探討大量客製之生產自動化成效-以手機製造商之測試自動化為例

A Study on the Effects of Production Automation for Mass Customization -A Case Study of Smart Phone Producer Testing Automation

李澤程(Lee, Adams)

指導教授 ： 朱詣尹 ； 邱銘傳

國立清華大學/工學院/工業工程與工程管理學系/碩士(2015年)

摘要

採取大量客製化策略之科技產品製造商，為了面對市場激烈的競爭及因應成本因素，需修正生產系統及作一連串的生產自動化改變。大量客製化之複雜度來自產品尺寸快速改變，軟體開發功能、治具設計、及自動化硬體擴充相容性，產品測試人機介面及產品轉換前置時間等，造成自動化之實質效益與期待結果有相當程度的差異。本研究探討製造商面對大量客製生產自動化之挑戰，如何重組製造系統關鍵技術以模組化提升彈性，並提出解決方案以修正建構彈性自動化系統。本研究藉由產品與製程模組化兩項核心技術應用至自動化解決方案，期望運用現場分析規劃產品導向及生產製程模組化。以生產績效比對模組測試自動化前後之差異，呈現模組化對大量客製化生產之成效。
藉由本研究現場實驗結果，以傳統人工生產及模組化自動化生產相比之下，模組化的效益將產品轉換的前置時間降低60%，設備稼動率由90%提升至95%，在產出效率由89%提升至93%。另外，在製造成本的基礎比較下，模組化的生產成本可降低30%。最終模組化評估步驟中，期望透過本研究案例期望提供製造業管理者運用模組化彈性製造系統技術，來達到彈性生產的決策參考。
關鍵詞：大量客製化、模組化、彈性、自動化

關鍵字

大量客製化 ； 模組化 ； 彈性 ； 自動化

並列摘要

Facing intense competition in market and on cost factors, technology product manufacturers who adopt mass customization strategies need to amend a series of production processes and to change manufacture automation. Complexity in mass customization arises from products size changes; compatibility in software development, fixtures design, augmentation of automation hardware and human-machine interface in product testing; as well as lead time for switching production, and so on. These factors cause the actual results of automation significantly different from those expected. This research discusses facing the challenges in automation for mass customization, how the manufacturers may combine key techniques of reconfigured manufacture system to promote flexibility by modularization, and generate the solutions to reform and build flexible automation system. This research explores the use of product and process modularization for flexible automation in a case analysis of production site scenario with planned product and process modularization. Production performance measures for the test automation are compared before and after product and process modularization.
The results show that modularization can decrease 60% of lead time in product shift. Equipment utilization will raise from 90% to 95%. In addition, output rate will improve from 89% to 93%. Further, manufacture cost will be reduce 30%. Therefore, this research provides a systematic modularization solution as strategic decision support system to manufacturers in production reconfiguration and automation.
Keywords : mass customization, modularization, flexibility, automation

並列關鍵字

mass customization ； flexibility ； modularization ； automation

參考文獻

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