精實生產之績效研究以某冰箱製造為例

近代生產型態逐漸以小批量、多樣化，交期短、訂單式的生產為發展趨勢。在此生產型態下，如何降低庫存成本、縮短製造流程時間及交貨延遲；並提高生產資源的有效運用，成為當前需要解決的問題。因此，本論文是以「家電冰箱製造廠」為例，實施『精實生產』作全面性的生產製造改善。『精實生產』是以(JIT)及時生產系統的觀念搭配5S基礎運動與TQC、TPM員工教育活動相互結合，來改善傳統製造廠在實施小批量生產訂單所增加的製造成本。研究方式是以小批量生產模式，將相同容積之冰箱，以改善前（87-89年）之生產數據；與改善後（92-94年）的生產方式及Layout進行製造比較，將實際運作的數據透過各項比較(例如各項庫存金額、製造流程時間、換型、搬運時間、設備可動率、及品質良率等等..)，經過比較之後，結果證明『精實生產』在冰箱製造廠所推行的最大成效為庫存金額降低，從原先總庫存金額佔總製造費用約55.8％降至19.01％，其次是生產流程時間縮短37.9％，而在製造成本上每年可節省5.29％的費用。由此證明家電冰箱製造廠實施『精實生產』是可以提升產業的競爭力。

關鍵字

庫存物料需求規劃；搬運時間；換型時間；品質良率；精實生產；即時生產；製造流程；設備可動率；產品生命週期

並列摘要

Modern production status gradually takes small batch, diversification, short delivery date, production by order as trend of development. Under this production status, how to reduce the stock cost and delivery delay, shorten manufacture flow time and enhances the effective utilization of the production resource becomes the current problem to be solved. Therefore, this paper takes「the electrical appliances and refrigerator factory」as an example to discuss implements of ‘fine really to produce’ to wholly improve production and manufacture. 『Lean Production』based on JIT matches the 5S foundation movement and unifies TQC, TPM staff training activities to improve the increased manufacturing cost of the traditional factory on implementing small batch production. The research is by the small batch production pattern and takes same-contents of refrigerators to make comparison on the production data before improvement year (87–89) and those production methods and layout after improvement year (92–94) through e.g. stock amount, the manufacture flow time, model change, the transporting time, the equipment available rate and the good quality rate and so on. After process comparison, finally it proves『Lean Production』makes the stock amount reduction the biggest profit ex all execution for the refrigerator factory. The total stock amount takes whole manufacturing expenses from the originally 55.8% down to 19.01%. The next is the production process time 37.9% reduction and every year may save 5.29% expenses in the production cost. Herein, this proves the electrical appliances refrigerator factory’s implements『Lean Production』will promote industrial competitive competence.

並列關鍵字

Material Requirement Planning ； Lean Production ； PLC ； TQC ； JIT ； TPM ； 5S ； MRP ； Total Productive Maintenance ； Total Quality Control ； Just In Time ； Production Life Cycle.