||The polarizer industry has officially entered an era of high quality demand and intense price competition. Other than improving performance and enhancing the slimness of the product, the R&D of companies in this industry focuses on cost reduction or new material discovery. Under the structure of Advanced Product Quality Planning of new product development, this research applies the concurrent engineering systematic concept to discover new product. With the cooperation of R&D, Quailty mangement, Engineering, and Production division, and the concept of robust decision and statistic analysis method, the new material development is capable of stabilizing the defects in grind process, minimizing the product defects variation, and allowing massive production.|
This study focuses on reducing defects of grind process after applying the new material. The two major defects are the surface crack and the third-layer peeling. In order to minimize the defects we apply the multi-criteria robust design. Through the cause-and-effect diagram, this research is able to identify the major characteristics of the defects and to locate the potential factors for the first-stage experiment, and the R-square of the results at this stage is about 80%. With the intention to have continuous improvement, the second-stage experiment is performed based on the optimized parameters from the first-stage results. All experiments applied the Taguchi Methods of Robust Design on S/N ratio analysis, mean analysis, Pareto frontier, and parameter application theorem. Furthermore, along with the cost and revenue relationship, these experiments also applied multi-criteria optimization comparision. Finally, confirmation experiments were performed to varify the proposed model. The optimal solution surface crack is reduced from 200um to 46um.Third-layer peeling is shorten from 250um to 66um. And the product defects variation is reduced from 17um to 5um.
With the achievement of producing representative product at current stage and minimized material costs, this research on new-materialized polarizer product can be served as a benchmark on polarize material application technique. Moreover, this research can also be served as a reference for future study on robust design, which prevents further cost due to corrective activity on mass production stage, and avoids defects from grind process which might cause customers’ complain or application problems related to product.
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