發展精實生產之無調整段取作業系統-以鋁合金輪圈生產段取為例

Development of a lean non-adjusting setup system - Case study of Aluminum rims production

江文振(WEN-CHEN CHIANG)

指導教授 ： 黃博滄

中原大學/電機資訊學院/工業與系統工程研究所/碩士(2016年)

https://doi.org/10.6840/cycu201600593

摘要

在台灣80年代時，產業自動化開始被推動並且奠定良好基礎。工業4.0強調利用物聯網、智慧機械/機器人、巨量資料與精實管理等技術，推動產業朝設備智能化、工廠智慧化與系統虛實化發展，加速提升自我產品的附加價值與生產力。傳統上消費者購買產品只能從現有固定的規格中選擇，製造商並不能即時蒐集顧客的使用偏好與使用情形，使得產品改良速度較緩慢。透過現今網路技術(物聯網感知)，供應商記錄消費者試用商品時偏好與使用情形。透過雲端將資料傳遞給製造商，提供快速、便宜、穩定的品質供應，於是製造業者都面臨了不再大量生產環境。在客戶的需求一直持續在改變的時代，最明顯感覺到的就是速度與時間競爭。消費者越來越注重效率，還有製造業將如何在最快時間內，製造出符合消費者需求的產品。相對的，生產快速、品質穩定、便宜將會是製造商獲得客戶下單的重要關鍵。
因此，本研究將透過豐田生產、福特生產、彈性製造三大系統中的段取手法，整合業界與學術界相關案例資訊，開發出適合CNC加工設備的無調整段取作業六大步驟系統整合，並且藉由鋁合金輪圈加工廠實例經驗進行研究測試。經過改善後，段取作業時間由原本1486秒降至599秒，減少887秒段取停機損失。

關鍵字

豐田式生產系統、精實生產、快速段取、系統模組化

並列摘要

In the 1980s, industrial automation was begun to promote and laid a good foundation in Taiwan. Industry 4.0 emphasizes the use of Internet of Things, intelligent machineries robots, big data and lean management to promote the industry towards the development of intelligent equipment, wisdom factory and the VR system, increase the added value and production capability. Traditionally, consumers can only purchase products from the current existing specifications, and manufacturers cannot collect the preferences and usage from customers immediately, cause the low pace improvement. Through Internet technology, product preferences and usage were recorded by suppliers when consumers try goods. Through the Cloud System, the data was passed to the manufacturers, and then fast, cheap and stable quality were provided in order to increase their self-profits. So manufacturers face a no longer mass production environment. The most obvious sense is the speed and time-based competition. Consumers increasingly focused on the efficiency and how the consumer-wanted products will be manufactured in the fastest time. Relatively, fast, stable quality and cheaper product will be the key to the manufacturer to get the next order.
Therefore, this study integrated the setup system of Toyota Production System, Ford Production System and flexible production, and the related practices in industry and academia, to develop six steps of non-adjusted setup system for CNC machining equipment. A verified test was conducted in the aluminum rums manufacturing factory. The results showed that the operation time of setup was reduced from 1486 to 599 seconds, 887 seconds setup time could be saved.

並列關鍵字

Toyota Production System, Lean production, quickly excised, modular systems, etc.

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