應用六標準差於耐熱瓶製程改善之研究

An Application of Six Sigma on HR Bottle Process Improvement

蔡永富(Yung-Fu Tsai)

指導教授 ： 蔡碩倉

亞洲大學/管理學院/經營管理學系碩士班/碩士(2008年)

摘要

根據財團法人食品工業發展研究所2007年4月所發行食品市場資訊資料顯示，這十年來台灣飲料市場需求規模平均高達450億~500億元。近年來由於全球暖化現象及商品銷售通路日益發達，一般消費者對於包裝飲料的接受意願大幅提高，因此，輕便、平價且隨處可購得的包裝飲料需求量，有逐漸攀升的趨勢。
鑑於傳統產業對新管理知識之應用及接受態度均趨向保守，在產業環境現實面之嚴苛考驗下，企業為求生存，必須引進新的品質管理模式，藉由製程改善，在滿足顧客需求、降低不良率、提高獲利前提下，創造企業永續經營契機。而眾多管理模式中，尤以80年代崛起之「六標準差」（six sigma）應用開始被廣泛討論。延伸至管理上的意涵，六標準差成為一種追求高品質、以數據為導向之具體做法，據以分析、解決問題的根源及減少流程變異。
本研究從品質改善發展趨勢，整理與六標準差相關的理論與文獻，藉以確立研究方向之正確性與合理性。並從比較品管圈（QCC）、全面品質管理（TQM）及六標準差（6σ）之定義與模式，瞭解三種不同管理模式之間差異及相互關係，以確立製程改善使用手法，另亦探討PET寶特瓶相關理論，提供本研究的理論基礎。
本研究藉由導入六標準差之DMAIC(Define、Measure、Analyze、Improve、Control)流程改善步驟，針對H公司飲料包材吹瓶製程改善為研究對象，以PET結晶瓶耐熱性為改善議題，改善耐熱不良的異常。研究結果顯示，導入六標準差後，發現模身溫度、底模溫度、吹瓶時間及瓶胚溫
度為關鍵改善因素，製程不良率由原先3.72﹪下降到1.08﹪，除可提高產品品質外，且能有效降低生產成本。

關鍵字

品管圈、全面品質管理、六標準差、DMAIC

並列摘要

According to the data on the food market issued by financial legal person’s food industry development research institute in April 2007, in the last decade, the scale of the Taiwan soft drinks market demand amounted to 45-50 billion dollars averagely. In recent years, due to global warming and increasingly developed merchandise sales channels, ordinary consumers’ need for packed drinks has arisen enormously. Therefore, the demand for inexpensive and portable packed drinks that are available everywhere is expected to arise gradually.
In view of the fact that traditional industries have become more and more conservative to apply and accept new management knowledge, in order to survive in a harsh environment, enterprises must introduce new quality management models to create opportunities for forever operation based on the improvement of manufacturing process and under prerequisites of meeting customers’ demand, lowering non-conformity rate and gaining more profits. In the many management models, the concept of “six sigma” introduced in 1980s is most heatedly discussed. In terms of management, the concept of “six sigma” has become a concrete practice to pursue high quality, as guided by data. With the concept, the basic cause of a problem can be analyzed so as to solve the problem, and variation in process can also be reduced.
This thesis aims to determine the correctness and reasonableness
of the research direction from the tendency of quality improvement and by sorting out the theories and documents related to the concept of “six sigma”; from comparison of the definitions of Quality Control Circle (QCC), Total Quality Management (TQM) and six sigma (6σ), to understand the differences and relations among these three management models, so as to determine the method for manufacturing process; to explore relevant theories on PET bottle, so as to provide theoretical foundation for the research.
This thesis aims to solve the problem of poor heat resistance based on the steps used to improve the manufacturing process that introduce the concept of “six sigma”: DMAIC (Define, Measure, Analyze, Improve, Control), with improvement of bottle blowing process as target of research, where the bottle is H Company’s packaging materials of drinks, and heat resistance of PET crystal bottle as subject. The result shows that after introduction of the concept of “six sigma”, it is found that the temperatures of die body and die bed, the time to blow bottles and the temperature of bottle embryo are key improvement factors, and the non-conformity rate in manufacturing process has been reduced from 3.72% to 1.08%. It can not only improve product quality, but also effectively lower production cost.

並列關鍵字

QCC, TQM, six sigma, DMAIC

參考文獻

張妤慧（2004）整合六標準差之通用問題管理歷程之研究 碩士論文 私立中原大學工業工程研究所。

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羅盛文（2002）品質小組問題管理模式之研究，碩士論文，私立中原大學工業工程研究所。

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呂芳深（2000）由顧客導向探討計數值改善之研究-以膠帶加工業為例 碩士論文 中原大學工業工程研究所。