本研究以TFT-LCD產業的Array廠為例，探討如何應用FlexSim離散事件模擬軟體實現數位工廠，提升生產效率與產能運用。隨著市場需求趨於多樣化，競爭日益激烈，個案廠自傳統TFT-LCD生產線轉型專注於電子紙顯示器(Electronic Paper Display, EPD)的製造。然而，由於電子紙顯示器的製程較為複雜，生產週期較TFT-LCD延長1.5至3倍，影響整體生產效率。
為解決此問題，個案擬導入新製程，透過減少黃光製程的PEP數(曝光次數)，以提升生產效率並降低碳排放，達成永續發展目標。研究運用FlexSim模擬軟體建構數位工廠模型，依據實際生產參數模擬不同產品類別的生產場景，並以現況與三種設計情境分析新製程導入對整體產能的影響。結果顯示，新製程可顯著提升黃光製程的產能，但在部分情境下，產能瓶頸轉移至乾蝕刻製程，進一步限制了整體產能提升幅度。
研究結果顯示，透過調整產品配置基準、精進製程參數及設備投資規劃，可逐步解決瓶頸轉移問題，並提高生產效率。同時，亦證明FlexSim軟體作為數位工廠工具的有效性，不僅可模擬實際生產情境，還能作為企業進行生產決策與產能管理的重要輔助工具。本研究成果可提供TFT-LCD及電子紙顯示器等產業在數位工廠轉型方面之參考，進一步推動製造業向智慧化與高效能生產邁進。

This study investigates the application of FlexSim discrete event simulation software to implement a digital factory and optimize production processes and capacity utilization, using the TFT-LCD industry's Array Fab as a case study. As market demand diversifies and competition intensifies, the case factory transitioned from traditional TFT-LCD manufacturing to electronic paper display (EPD) production. However, due to the complexity of the EPD manufacturing process, the production cycle was extended by 1.5 to 3 times compared to TFT-LCD, with the photolithography process (exposure machines) becoming a major bottleneck that constrained overall production efficiency.
To address this issue, a new process was introduced to reduce the number of photolithography exposure steps (PEP count), thereby improving production efficiency and reducing carbon emissions to achieve sustainability goals. This study utilized FlexSim to construct a digital factory model, simulating various production scenarios based on real-world parameters and analyzing four different conditions to evaluate the impact of the new process on overall capacity. The results demonstrated that the new process significantly improved the capacity of the photolithography stage; however, in certain scenarios, the bottleneck shifted to the dry etching process, further limiting overall capacity improvements.
Findings indicate that optimizing product configurations, refining process parameters, and strategically planning equipment investments can help mitigate bottleneck shifts and enhance production efficiency. This study confirms the effectiveness of FlexSim as a digital factory tool, capable of not only simulating real production scenarios but also serving as a valuable decision-making and capacity management aid for enterprises. The research findings provide insights for the TFT-LCD and EPD industries in their digital transformation efforts, contributing to the advancement of smart and high-efficiency manufacturing.

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