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Simulation of Array Manufacturing Process in LCD Production

#Visualization of Work-in-Process #Reentrant Flow #Lot Size for Processing #Variation in Layered WIP

Purpose of this Simulation Model
Confirm the amount of work-in-process within the production line. Check the WIP for each layer in a complex production system where products repeatedly re-enter the line.
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Model Overview

  • Production Line Characteristics
  • A series of processes—“Cleaning → Deposition → Patterning → Etching → Stripping”—is repeated multiple times.
    Due to this repetition, products re-enter the line for multiple cycles.
  • For layers such as “Gate,” “Semiconductor,” “Source,” “Drain,” “Protective Film,” and “Pixel Electrode,” the same sequence of processes is performed repeatedly.
  • Different equipment is used depending on the material type being processed. For example, etching may require switching between “Dry Etching Equipment” and “Wet Etching Equipment” depending on the material.
  • Key Points

Each area houses numerous identical pieces of equipment, with different equipment used for each process step (or material type) even for the same product. Furthermore, different equipment is used for each product, creating a job shop production system where products move between these various pieces of equipment.

The key point is to accurately describe this job shop production system in GD.findi.

This simulation model was created to assess work-in-process levels at each layer and evaluate the quality of setup times for the purposes outlined above.

Modeling Screen

Floor Plan Information on Equipment Layout and Transport
Process Plan Information on Process Sequence and Cycle Time
Production Plan Information on Input Lots
Process-by-Process Equipment Allocation 1 Information regarding the association between processes and equipment
Process-by-Process Equipment Allocation 2 Information on the capacity settings for each piece of equipment

This modeling was created using GD.findi MS.

It is a no-code production simulator that performs production simulations in a digital virtual space, providing powerful support for line design and process design.

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Output Report Example

■ Inventory trends for each reentrant layer

Visualize time-based WIP changes for each layer:

Layer 1: Gate
Layer 2: Semiconductor
Layer 3: Source/Drain Electrode
Layer 4: Protective Film
Layer 5: Pixel Electrode

※About the Legend

GATE: Gate Layer
SEMI: Semiconductor Layer
S_D: Source/Drain Electrode Layer
PAS: Protective Film Layer
RGB: Pixel Electrode Layer
FIN: Finished Product

Applicable Industries/Line Configurations

  • LCD manufacturing
  • Job-shop type production line where equipment varies by product and process
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