爵士鼓製造廠之瓶頸優先指派模式研究

A Study of the Bottleneck Machine First in a Drum Set Manufacturing Plant

吳鴻輝(Horng-Huei Wu) ； 鄧肖琳(Hsiao-Lin Teng) ； 李明峰(Ming-Feng Li)

《創新與經營管理學刊》 9卷1期 (2020/06) Pp. 35-50

https://doi.org/10.6270/JIBM.202006_9(1).0004

摘要

儘管全球約有70%的爵士鼓是在台灣製造的，但台灣大多數爵士鼓製造商都只是不同品牌或代理商（例如PEARL，LUDWING或GRETSCH等）的代工廠（OEM）。面對競爭壓力的增加，台灣爵士鼓製造商被迫要提高其交期準確率、提升有效產出和降低庫存等製造績效。因此某家位於台灣中部的爵士鼓廠導入了限制理論（TOC）這套系統以提升該廠之績效。根據限制理論的基本原理，一個系統的績效主要是決定於其瓶頸資源。因此，該爵士鼓工廠首先確認了鼓肚成型（drum shell construction, DSC）站為該廠之瓶頸站，並且充份利用DSC站的所有機台器。但這些努力雖然有些效果，卻非常的有限。管理人員仍然要面對許多不想看到的現象，例如在交貨時會缺少某些尺寸規格的鼓、高庫存存貨、太頻繁的加班以至於增加了過多的費用、或者難以控制不同尺寸規格的成品庫存等。在進一步對DSC瓶頸工作站的研究後，發現該DSC工作站由幾種不同尺寸的DSC機台所組成，某一尺寸的DSC機台只能生產該尺寸的鼓。其次一套爵士鼓組是由幾種不同尺寸的鼓所組成，而不同規格的爵士鼓組所組成的鼓，其尺寸亦會不同。因此，DSC工作站中的某些尺寸的DSC機台才是真正的瓶頸，而且必須在客戶訂單所需的爵士鼓組規格的需求下才能確認。因此本研究提出了一套雙資源限制（DRC）系統人員指派模式，以解決上述的問題。其次本研究並提出瓶頸優先（BF）和前瞻式瓶頸優先（LABF）兩種人員指派法則，以提升系統之績效。最後本研究並設計了模擬和實驗，以驗證這套DRC系統及這些法則的可行性和有效性。結果顯示，這套DRC系統及法則不但可以消除上述之不想看到的現象，並且能提高系統的產出、降低WIP、縮短交貨週期時間、並能提高達交率等績效。

關鍵字

爵士鼓工廠 ； 雙重資源限制系統 ； 瓶頸優先指派 ； 前瞻式瓶頸優先指派 ； 限制理論

並列摘要

About 70% of the global drum sets are manufactured in Taiwan, however, most of drum set manufacturers in Taiwan are OEMs (Original Equipment Manufacturer) for different brands or agents, such as PEARL, LUDWING or GRETSCH etc. Facing the competitive pressure recently, the Taiwan drum set manufacturers have been forced to improve their manufacturing performance, such as order delivery quality, throughput increase and inventory reduction etc. Theory of constraints (TOC) is then recommended to be utilized in a drum set plant in Taiwan. Basically, the performance of a system usually is decided by its bottleneck, which is the fundamental principle of TOC. The bottleneck station is therefore first identified in this drum set plant to be drum s hell construction (DSC) station. The machines in this DSC station are then exploited. However, some limited performances are obtained and the undesired effects are still faced by the managers, such as lack of some size drums for delivered orders, high inventory stocks, too frequent overtime to increase too much overhead, or hard to control different size drums inventory, etc. Because a drum set is composed of several different size drums and a different size drum must be produced by its required size of DSC machine. Based on the further study of this DRC station, however, some sizes of DSC machines in this station are found to be real bottleneck , which are determined by the required drum sets orders. A dual resource constrained (DRC) system is then modeled for the DSC station. The bottleneck first (BF) rule and look-ahead bottleneck first (LABF) rule are then proposed to be utilized in this DSC system. A simulation and experiment is then presented to explore the feasibility and effectiveness of these rules. The results show that employing the proposed methodology eliminates those undesired effects described above and improve s the manufacturing performance.

並列關鍵字

Drum Set Manufacturing ； Dual Resource Constrained (DRC) system ； Bottleneck First rule ； Look-ahead bottleneck first rule ； Theory of Constraints (TOC)