[Production Planning Of Flat Panel Display]

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TABLE OF CONTENT

CHAPTER 4: DISCUSSION AND ANALYSIS3

Impact Of Product Design On Production Lead Time Prediction6

Resource Utilization Based Upon State Graph11

Resource Allocation Based On Product Design13

Deployment And Training Strategies Of Labor Resources17

Contract Manufacturing20

Inventory Performance24

Chapter Summary33

CHAPTER 5: CONCLUSION36

Research Contributions37

Integrating Product Design Into Production Planning System37

Incorporating Resource Constraints By Defining Interactivities Among Resources38

Emphasizing Labor Resource In Planning System39

Proposing A New Framework For Generating Simulation Models40

Incorporating Yield Prediction Techniques Into A Production Planning System41

Impact Of This Dissertation42

Potential Extensions Of This Research43

Scheduling Optimization Techniques In Production Planning43

Automated ERP Information Retrieval43

Summary44

REFERENCES46

CHAPTER 4: DISCUSSION AND ANALYSIS

The flat panel display industry has always been extremely competitive. The level of competition has been exacerbated by the recent economic downturn coupled with fluctuating demands and the uncertainty in the electronic market. An flat panel display provider has to provide better service, better product quality with competitive production costs in order to increase profitability and competitiveness. For this purpose, an flat panel display provider needs to be more competitive vis-à-vis appropriate production planning given a perceived demand in order to effectively deploy the necessary resources and workforce along with the appropriate manufacturing infrastructure.

In this study, a planning system for PCB assembly production has been conceptualized, designed, and developed. The principal objective of this framework is to address one of the major characteristics of PCB assembly production, namely 'Product Oriented Production' by integrating product design into planning systems. Based on this proposed planning system, flat panel display suppliers can effectively plan the required manufacturing resources, predict production lead time and 'optimize' resource deployment for a particular product in their daily production planning. In addition, the dynamic impacts of resource constraints during production and impact from operators' performance are addressed in this research. Incorporating these concerns can dramatically enhance the accuracy of predicted results and provide reliable production solutions during their daily production.

In this chapter, several application cases based upon the proposed planning system are presented and discussed. Because the major objective of this proposed framework is to emphasize the necessity of integrating characteristics of products into a planning system, case studies in this chapter are majorly selected to demonstrate the impact of product designs on production scheduling and resource deployment. Though this research principally focuses on PCB assembly production, it should be noted that the concepts presented in this research can also be applied to other domains which have production scenarios that are similar to a high mix low volume environment.

Furthermore, the impact of labor resources has been addressed as an important factor in this research. The impacts of operator interference and performance differences among operators are incorporated into the proposed planning system. The significance of incorporating the impact of labor resource in a production system is illustrated in case studies. In addition, training strategies can be developed on the basis of integrating the matrix of operator performance index. Based on "what-if" analysis, the most cost-effective training and resource deployment strategies can be determined.

In this chapter, case studies are selected to present the robustness of the proposed planning ...