Sustainable scheduling of TFT-LCD cell production: A hybrid dispatching rule and two-phase genetic algorithm

Abstract

TFT-LCD manufacturing process involves Array, Color Filter (CF), Cell, and Module. The Cell process is pivotal in the TFT-LCD production supply chain; it bridges the front-end (Array and CF) and back-end (Module), maintaining a balance of production capacities. Supply from the front-end is transmitted to the back-end, ensuring prompt responsiveness to customer demands. As awareness of environmental conservation grows, implementing sustainable development in the TFT-LCD manufacturing industry has become crucial. Specifically, reducing the machine setup frequency in TFT-LCD scheduling decreases energy consumption during machine operation and wait times and prolongs equipment lifespan by minimizing wear from repeated shutdowns. To tackle the intricate scheduling challenges within TFT-LCD production, this study proposes an intelligent, sustainable scheduling approach that employs a rolling dispatching and line balancing mechanism and a two-phase genetic algorithm (HDTPGA) for Cell scheduling. The goal is to minimize makespan considering product diversity, production constraints, work-in-process balancing, and machine setup frequency. This holistic approach promotes energy-efficient and sustainable manufacturing practices. According to the empirical study, the proposed HDTPGA reduces the makespan by approximately 10% compared to the baseline. Additionally, it reduces the average daily setup frequency of bottleneck stages (ODF and CCT) in the Cell process by approximately 68.25% and 66.25%, respectively. The main contribution of this paper is to propose an intelligent scheduling algorithm to optimize Cell production scheduling in practice. The HDTPGA achieves equilibrium between front-end and back-end production, utilizing an efficient line change mechanism to reduce energy consumption. The enhancement in efficiency not only restricts material waste but also reduces the environmental impact, enabling manufacturers to adopt green production practices and promoting a transition of the entire panel industry toward sustainability.