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系統識別號 U0026-1207201714141500
論文名稱(中文) 以模擬最佳化求解自行車鏈條生產系統之批量決策問題
論文名稱(英文) The Use of Simulation Optimization in Solving the Production Batching Problem from Bicycle Chain Manufacturing
校院名稱 成功大學
系所名稱(中) 製造資訊與系統研究所
系所名稱(英) Institue of Manufacturing Information and Systems
學年度 105
學期 2
出版年 106
研究生(中文) 宋偉欽
研究生(英文) Wei-Chin Sung
學號 P96041128
學位類別 碩士
語文別 中文
論文頁數 87頁
口試委員 指導教授-楊大和
召集委員-王逸琦
口試委員-李家岩
口試委員-葉桂珍
中文關鍵字 精實生產  價值流圖  批量  CONWIP  離散事件模擬  模擬最佳化 
英文關鍵字 Lean production  VSM  Batch size  CONWIP  Discrete-event simulation  Simulation optimization 
學科別分類
中文摘要 本研究探討之案例公司為一家自行車鏈條製造廠,目前面臨少量多樣產品及銷售量不穩定的情況下,如何在既有的生產環境下改善生產流程的流暢性,降低生產的前置時間及縮短交期來增加製造系統的彈性;並且在滿足顧客訂單的情況下,以最低的庫存成本來進行有效的庫存管理,是目前自行車產業所面臨的重要議題。因此本研究將透過導入精實的生產的觀點,以小批量及CONWIP拉式生產系統的導入,進一步縮短生產前置時間及降低的在製品水準。
首先以價值流圖的繪製,找出現況之改善契機,在考慮產業特性及生產限制下,發展出可行的改善設計方案,進一步以模擬及最佳化工具產生各方案之績效值,接著以敏感度分析探討在需求變動的情況下,各方案對系統績效的影響。
根據實驗分析之結果,案例公司目前推行的改善方案前置時間改善百分比為25%,在製品數量改善百分比為21%;而案例公司未來的目標最佳化方案能使前置時間改善百分比為76%,在製品數量改善百分比為81%,由此可看出,導入CONWIP拉式生產系統並同時縮小製程中的加工批量及移轉批量,可以有效的縮短生產前置時間和降低在製品數量,能夠以更短的時間滿足顧客需求,提升系統績效。
英文摘要 Lean production is one of the initiatives that major businesses in the world have been trying to adopt in order to maintain competitive in an increasingly global markets.In this case, bicycle chain manufacturing presented here to be example, currently face to the small-volume, large-variety products and sales instability. Under the existing production environment how to improve reduce production lead time and shorten the production delivery to increase the flexibility of the manufacturing system.
First, we use Value Stream Mapping(VSM)to find out the potential improvement opportunities in the system. Second, This study is conducted to the case firm, we proposed appropriate lean principle to design the four scenario. And how to measure the performance of every scenario? We used discrete-event simulation to generate the value of performance index, and also used optimization tool to find out better production batching problem and Constant Work-in-process(CONWIP)level in order to reduce lead time and Work-in-process (WIP) level. Finally, we conduct a sensitivity analysis to discuss the different scenario performance under the circumstances of customer’s variable demand.
After experiment, the results shows that the proposed plans could reduce the WIP and lead time when throughput didn’t impacted. Based on these reasons, it represents the true efficiency in the manufacturing system. And at the end of the experiment, we use sensitivity analysis to see that when demand change if system need to meet service level. From sensitivity analysis can be proved that the proposed plan is still effective in different situations. Now, case firm have already impelled the improvement plan and it have brought advantages to them obviously.
論文目次 摘要 i
誌謝 iv
目錄 v
表目錄 vii
圖目錄 x
1. 緒論 1
1.1 研究背景與動機 1
1.2 研究目的 4
1.3 研究流程 5
1.4 研究架構 5
2. 文獻探討 6
2.1 精實生產系統 6
2.2 價值流圖 10
2.3 批量 13
2.4 模擬最佳化 14
3. 案例說明及價值流圖分析 22
3.1 案例公司簡介 23
3.2 繪製現況價值流圖 26
3.3 現況方案價值流圖分析及找出改善目標 33
4. 方法與分析 36
4.1 精實改善及方案產生 36
4.2 模擬模式建構 43
4.3 模擬最佳化 67
4.4 實驗結果與分析 69
4.5 敏感度分析 71
5. 結論與建議 74
5.1 結論 74
5.2 未來研究與建議 75
參考文獻 76
附錄A論文符號說明 79
附錄B各製程人員上、下料時間表 80
附錄C方案二之最佳化批量 82
附錄D方案四之最佳化批量與看板 83
附錄E P2~ P9品項之績效指標 84
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