industries, such as bars, pipes, cables for One-dimensional, wood, glass, paper, liquid crystal panels, film for two-dimensional and diamond for three-dimensional cutting problems. It is beneficial that existing equipments can be used to obtain better raw material yields if cutting problems can be appropriately solved. Cutting allocation strategy and cost competitiveness are absolutely correlated which results in the fact that if an allocation strategy can not achieve a higher yield, then the production cost and price competitiveness would be negatively affected.
    The purpose of this paper is to construct a two-stage cutting pattern using linear programming for optical films. Lingo software is used to solve this problem. The results of this study and those using actual data in factory are compared for verification. This study suggests a strategical direction and provides an approach to improve the yield of cutting material and reduce the production cost. The results of the proposed cost-oriented planning is better than the fix-angle planning which can reduce 6.2% of the total cost comparing to the original allocation method. The improvement of material yield is a major contribution of cost reduction which is based on the considerations of material usage and scrap costs.

    第一章 緒論 1 第一節 研究背景 1 第二節 研究動機 2 第三節 研究目的 2 第四節 研究流程 3 第五節 論文架構 4 第二章 文獻探討 5 第一節 切割問題相關文獻 5 第二節 平面切割策略分析 8 第三節 切割問題最佳化方法 10 第三章 光學膜片切割問題描述與模式建構 12 第一節 光學膜切割製程 12 一、檢驗、貼膜及包裝 14 二、分條 15 三、斜切 16 四、模切 18 第二節 問題描述 19 一、問題參數 21 二、二元變數 22 三、分條 22 四、斜切 23 第三節 問題架構及限制 24 第四節 光學膜片切割問題數學模式建構 25 第四章 實例驗證 31 第一節 光學膜片切割實際案例介紹 31 第二節 規劃結果與成效 34 第三節 敏感度分析 37 一、母材寬度 38 二、材料價格 39 三、加工成本 40 四、斜切效率 42 五、片進料模切效率 43 六、綜合敏感度分析 44 第五章 研究貢獻、限制與未來方向 46 第一節 研究貢獻 46 第二節 研究限制與未來方向 47 參考文獻 49

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