裝配流水線之最佳化人員調配問題之研究- 以變電箱製造商為例

Research on the Problem of Optimal Worker Assignment in Assembly Line – The Case Study of Transformer Manufacturer

林亞嫺(YA-HSIEN LIN)

指導教授 ： 周永燦

中原大學/電機資訊學院/工業與系統工程學系/碩士(2022年)

https://doi.org/10.6840/cycu202201234

摘要

在科技的進步、貿易壁壘的削減以及全球化的趨勢下，為了佔有競爭優勢各家廠商相繼打出價格戰，在不斷降價的同時，勞動成本卻逐年提升。企業在成本壓力下力求改善，透過不斷提升生產效率，降低不必要的成本與浪費，增加公司競爭優勢。而造成生產效率低通常是由多種因素所構成，例如：不必要的移動時間、人力資源的安排、機台的利用率等。某些產業主要以高百分比人工組裝，且不易自動化，因此人員的有效利用尤為重要，在有限的資源下，如何做好人力資源的調度，有效的利用人力資源完成目標為一個重要的課題。
個案公司主要的生產方式屬於裝配流水線生產模式，受到批量生產時間過長的瓶頸站別之影響，在不同作業員的技能多樣性差異下，根據人員的特性，找出如何有效的分派工作給員工，降低生產週期，以達到生產線平衡，是本研究要探討的問題。
本研究以個案公司為研究對象，主要目的在於探討人力資源的調配是否能有效提升生產績效。本研究根據產品所需產量、處理時間、人員特性及批量生產機台產量影響，透過混合整數規劃模型建置，進行人員配置下的生產線平衡，做人員有效調配；再透過FlexSim系統模擬進行模擬驗證，比較不同情境下的人員利用率、崗位移動造成的產出影響，最後經由模擬出的資料進行假設檢定。通過本研究可以提供勞力密集且不易自動化的公司進行工作站別分配的參考。

關鍵字

系統模擬 ； FlexSim ； 生產線平衡 ； 混合整數規劃 ； 人員派工

並列摘要

With the advancement of technology, the reduction of trade barriers and the trend of globalization, in order to have a competitive advantage, many manufacturers have launched price wars one after another. While continuously reducing prices, labor costs are increasing year after year. Under the pressure of cost, enterprises strive for improvement by continuously improving production efficiency to reduce unnecessary cost and waste, and increase the company's competitive advantage. Low production efficiency is usually caused by a variety of factors, such as unnecessary movement time, manpower arrangements, machine utilization, etc. Some industries mainly use a high percentage of manual assembly. It is not easy to automate, which makes the effective use of worker particularly important. Therefore, to do a good job of human resources scheduling under limited resources, and effective use of human resources to achieve the goal is an important issue.
The case company mainly produces products on the assembly line, which is affected by the bottleneck of long batch production time. With the diversity of skills of different operators, it is the problem of this study to find out how to effectively assign work to employees and reduce production cycle time to achieve the production line balance according to the characteristics of the employees.
The main purpose of this study, doing researches on a case company is to investigate whether the deployment of human resources can effectively improve production performance or not. Based on the required product output, processing time, worker characteristics, and batch production machine output, this study uses a mixed-integer planning model to build a balanced production line with advanced worker allocation for effective worker deployment. The FlexSim system is then used for simulation verification to compare the number of staff utilization and post movement on output under different scenarios. Finally, the simulated data is used to test the hypothesis. This study can provide a reference for workstation assignment in companies with labor intensive and not easy to automate.

並列關鍵字

System simulation ； FlexSim ； Production line balance ； Mixed Integer Programming ； Worker assignment

參考文獻

英文文獻

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Baybars, I. (1986). A survey of exact algorithms for the simple assembly line balancing problem. Management science, 32(8), 909-932.

Baykasoglu, A., & Dereli, T. (2008). Two-sided assembly line balancing using an ant-colony-based heuristic. The International Journal of Advanced Manufacturing Technology, 36(5), 582-588.