士林染料(Indanthren dyestuffs)在染色工程中的熱能耗用少且工時短,具有優異之成本效益,其高均標之耐氯牢度及高日光牢度更是獨步市場,因此常被指定應用在泳池或海灘高級浴巾的生產中。 由於甕化(vatting)染色之瞬染(strike)常導致不均勻或不對色發生,造成重修率高,其不良的再現性(reproducibilty)嚴重影響品質與成本。本研究以「提升士林染料對棉纖維於浸染染色再現性」之實務案例為研究主題。透過文獻探討與Kepner-Tregoe(K-T)理性思考模式做為問題分析與找出染色問題關鍵因素。以此染色關鍵因素設計成實驗構面,進行實驗設計(experimental design),由實驗中所得數據作為品質改善的依據,從中決策出一個可行性高且適用的染色流程套用於量產模式中進行生產。 經過四個月的實驗,得到的改善績效為:一次不對色次數,由重修次數5次降低至0-1次;良率由50% 提升至90%;深色染色流程由190分鐘縮短為150分鐘;工時效率提高了26%;在助劑成本上節省了45%;耐氯漂堅牢度由3級提高至4級。由此改善結果可知本研究所提出的方法成效卓著,同時也達成資源整合與創造價值之目標任務。
The topic is analyzed by Kepner-Tregoe decision making analytic process to obtian the key factors cause the dyeing problem. Those factors are then become the dimensions of designing the experiments. Finally, data and results from these exprientments are used to improve the dyeing quality and applied into the dyeing process for mass production. After four months’ experientments, the outcomes from these experientments are as follows: 1. For the right dyed at the first-time dyeing, numbers of redyeing reduced from 5 times to 0-1 time. Yield rate increased from 50% to 90%. 2. The time of the process of deep color dyeing reduced from 190 minutes to 150 minutes and the man-hour efficiency enhanced by 26%. Cost of the auxiliary cost saved by 45%. 3. Color fastness to bleaching with chlorine upgraded from level 3 to level 4. It is obvious that the operations suggested from this study generate significant performance and also achieve the purpose of resources integration and value creation.