家崎科技─FXE石英環加工最佳排程

Abstract

石英(quartz)是半導體重要輔助性耗材，但隨著半導體銷售量提升、石英環製造專利過期而開放的情況下，加入石英環製造的競爭者大幅增加，到2017年，利潤僅剩下加工費用，利潤微薄，使得多數廠商陸續退出市場。「家崎科技」（We Solutions Technology）是少數存活的優良供應商，卻仍面臨無法滿足客戶需求數量的困境。在無法新增設備、擴充產能的前提下，檢討與改善現有製程，成為家崎科技的當務之急。 本個案主要在跟隨陳總經理對於製造現場的問題追蹤，陸續發現加工件數的安排、工件夾治具的設計、加工程序的改善、人機配置的平衡等關鍵因素必須改善。本個案透過要徑法(Critical Path Method, CPM)分析，呈現石英環的製程瓶頸，讓學生透過排程規劃的計算與改善，以解決產能不足、成本過高等問題。

Quartz plays a crucial role in the wafer processing procedure. With the increase in semiconductor sales and the disclosure of quartz ring manufacturing technology due to the expiration of patent protection, the number of competitors entering the quartz ring manufacturing industry has increased significantly. Until 2017, the profit potential of this semiconductor consumable— the FXE quartz ring—could only be obtained from processing. The low profit margin and severe competition caused most manufacturers with poor benefit structure to withdraw from the market. We Solutions Technology is one of the few existing suppliers of FXE quartz rings in this market, but it still faces the difficulty of being unable to meet the demands of customers. In circumstances where We Solutions Technology is unable to acquire additional equipment and expand production capacity, reviewing and improving existing processes has become the top priority. This case study was based on the tracking of every detail at the manufacturing site by General Manager Da-Yu Chen. Through Chen’s professional knowledge and deep practical experience, it was found that key factors, such as the arrangement of the number of processed work pieces, the designs of jigs and fixtures, planning of the processing schedule, and the configuration of human-machine balance, must be improved. Through analysis of the critical path method (CPM), the bottleneck of We Solutions Technology in the manufacturing process of FXE quartz ring was identified. This case can facilitate students’ motivation and understanding through calculated and improved planning of the manufacturing schedule to increase production capacity and reduce costs.