多廠區跨廠產能規劃之探討

Multi-Plant Capacity Planning for Coordinated Manufacturing

張美滿

指導教授 ： 鄭元杰

元智大學/工程學院/工業工程與管理學系/碩士(2002年)

摘要

近年來企業為承接更大量的訂單，不斷的擴充產能，從企業成立之初單廠區模式，不斷的擴廠與合併，使得企業規模日漸增大，製造工廠也從一廠的模式擴充至多廠，為因應此生產環境的改變，以往單廠之生產規劃已不敷使用。所以，如何在現階段生產環境下，規劃多廠間跨廠產能規劃就顯得相當重要。
本研究針對多廠生產規劃問題，在廠與廠間歷史銷售量及既有的資源設備下，建立三階段規劃模式以生產總成本最小為目標。業務依據歷史銷售量統一接單，根據銷售量產能限制分配訂單，再以機器產能限制規劃工作站產能負荷，找出瓶頸工作站利用跨廠生產方式解決多廠區產能規劃問題。其中三階段模式並考量生產成本、製造成本、外包成本、延遲成本與運送成本等之總成本最小下，取得第一階段各廠區訂單產品需求量；第二階段各廠工作站產能負荷及瓶頸工作站；第三階段平衡瓶頸工作站需求量，取得工作站跨廠生產量、外包量與產能利用率。如此，可以依據最佳跨廠產能規劃結果安排生產細部規劃與排程規劃。

關鍵字

跨廠產能規劃 ； 銷售量產能 ； 機器產能 ； 瓶頸工作站

並列摘要

In order to satisfy the demand of increasing orders, a company must expand the production capacity to meet the orders. Due to the increasing production scale, a company must adopt a multi-plant manufacturing strategy to increase the capacity to satisfy the ordered demands. Under this consideration, it is important to develop a coordinated capacity planning in the manufacturing model to meet the change in such production environment.
The objective of this research is to develop three integrate capacity planning models in three phases. This model is aimed at minimizing the total production cost under the consideration of historical sales volumes among plants and constraints of resources and equipment. The multi-plant capacity planning model is analyzed according to the historical sales volume, order allocation by sales capacity constrain, workstation capacity load by machine capacity constrain to find the bottleneck workstation. In this model, we obtain the minimal integrated cost including production cost, manufacturing cost, out-sourcing cost, delay cost, and delivery cost. In phase one, we can obtain the amount of product order requirement of each plant. In phase two the workstation capacity load and bottleneck workstation of each plant is obtained. In phase three, we can obtain the workstation production amount, outsourcing amount and utilization of capacity by means of balancing the bottleneck workstation requirements. The multi-plant capacity is modeled and solved using the linear programming formulation and technologies. In this way, an optimal multi-plant capacity planning solution can be found. We can arrange the production planning and schedule planning according to the optimal solution of multi-plant capacity planning.

並列關鍵字

Multi-Plant Capacity Planning ； Sales Capacity ； Machine Capacity ； Bottleneck Workstation

參考文獻

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