Research On Improvement Strategies Of Sapphire Substrate Production Cycle

With the development of the LED industry,the domestic demand of sapphire substrates is increasing rapidly,China has been a major market for sapphire substrates.The LED industry is a high-investment,high-yield and high-risk industry,affect by supply and demand,competition among enterprises is extremely fierce.At present,competition in the sapphire substrate market is not only limited in yield and price,production cycle also received increasingly attention.Reducing the production cycle of sapphire substrates could not only reduce production cost,speed up capital turnover,but also improve customer satisfaction,enhance the market competitive strength.In order to resolve a problem in a sapphire substrate manufacturing enterprise that production cycle of sapphire substrates is long,and the target production cycle achievement rate is not ideal.The research on improvement methods of the production cycle of sapphire substrates is carried out in this paper,the main research content as follows:(1)Identification of key effect factors of the sapphire substrate production cycle.Firstly,analyzing the composition of the sapphire substrate production cycle and process of sapphire substrate respectively,to determine the main production composition of the production cycle and the characteristics of cycle time consumption.Then the failure mode and effect analysis methods are used to identify key effect factors of the sapphire substrate production cycle from the perspective of persons,machines,materials,methods,environment and measurement.Besides,statistic production cycle of sapphire substrate at different processes by manufacturing execution system,which reflects the influence of different factors on the production cycle of each process at different periods,it is supporting for making production cycle improvement strategies.(2)According to the characteristics of sapphire substrate production system,the production cycle improved methods are proposed.Based on constraints theory and lean production management,making improved strategies for identified key effect factors.Firstly,advanced drum-buffer-rope production control method is applied to identify bottleneck,set buffers and improve release and dispatch strategies for improving the performance of sapphire substrate production system,and the effectiveness of method is verified via an example.Besides,combined lean production concept,applying total productive maintenance,one piece flow,visual management to reduce the influence of uncertain factors on the production cycle and shorten the production cycle of sapphire substrates.(3)Evaluation of production cycle improvement strategies.By combining the changes of sapphire substrate production cycle before and after,the effectiveness of the improvement strategy is tested and evaluated.After approximately six months production cycle improvement,the result shows that the target achievement rate of sapphire substrate production cycle increase more than 10%,and the number of work-in-process decrease at same time.That is verified the effectiveness of the sapphire substrate production cycle improvement strategies.The research results of this paper enrich the research content of product production cycle management of sapphire substrate manufacturing enterprises.And it provides a reference for enterprise product production cycle management.