장치공정에서의 설비 주변 환경 관리에 관한 연구 = (A) Study on ambient control in the instrumental process

다국어 초록 (Multilingual Abstract)

Up until now, it has been a common notion that instrumental process has no predictability(repeatability.) That is, instrumental process is inherently unpredictable and thus inspection task cannot be standardized. In this paper, we show how to implement cost-effective Ambient Control around glass furnace, reducing the non-conforming rate and the quality variation of its products. It leads to significantly lowered cost and significantly raised predictability of the production process, allowing 4M standardization.
Frequent unpredictable external disturbances compel operators to change setting values of instruments in ad-hoc manner, This is called "Reactive Control." Such control has serious drawbacks. First, monitoring and adjusting setting values require numerous man-hours. Second, it increases COPQ (cost of poor quality.) In this research, we put forth cost- effective control of external disturbances, using Ambient Control(A/C), especially in large-scale glass furnace. Once ambient control is in place, the setting values can be fixed for most of the time, which could enable genuine 4M standardization. In this situation, even in the event that setting values need to be changed (infrequently), it would be a response according to a "Recipe", a set of response plan which has been worked out in advance by analyzing potential predictable situations. As a result, ambient control would lead to stabilization and increased predictability of production process, which allows 4M standardization, and man-hour and nonconforming rate drop, and the lifespan of a furnace increases.
Along with ambient control, we also propose new test method to verify 4M standardization. The instrument like glass furnace is characterized by non-Newtonian fluid dynamics due to high viscosity. The resulting process inside the furnace exhibit significant level of autocorrelation. This makes unsuitable the use of traditional "Control-chart" method. That is why we need a new method.

목차 (Table of Contents)

• Abstract = ⅰ
• 목차 = ⅰ
• 제1장 서론: 장치공정에서의 Ambient Control = 1
• 제1절 문제제기 및 목적 = 1
• 제2절 연구방법 및 범위 = 3
• 제2장 로(爐)와 로 운전(爐運轉) = 5
• 제1절 용해로의 종류 = 5
• 제2절 로의 운전요소 = 8
• 제3장 4M 표준화를 입증하는 방법(control-in) = 13
• 제1절 White Noise 방법: 새로운 C/I 측정방법 = 15
• 제2절 AR(2)에 의한 UCL과 LCL의 확장방법 = 16
• 제4장 A/C(ambient control)의 방법 = 18
• 제1절 외란방지의 필요성 = 18
• 제2절 Input 외란방지 = 18
• 제3절 기류관리 = 19
• 제5장 Ambient Control과 4M표준화 = 25
• 제1절 4M표준화와 기대효과 = 25
• 제2절 효과적인 Ambient Control의 사후관리 = 27
• 제6장 결론 및 향후 과제 = 31
• ◆ 참고 문헌 = 33
• ◆ 부록 = 36