整合系統模擬與價值流分析以有效提升健身器材製造工廠生產效能

Integrating Value Stream Analysis with Simulation Study to Effectively Improve Production Performance in a Fitness Equipment Factory

林煜昌(YU-CHANG LIN)

指導教授 ： 洪弘祈

朝陽科技大學/理工學院/工業工程與管理系/碩士(2014年)

摘要

健身器材產業包含焊接、噴漆、組裝三個主要製程，其中焊接與組裝是由數個工作站所組成。過去通常都只對單一製程工作站之績效加以探討，而忽略了總體產能的平準化。加上製程中有著許多先天因素上的限制，例如:噴漆需為大批量生產、焊接車架使用翻轉模，測試治具特殊站限制，組裝工序順序性…等，諸多因素使其生產的複雜性較高。因此，本文考慮總體製程進行價值流分析與模擬研究，期待產能最大化並有效縮短生產週期時間。
本論文以個案公司製程為主，繪製從顧客端到供應商間之價值流圖，並以系統模擬為分析工具，建構出主要三種產品之現況價值流圖的模擬模式，並以Excel進行驗證分析，確認三種模擬模式的績效與現狀並無顯著差異。
本研究以精實觀念規劃出此三種產品的未來價值流圖，並利用Arena模擬軟體進行分析，提供個案公司更佳的生產方案。三種產品的未來價值流模擬模型能有效地改善企業中各項資源的利用率，並提高整體生產效益。

關鍵字: 健身器材、精實生產、價值流圖、系統模擬

關鍵字

系統模擬 ； 價值流圖 ； 精實生產 ； 健身器材

並列摘要

There are three main processes, welding, painting, and assembly, in the manufacturing process of fitness equipment industry. However, welding and assembly process are performed in several workstations. In the past, the performance of the manufacturing only was explored on each single workstation, where as the leveling of overall production capacity was ignored. In addition, the requirement of mass production in painting, the overturning of mold tools during welding, the specialty of testing tools, and the unique assembly sequences all increase the complexity of analyzing the overall system performance. Therefore, to shorten the production cycle time and to make the maximize productivity by integrating value-chain analysis and systems simulation will be briefly detailed in this paper.
The major part in this paper is a case study about the process of an individual fitness equipment company. This study first drew the value stream mapping from suppliers to customers for the three main products of the company. Then system simulation analysis tool was applied to construct simulation models. Finally, these models were validated via statistical analysis as compared to the actual system outputs.
After validations, this study further applied the concept of Lean production to create future value stream mapping of these three products. Future value stream simulation model of the three products were also constructed. Simulation results of these models shown that they can effectively improve the utilization of enterprise resources and improve overall production efficiency.

Keywords: Fitness equipment, Lean manufacturing, Value stream mapping, Systems simulation

並列關鍵字

Systems simulation ； Value stream mapping ； Lean manufacturing ； Fitness equipment

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