拉式生產效率穩定及最佳化研究-以A鋼鐵公司為例

傳統生產習慣以大批量生產來降低成本。這會導致前後製程資訊不流通、大量庫存堆積、生產動線不佳等問題。本研究導入精實生產模式，透過價值流程圖搭配分析問題方法找出真因，並針對真因提出改善方法。為了讓現場產生流動，導入拉式生產模式，連結前後製程資訊，同時清理現場不必要的物件，本研究提出三個提升生產效率階段，分別為階段一的創造流動、階段二的提升流動效率、階段三的穩定流動。且本研究將這三個施行階段在一家鋼鐵廠推行後，可以看到有效降低半成品及成品數量，間接也增加了現場使用空間，同時也顯著提升了現場的作業效率。

關鍵字

精實生產；拉式生產；平準化；生產批量表

並列摘要

Steel bars are indispensable raw materials for construction. Rebar manufacturer are used to product with large batch to reduce costs. However, that leads to problems such as disconnection between two processes, the accumulation of a large amount of inventory, and deliver delays. This research introduces the lean production management to improve the performance of a case steel bar manufacturer in Taiwan. First we find out the root causes of the above mentioned problems through the value flow diagram and the 5-whys problem analysis method. Then we propose improvement methods with three steps for solving the root causes. in step one the production flow is generated gradually through setting up the environment of pull production. In step 2 the efficiency of production flow is optimized using the result of a mathematical model. in step 3 some supplementary tools are proposed to stabilize the flow. We implemented the three steps in the case manufacturer and resulted a significant improvement of decreasing inventory and then increasing the rate of on-time delivery.