電鍍製程的精實改善探討-以W公司為例

電鍍是一種表面處理的技術，產業涵蓋範圍遍及整個製造業，台灣內外銷產品中約有五分之二以上的商品都必需經過表面處理。台灣電鍍產業多以家庭式中小型企業為主，現今面臨員工高齡化，人力資源不足的問題，舊有的技術無法傳承之外，在轉型上也會因缺乏數據，而無法傳承，除了技術、人力外，還面臨節能、環保問題，因近年來環保意識提升，電鍍產生的廢水處理需更加重視，綜合以上問題，公司必須將人員、機台、物料做到最有效的管理，減少浪費。本研究以台灣某南部電鍍公司為例，透過實地調查個案公司作業流程繪製出價值流圖，從價值流圖發現作業流動的時候會產生的浪費。並使用精實管理的五大步驟，分別為確認價值、掌握價值流、作業暢流、依顧客需求建立後拉式生產及追求完美，協助現場進行問題改善；建立容易執行與遵守的現場作業模式，以利後續技術傳承，且同時考量削減過程裡的浪費，提升人力與物料的生產價值，讓電鍍產業更具有永續經營的能力。透過這次精實改善重工滾桶數比例減少62.5%，混料頻率降低62.5%，去除製程中不必要的浪費，增加有效產能，提升產線的價值流動。

關鍵字

電鍍業；精實生產；價值流程圖；目視化管理；迴歸分析

並列摘要

Electroplating is a surface treatment technology that covers the entire manufacturing industry. About two-fifths of Taiwan's domestic and foreign products must undergo surface treatment. Taiwan's electroplating industry is mostly family-owned small and medium-sized enterprises, but it has been facing the problems of aging employees and insufficient human resources nowadays. In addition to the inability of passing on this old technology, it is impossible to transform and pass it on due to insufficient data. Besides the above-mentioned issues, the issues of energy-saving and environmental protection are generated in this industry. Due to the heightened awareness of environmental protection in recent years, more attentions are given to the treatment of wastewater generated by electroplating. In view of the above issues, the effective management on personnel, machines, and materials are therefore required to reduce any unnecessary waste. This study takes an electroplating company in the Southern part of Taiwan as an example. The value stream maps are drawn through the field investigation regarding the operation process of company and the waste are therefore excavated when the operation flows from the map. By utilizing the five critical steps of lean management, respectively Defining Value, Mapping the Value Stream, Creating Flow, Using a Pull System on the Basis of Customers’ Requests, and Pursuing Perfection, the improvements are then carried out on site. It’s suggested that by establishing an on-site operation models that are easy to implement and abide by, this technology can be easily passed on. Also, by taking the issue of reducing waste in the process into account, it increases the production value of manpower and materials as well as create sustainability in the electroplating industry. Through this lean improvement, the proportion of drums in heavy industry has been reduced by 62.5%, and the frequency of mixing materials has been reduced by 62.5%. This eliminates unnecessary waste in the manufacturing process, increases effective production capacity, and improves the value flow of the production line.