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系統識別號 U0026-0508201710142400
論文名稱(中文) 以部分因子實驗設計提升車用面板網版印刷製程能力之研究
論文名稱(英文) A Study on Using Fractional Factorial Experimental Design for Improvement of Automotive Panels Printing Processes
校院名稱 成功大學
系所名稱(中) 工業與資訊管理學系碩士在職專班
系所名稱(英) Department of Industrial and Information Management (on the job class)
學年度 105
學期 2
出版年 106
研究生(中文) 莊辰昱
研究生(英文) Chen-Yu Chuang
學號 R37031257
學位類別 碩士
語文別 中文
論文頁數 50頁
口試委員 指導教授-黃宇翔
口試委員-王惠嘉
口試委員-翁慈宗
口試委員-黃仲正
中文關鍵字 車用面板  網版印刷製程  因子實驗設計  反應曲面法 
英文關鍵字 Car Panel  Screen Printing Process  Fractional Factorial Experimental Design  Response Surface Methodology 
學科別分類
中文摘要   面板產業長久以來為台灣重點發展產業,但歷經數次景氣循環與財務不佳的衝擊,加上對岸紅色供應鏈之崛起,原有之市場競爭更加激烈,勢必要另尋新市場來解決產能過剩之問題。因應時代趨勢,面板在智慧生活產品上應用甚多,其中在車用市場方面成為各家面板廠商必爭之地。目前車用面板黑色邊框之製造,以網版印刷製程進行生產,品質依賴工程師的經驗將機台參數與製程條件進行優化,但車用市場規範嚴苛,原有製程能力已無法滿足客戶需求,如何有效提升車用面板網版印刷製程能力成為新課題。
  本研究之目的在於使用一套實驗設計方法改善車用面板網版印刷製程能力,藉此降低現行黑色邊框內緣油墨溢墨問題,透過假設檢定與部分因子實驗篩檢出顯著因子,並以反應曲面法討論出參數最佳值。其研究流程可作為相關產業人員日後在新產品導入初期製程條件評估使用,研究結果也可作為車用面版、觸控面板網版印刷人員在遇到類似問題時參數調整的依據。過去在網版印刷製程能力提升上,多採用二到三組因子進行小範圍的討論,且沒有考慮到製程原料之影響,並無全面性的探討,且研究過程所使用機台多為手動機台,對於參數值的穩定性上有待提升,對照現況,網印製程使用自動機台進行生產,且取得廠商提供多款原料,進行更全面性的討論。
  由實驗結果可知,因應製程變更所改良後的油墨種類Type γ有最顯著作用,搭配刮刀速度100 mm/sec、刮刀印壓20kg、刮刀下壓量0.2mm,會有最佳的溢墨反應值92.64 μm,並進行印刷測試證實經驗模型優於原生產參數。 將該參數應用在實際生產後,達到降低擦版頻度33%、產量提升46.7%、不良率下降0.3% 的成效,另外研究方法也可作為日後產品製程改善之參考,藉此提升公司競爭力。
英文摘要 The panel industry has been indispensable in the rapid development of information technology for nearly 20 years. In considering the increasing competition, firms have to deal with production capacity, supply and demand imbalance, and price competition. The emergence of consumer electronic products enhances the panel applications, especially in the automotive panel market, such as central navigation systems and digital dashboards. However, the panel industry encounter challenges of changes in production processes to enhance product quality and correspond to diverse consumer segments, and thus how to improve the process capacity to enhance business competitiveness becomes a critical issue. This study investigates a screen printing process for a high-tech factory, in which the factory mainly produces automotive panel products but encounters the problem of inner edge overflow ink after printing due to changes in the production process. Thus, this study uses the fractional factorial experimental design and response surface methodology to obtain the theoretical model and optimal solutions for the related parameters and improve the problem of inner edge overflow ink. This study considers all related factors that may affect the printing process based on the current condition. In considering costs and machine capacity, we firstly select the factors that result in overflow ink and use the fractional factorial experimental design to investigate the effects that the main factor and other related factors have on the reaction values. Then, we construct first and second order response surface model to examine the obtained significant factor and obtain the empirical model and optimized parameters. The results show that the optimal parameter settings for the ink type (X1) Type γ are the squeegee speed 100 mm / sec, squeegee pressure 20 kg, squeegee under pressure 0.2 mm, and the optimal overflow ink value is 92.64 μm. Moreover, the rubbing frequency can be reduced by 33%, the production capacity can increase 46.7%, and the defect rate can be decreased by 0.3%. Thus, the proposed approach is feasible for future applications in the screen printing process.
論文目次 摘要 I
Abstract II
誌謝 VIII
目錄 IX
表目錄 XI
圖目錄 XII
第一章 緒論 1
第一節 研究背景 1
第二節 研究動機 3
第三節 研究目的 3
第四節 研究流程 4
第五節 論文架構 5
第二章 文獻探討 6
第一節 車用面板網版印刷製程與應用 6
一、網版印刷製程介紹 6
二、車用網印製程介紹與其他產業應用 7
三、網版印刷製程因子 8
第二節 部分因子實驗設計 9
一、部分因子實驗設計介紹 9
二、部分因子實驗設計之應用 10
第三節 反應曲面法(Response Surface Method, RSM) 12
一、反應曲面法介紹 12
二、反應曲面法之應用 14
第三章 研究方法 16
第一節 問題描述 16
一、車用面板網版印刷製程 16
二、黑色邊框內緣溢墨問題 19
三、網版印刷製程因子 20
第二節 研究架構 23
第三節 假設檢定 25
第四節 部分因子實驗設計 28
第五節 反應曲面法 30
第四章 實驗結果與討論 33
第一節 部分因子實驗 33
第二節 反應曲面法 36
第三節 比較分析 41
第五章 研究成果與建議 44
第一節 研究成果與貢獻 44
第二節 未來研究方向 44
參考文獻 46
中文文獻 46
英文文獻 46
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