運用系統模擬探討精實生產方式在流程式組裝廠接單後生產之優勢

A Study of Applying Lean Production to a Make-to-Order Flow Shop Assembly Factory Through Simulation

林垣成(Yuan-Cheng Lin)

指導教授 ： 張玉鈍

國立臺北科技大學/管理學院/工業工程與管理研究所/碩士(2008年)

https://doi.org/10.6841/NTUT.2008.00353

摘要

組裝業是屬於高度勞力密集的產業，在組裝程序中人力使用的比重相當高，也因此在生產系統的改善方面，不單單只從現場硬體設施改善，還必須考量到人員因素的影響，而精實生產系統的導入正好可以為生產系統做全面性的改善。不過，精實生產系統的導入並非全面適用於任何環境以及任何型態的產業。所以，有鑑於精實生產系統在全面導入組織後的效益在事前仍需仔細評估，利用模擬方式來針對導入做事前性的評估有其必要。本研究利用系統模擬的方式建構一流程式組裝工廠，探討該工廠在採接單後生產的生產環境下，精實化技巧的導入可能為其帶來的優勢。實驗結果顯示，在不同訂單需求型態下，採用多能工單元式佈置相較於GT佈置與功能式佈置，對於訂單前置時間以及訂單延遲時間的降低皆有非常良好的成效，而且當訂單的產品需求類別愈多時，較高的多能工水準對於系統績效的改善也將愈好。不過，SMED的施行在隨著產品種類增多的生產環境中，對於訂單前置時間以及訂單延遲時間的改善成效是會增加，但由於本研究的整備時間設定並不是很長，所以相對於其他精實化技巧的改善幅度卻是相當有限的。而多能工單元式佈置如果要發揮最佳的生產效率，則工作標準化是必須施行的重要精實化技巧。

關鍵字

精實生產 ； 接單後生產 ； 系統模擬

並列摘要

The assembling industry belongs to the high labor intensive industry. In assembly processes , the proportion of workforce involvement is quite high. If we want to improve our manufacturing environment, we would not only improve the hardware facilities in factory shop but also need to consider the human aspects. The lean production system at the right moment can do a comprehensive improvement approach in the manufacturing system. However, the conduction of the lean production system may not be applicable to all environment and industry types. It is necessary to do prior evaluation of the benefits of comprehansive introduction of lean production system. It is rather valid to use simulation to aim at conducting lean production to a organization. This research makes use of the system simulation to construct an flow shop assembly-factory, and study the advantage of adopting the lean technology in make-to-order manufacturing environment. Experiment result suggest, under the different demand variation types, adopting cell layout will reduce the order lead time and lateness. While comparing with GT layout and function layout, when the number of product types increases, the more multiskill workforce will improve more efficiency in this system.However, improvement of the order lead time and lateness due to the “single-minute exchange of die” enforcement in cell layout environment is rather limited.Standardized work is one of the most importance lean techniques to bring about the significant improvement in cell layout lean production system.

並列關鍵字

Lean Production ； Make-to-Order ； Simulation

參考文獻

【7】豐田汽車著，國瑞汽車譯，豐田生產方式基本篇，2004

【10】Abdulmalek ,F.A. and Rajgopal, J., “Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study,” International Journal of Production Economics , 2007.

【11】Chang, T.M., Yih, Y., ”Generic kanban system for dynamic environments,” International Journal of Production Research , 1994.

manufacturing with discrete event simulation: a case study,” International Journal of Production Research, 2000.

【13】Durmusoglu, M. B., “Analysis of the conversion from a job shop system to a cellular manufacturing system,” International Journal of Production Economics, 1993.