建構單件流程的精實生產模式－以S公司為例

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姓名

段漢林(Han-lin Tuan) 查詢紙本館藏

畢業系所

工業管理研究所在職專班

論文名稱

建構單件流程的精實生產模式－以S公司為例
(The construction one-piece flow process of lean production-take S Corporation as an example)

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摘要(中)

氣體原物料對於半導體產業、TFT-LCD薄膜面板產業、薄膜太陽能電池產業的重要性，就像電與水一樣，缺一不可。但綜觀國內電子氣體業，大都由傳統工業氣體發展而來，所以對於氣體生產模式大都依循傳統的大量批次式生產模式進行。此模式固然具有簡單、易管理的優點，但相對也產生高庫存、反應時間、交期長等缺點。因此批次式生產種模式愈來愈無法滿足電子業要求少量多樣式、快速反應的作業型態。
因此本研究由氣體鋼瓶生產的一個小環節，試圖比較批次生產與單件流程生產的優缺點。並藉由個案公司以持續改善的手法，用於鋼瓶包裝檢驗流程改善專案中，導入單件流程所用的步驟與方法、所遇到的困難與挑戰，作為研究的重點。企圖找出可行的方式，使精實生產的觀念能逐漸地有效運用於氣體生產業。使產品的產出模式能與供應鏈的下游配合，達到快速反應、零庫存、零缺點的終極目標。
本研究發現單件流程(One-piece flow)亦能適用於氣體鋼瓶(gases cylinders)生產的部份流程，但仍需針對鋼瓶的運送自動化加以改善，方能真正發揮單件流程的效益。

摘要(英)

Just like electricity and water, gas raw material plays the key and significant role in semiconductor producer, thin-film transistor liquid crystal display manufacturers and solar industries. Generally speaking, most of the local electronic gases companies basically developed their businesses by traditional batch flow. The traditional production is simple and easy to manage, but on the other hand we also could see the weakness of high inventory, slow response timing and long lead time. Therefore, gradually, Batch flow couldn’’t satisfy the Electronic Industry on the requirements of varieties and quick response.
Therefore, my study tries to compare the batch flow with one-piece flow by one key point from the production of gas cylinders. Besides, to observe the difficulties and challenges of improving the cylinders package inspection process by inputting the one-piece flow from the case study will be my main research part, and then try to find the possible solutions to make the production more efficiently. The purpose is to find the right production pattern which works perfectly with the end suppliers and reach the target of quick response, zero inventories and no defect.
My study figure out the One-piece Flow also could be applicable to the production of gases cylinders in some parts. To earn the biggest profit from the One-piece Flow, the cylinders’ automatic distribution should be improved.

關鍵字(中)

★ 單件流程
★ 精實生產
★ 持續改善
★ 電子氣體
★ 工業氣體

關鍵字(英)

★ One-piece Flow
★ Lean Production
★ Continuous Improvement
★ Electronic Gases
★ Package Gases

論文目次

摘要...............................................................................................................................i
Abstract ..........................................................................................................................ii
目錄..............................................................................................................................iii
圖目錄..........................................................................................................................vi
表目錄........................................................................................................................viii
第1章緒論...................................................................................................................1
1.1 研究背景與動機............................................................................................1
1.2 研究目的........................................................................................................2
1.3 研究範圍與限制............................................................................................2
1.3.1 限於製造業之探討............................................................................2
1.3.2 研究限制............................................................................................2
1.4 論文架構........................................................................................................3
第2章文獻回顧...........................................................................................................4
2.1 精實生產........................................................................................................4
2.1.1 確定價值............................................................................................5
2.1.2 掌握價值流程....................................................................................7
2.1.3 朝流線生產方式邁進........................................................................7
2.1.4 建立後拉式生產系統........................................................................7
2.1.5 追求盡善盡美....................................................................................8
2.1.6 精實生產的效益................................................................................8
2.2 單件流程........................................................................................................8
2.2.1 單件流程的基本定義........................................................................9
2.2.2 節拍時間..........................................................................................11
2.2.3 看板..................................................................................................12
2.2.4 工作標準化......................................................................................14
2.2.5 拉式生產..........................................................................................15
2.2.6 自働化..............................................................................................16
2.3 生產流程化..................................................................................................17
2.4 生產平準化..................................................................................................17
2.4.1 前置時間..........................................................................................17
2.4.2 平準化..............................................................................................18
2.4.3 多能工..............................................................................................19
2.5 延遲策略......................................................................................................20
2.5.1 延遲策略的意義與作用..................................................................20
第3章產業背景與個案公司簡介.............................................................................24
3.1 氣體產業介紹..............................................................................................24
3.1.1 工業氣體與電子氣體......................................................................24
3.1.2 氣體容器..........................................................................................27
3.2 個案公司......................................................................................................31
3.2.1 個案公司背景..................................................................................31
3.2.2 個案公司持續改善組織、流程、與所運用之工具......................32
3.2.3 持續改善組織與架構......................................................................32
3.2.4 持續改善流程..................................................................................33
3.2.5 持續改善工具暨選用時機..............................................................36
3.3 個案背景......................................................................................................40
3.3.1 地理位置..........................................................................................40
第4章個案案例.........................................................................................................42
4.1 改善活動執行模式分析..............................................................................42
4.1.1 問題背景..........................................................................................42
4.1.2 問題分析..........................................................................................43
4.1.3 問題分析..........................................................................................47
4.1.4 程序流程圖......................................................................................47
4.1.5 流程格子表、流向比率表與產出率圖..........................................48
4.1.6 事件序列..........................................................................................51
4.1.7 單件流程規劃表的使用..................................................................52
4.2 結果分析......................................................................................................54
4.2.1 修正流程順序..................................................................................54
4.2.2 規劃單件流程..................................................................................56
第5章研究結論與建議.............................................................................................61
5.1 研究結論......................................................................................................61
5.2 研究貢獻......................................................................................................61
5.3 後續個案研究建議......................................................................................61
參考文獻.....................................................................................................................63

參考文獻

1. Alderson W., 1950, Marketing Efficiency and the Principle of Postponement. Cost and Profit Outlook, September 3.
2. BCC Research, 2007, The Global Industrial Gas Business.
3. Feld, W. M., 2001, Lean Manufacturing: Tools, Techniques, and how to Use Them, St Lucie Press.
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5. Liker, K. Jeffrey, 2004, The Toyota Way, Mc Graw-Hill.
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7. Miltenbugr, John, 2001, One-piece Flow Manufacturing on U-shaped Production Lines, IIE Transactions,Vol. 33, No.4 (2001), pp. 303-321
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指導教授

何應欽(Ying-chin Ho)

審核日期

2008-6-23

推文