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The backlight module is one of the key components for the liquid crystal display. Its function is to supply sufficient and uniform distribution of light, so that it can display the image properly. The companies in Taiwan have had the ability to design the optical light guide plate and mechanical structures. Moreover, the assembly process has a cost advantage than that of Japan and South Korea. Because of the low barriers to entry backlight module industry and low technology, manufacturers still need to improve the production technology, the assembly process and the mass production economies of scale and strive to play a synergy, to reduce costs in order to ensure market share.
Manufacturing production processes is a vital part of the enterprise, especially in backlight module industry. When a manufacturing company needs to develop improvements to the current situation, the company has to plan a value stream analysis, which we found necessary means and effective measures is the key value of optimizing production processes. Therefore, in order to maintain a competitive edge in the market, the optimization of production processes is the need for continuous ongoing process.
In this study, we present a case study including reviews on related literatures. The company introduced lean production method to improve the backlight module manufacturing processes and the effectiveness of the implementation of productivity improvements, with the aim of enabling the optimization process of the work stations, assembly operations, staffing allocations, increasing capacities, downsizing costs and creating profits to increase the productivity and competitiveness of the industry. The empirical results show that application of lean production techniques can be increased from 4500PCS / line / 10 hours to 8000PCS / line / 10hours. The production capacities is increased by 78%; the output space is increased by 77.8%, and monolithic labor costs were decreased by 12%. As a result, it is capable of extending the lean production techniques from a single production line to the others, and tp the production units in the companies as well. | en_US |