Lean-pull strategy in a re-entrant manufacturing environment

A pilot study for TFT-LCD array manufacturing

Ta-Ho Yang, Chiung Hsi Hsieh, Bing Yuan Cheng

Research output: Contribution to journalArticle

23 Citations (Scopus)

Abstract

The increase of a panel's size in thin film transistor - liquid crystal display (TFT-LCD), results in an increase in stock space and increased cost from work-in-process (WIP). This paper proposes a lean-pull strategy, combining buffers with CONWIP (CONstant work-in-process), which results in shared resources to a re-entrant process in TFT-LCD manufacturing. The buffer size and CONWIP levels are the decision variables and are solved by simulation optimisation. The proposed procedure is applied to a factory that manufactures TFT-LCD. The study shows that the proposed lean-pull strategy can reduce the cycle time and achieve a reduction of 34.57% in WIP. The automated material handling systems (AMHS) stocker utilisation can be reduced from 62.13% to 18.49% without additional investment or facilities. Sensitivity analysis indicates the maximum daily throughput will achieve over 10% improvement. The empirical results from this pilot study provide useful managerial insights for the production control of array manufacturing.

Original languageEnglish
Pages (from-to)1511-1529
Number of pages19
JournalInternational Journal of Production Research
Volume49
Issue number6
DOIs
Publication statusPublished - 2011 Mar 15

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Thin film transistors
Liquid crystal displays
Production control
Materials handling
Sensitivity analysis
Industrial plants
Throughput
Pull
Manufacturing
Costs
Buffer

All Science Journal Classification (ASJC) codes

  • Strategy and Management
  • Management Science and Operations Research
  • Industrial and Manufacturing Engineering

Cite this

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Lean-pull strategy in a re-entrant manufacturing environment : A pilot study for TFT-LCD array manufacturing. / Yang, Ta-Ho; Hsieh, Chiung Hsi; Cheng, Bing Yuan.

In: International Journal of Production Research, Vol. 49, No. 6, 15.03.2011, p. 1511-1529.

Research output: Contribution to journalArticle

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