瓦楞紙箱因成本低、重量輕與保護性佳，長期為供應鏈中不可或缺的包裝材料。然而近年受區域競爭加劇與電子商務崛起影響，訂單型態從大量長期訂單轉變為少量多樣、交期極短的碎片化模式，傳統仰賴人工經驗的排程方式已無法應付複雜的生產需求。本研究以中國華東地區某瓦楞紙器二級廠為個案，針對其長期存在的交期達交率偏低與產能受限問題進行系統性診斷。 紙器生產流程具兩階段特性：前端複瓦機屬推式生產，須遵循紙幅由大到小、基重由高到低的物理連續性規則；後端印刷機屬拉式生產，以達交與換線最小化為目標。本研究蒐集個案公司2025年1月共591筆工單之實際生產數據，針對推拉介面的結構性衝突進行量化分析。 現行排程模式下整體達交率僅49.7%，設備有效生產時間不足一半，非計畫停車損失佔全月上機工時的18.8%。根本原因在於待印區空間嚴重積壓——以單台印刷機有效容量225板為基準，近半數工作日佔用率超過75%警戒值，部分日期甚至超過物理容量上限，導致現場操作人員無法順利取件，進而引發大量停車與延誤。 本研究提出以空間佔用率為核心指標的動態排程優化策略，在傳統強森法則之上（Johnson′s Rule），導入空間敏感型派工機制：當待印區積料超過75%警戒閾值時，強制優先執行大批量訂單以快速釋放空間。硬體層面則建議將人力滾輪排升級為智能鏈板輸送帶、導入全自動送紙機，以消除人為遲滯並擴增有效儲放空間。 最後，本研究建構瓦楞紙器製造業推拉介面之空間感知型排程框架，證明在低毛利環境下，精準排程具有顯著的經濟槓桿效益，並為傳統紙器廠邁向數位化與智能化轉型提供具高度實務操作性的改善藍圖。;This case study examines improvements to production scheduling methods in the corrugated packaging industry， focusing on how advanced planning and scheduling (APS) and on-site logistics automation can resolve production bottlenecks， particularly under the trend of high-mix， low-volume orders and extremely short lead times. Using a corrugated box plant in East China as a case study， an analysis of actual production data from January 2025 revealed that the overall order fulfillment rate was only approximately 50% under the current scheduling model， accompanied by a disproportionately high rate of unplanned downtime. In-depth investigation indicated that the root cause of this low fulfillment rate lies in the structural conflict between the push-based continuous production rules of the corrugator and the pull-based delivery scheduling of the printing machines. This conflict frequently leads the pre-printing buffer zone to exceed its physical capacity， resulting in severe material backlogs and retrieval difficulties. To address this dilemma， this research proposes a modified Johnson′s Rule that incorporates spatial occupancy as a dynamic trigger for printing machine dispatching. When the buffer zone load reaches a predefined threshold， large-volume orders are prioritized to rapidly release space， which is expected to significantly reduce downtime losses and improve fulfillment rates. Furthermore， the study evaluates a hardware improvement plan involving the implementation of an automated plastic chain conveyor system. The results suggest that automated logistics can help eliminate manual handling errors， enhance space utilization， and optimize long-term labor costs， providing a concrete practical path for the digital transformation and scheduling optimization of traditional corrugated box factories.
