應用萃思(TRIZ)理論探討提升電纜絞線設備產能之研究-以W公司為例

本研究以針對(W 公司為研究對象)，在W 公司裡生產中高壓電纜製程設備環節裡，對於銅線絞製程中表面缺陷及線徑真圓度品質、單位小時平均標準產能，來如何提升品質要求及降低廢線率做為研究，如何在現有設備的條件資源下改善提高製程效率能力，達到對設備異常、少子化及一例一休短少工時所帶來的衝擊下產能減少狀況，能更效率的控制提升絞合機台產出品質及產能與機台稼動率，及設備異常損壞之故障率在產能及產量間的矛盾。研究方式是利用及運用(萃思TRIZ)中的發明原理，研究不同領域的已有創新成果進行W 公司電線電纜絞合過程設備狀況做分析、總結，歸納、來得到的已有前人的經驗法則，導入可改善方針及執行的創新方法，並將各種可能之創新方法轉化成及歸納出多個或單點可行的方式及目標，這些創新方式都有重要參考價值，利用大數據收集及專家資料庫等方式，做為日後參考及快速搜尋的方向指標。在現有研究方向下使用目前常用的 (粹思 TRIZ)發明原理中有40 條，參考及思考下，如何實踐證明這些原理對於發明創造具有重要的作用。透過對設備維修管理機制之建立及執行，隨著設備運轉時間縱軸(現在及未來)需充分且有效的掌握、當找到設備異常點，總結歸納在確定40 個發明原則內容中，就可以根據這些發明原理來考慮具體的快速解決及降低設備故障率所帶來的品質異常造成之廢線率，配合企業生產流程在造及整體策略做出適當的改善提生生產稼動率。將此研究的方法運用於W 公司的歷年單一61B 框絞設備稼動率驗證，而其效益會展現於設備故障及生產工時減少之降低，包括維護成本、設備運轉時數。經過2018 年度的驗證結果發現稼動率提升，而產能提升沒有因機台故障及減少工時的降低而減少。故結論證明生產製造設備管理可以運用TRIZ 的創新思維與創新的方法來優化。

關鍵字

TRIZ 理論；矛盾矩陣； 40 個發明原則；稼動率

並列摘要

This research is aimed at (the W company as the research object), in the process of producing medium and high voltage cables in the W company, how to improve the quality of surface defects and wire diameter roundness that may occur during the copper wire stranding process, how to improve the average standard productivity per hour, and how to not only increase the quality requirements but also reduce the defective rate as research. How to improve the process efficiency ability under the existing equipment conditions and resources, to deal with these impacts, i.e. equipment abnormalities, declining birthrates, and short working hours brought by one fixed and one flexible day off per week. How to control and improve equipment more efficiently output quality, production capacity and equipment operating rate, and how to deal with the contradiction between production capacity and output caused by abnormal equipment failure rate. The research method is to use and apply the principle of invention in (TRIZ), to study the existing innovations in different fields to analyze, summarize, and obtain the existing experience of the W company's wire and cable stranding process equipment. By introducing innovative methods that can improve the policy and implementation, and transform various possible innovative methods into multiple or single-point feasible methods and goals. These innovative methods have important reference value, with the use of big data collection and expert database, etc. as directional indicators for future reference and quick search. In the existing research direction, there are 40 commonly used (TRIZ) invention principle, with reference and thinking, how to prove that these principles play an important role in invention and creation. Through the establishment and implementation of equipment maintenance management mechanism, as the vertical axis of the equipment operation time (now and in the future) needs to be fully and effectively grasped, when equipment anomalies are found, summarized in the determination of 40 invention principles, which one can take into account to quickly solve and lower the defective rate causes of quality abnormalities caused by the equipment failure rate, and make appropriate improvements to improve the production utilization rate in accordance with the production process of the enterprise and the overall strategy. This method of study is applied to the W company's calendar year single 61B frame winch equipment rate verification, and its benefits will be demonstrated in the reduction in equipment failure and production hours, including maintenance costs and equipment operating hours. The validation result in 2018 found that the utilization rate has increased, and the productivity has not been reduced due to machine failures and reduced working hours. Therefore, the conclusion proves that the management of manufacturing equipment can be optimized by using TRIZ's innovative thinking and innovative methods.