Abstract
The thin film transistor liquid crystal display (TFT-LCD) including three fundamental process stages: array process, cell process and module process is generally called liquid crystal panel by consumers. Each process stage existing the variable manufacturing flow-process and characteristic of capacity results in acquiring individual objective in each plant, however, ignoring the demand in entire supply chain. For instance, array process and cell process enthusiastically pursue to reach maximal throughput contributed to have much more work in process (WIP) of the panel to Module process. However, the module process depends on the demand of final customers to assemble finished products. Therefore, the demand of customers and the supply from the upstream process exists asymmetrically to lead the inventory levels ineffectively for controlling. The theory of constraints supply chain replenishment system (TOC-SCRS) is supposed to apply the TFT-LCD plants, and is mainly discussed the inventory of TFT-LCD in each plant to study this model of replenishment. The inventory of TFT-LCD in each plant has three critical parameters: frequency of replenishment (FR), reliable replenishment time (RRT) and maximum inventory buffer. Furthermore, utilizing FR, RRT, and maximum inventory buffer parameters to calculate the replenishment quantity and delivery quantity. However, each inventory is related to each other between upstream and downstream. This study is concerned with TOC-SCRS to each inventory and uses the simulation model to simulate the variation of the each inventory to demonstrate the significance and feasibility of this proposed TOC-SCRS for TFT-LCD plants. Key words: Thin film transistor liquid crystal display, theory of constraints, supply chain management, TOC supply chain replenishment system.
Highlights
In recent years, being driven by the demand of largesized panel on LCD monitors, notebook computers and LCD TVs mainly, the flat-panel display industry has been gradually heading towards the peak
The theory of constraints supply chain replenishment system (TOC-SCRS) is supposed to apply the thin film transistor liquid crystal display (TFT-LCD) plants, and is mainly discussed the inventory of TFT-LCD in each plant to study this model of replenishment
This study focused on the assessment of the largest buffer inventories, replenishment frequency, replenishment volume, and expected purchasing quantity, to develop a suitable inventory replenishment mechanism for inventory points in the TFTLCD supply chain, and, through this mechanism, to work out production planning without using the mode of demand forecast
Summary
In recent years, being driven by the demand of largesized panel on LCD monitors, notebook computers and LCD TVs mainly, the flat-panel display industry has been gradually heading towards the peak. The global market demand for TFT-LCD has been growing and diversified, such as the desktop LCD monitors and notebook computers in information application and the LCD TVs, automotive-specific display in video application Customers in this industry tend to specify their own suppliers or components which often lead into a situation of the same product with different models after being subclassified. The production-oriented planning, for example, focuses on the quantity of output, whereas the planning of make to order concentrates on meeting the customers’ specific demand in components and suppliers, in which the material supply and order delivery are the major concern Such condition of different goal of each process in TFTLCD generates the following problems: (1) the difficulty in inventory control: as the production of current TFT-LCD is based on forecast demand, it is difficult to have an accurate prediction when the business cycle changes. There have already been many studies that explored the multi-site production planning, and this study will focus on the various upstream and downstream replenishment model of the supply chain in the TFT-LCD industry
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