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系統識別號 U0026-2706201811453400
論文名稱(中文) 以模擬最佳化求解光學眼鏡製造之拉式系統設計
論文名稱(英文) The use of simulation optimization in solving the pull system design for optical glasses manufacturing system
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) Institute of Manufacturing Information and Systems
學年度 106
學期 2
出版年 107
研究生(中文) 李佳勳
研究生(英文) Chia-Hsun Lee
學號 P96051076
學位類別 碩士
語文別 中文
論文頁數 93頁
口試委員 指導教授-楊大和
口試委員-王鵬森
口試委員-洪郁修
口試委員-郭宜雍
中文關鍵字 CONWIP  限制理論  系統模擬  精實生產  拉式系統  價值流圖 
英文關鍵字 CONWIP  Theory of Constraints  Discrete-event simulation;Lean production  Pull system  Value stream mapping 
學科別分類
中文摘要 台灣的光學眼鏡製造產業已在台至今發展約60年,從早期的廉價代工(Original Equipment Manufacturer,OEM)逐漸轉型原廠委託設計代工(Original Design Manufactures,ODM),但面臨到塑膠眼鏡出口數量逐年減少,以及少量多樣的顧客需求,以及面臨環境競爭與國際化的趨勢,如何維持顧客滿意度,提高品質、降低成本、縮短交期與增加彈性的目標,將會是企業急迫需要重視的課題。
首先,以價值流圖分析發現案例公司前置時間過長以及在製品堆積的問題,成為改善的契機,而製造業常使用生產排程規劃的傳統推式生產系統因而容易發生上述兩大問題,故此本研究為解決此問題將導入拉式系統;接下來利用離散事件模擬仿造現況推式系統的績效作為之後改善策略發展後對照的基準,並依照案例公司製程瓶頸工程與生產限制進行策略擬定,提出CONWIP拉式、限制理論結合批量生產看板、混合上述兩者等三個改善策略方案,並利用模擬最佳化求得最適在製品數與緩衝庫存,接著以敏感度分析討論在顧客需求量變化的情況下,生產系統的變化與因應。
實驗結果與案例公司現況使用的推式生產系統相比,三種拉式策略對於現況方式皆有顯著改善,策略間為混合策略表現最優異,在製品改善百分比為86%、週期時間改善9.8%;其餘三個方案亦有在製品有60%以上改善、滿足率有13%以上改善,可知拉式系統的導入能大幅減少製程中在製品數量,提高滿足率,達到降低成本、滿足顧客需求等目的,將來案例公司可以藉由持續改善朝本研究的最佳化方案為發展目標。
英文摘要 Optical glasses manufacturing industry has been developing in Taiwan for about 60 years. From the Original Equipment Manufacturer gradually transformed the Original Design Manufactures and now is facing to a problem of demand with multiple products and low volume and facing the future of environmental competition and internationalization. That is worth to discuss how to improve quality, reduce costs, shorten delivery and increase flexibility but also fill the order on time. This study is conducted to the case firm, an optical glasses manufacturing, and use pull system to production line. Constructing three kinds of pull strategies into practice, and using optimized software to finding the best strategy which can reach the goal.
First, use value stream mapping to find two problems, long lead time and many work in process, as the starting point of kaizen. The two problems mentioned above can easily occur in traditional push production systems that use production scheduling in the manufacturing industry. Pull system has significant improvement on this two problems, so this study will import pull system into real production line and use discrete-event simulation to collect productive information, and according to the case company process bottleneck process and production restrictions. Propose three kinds of strategies, the first CONWIP pull system second Theory of Constraints mix mass production of Kanban and third hybrid strategy, and use the simulation optimization to obtain the optimal product count and buffer inventory, and then analyze and discuss with sensitivity the change and response of the production system in the event of changes in customer demand.
The result of optimization scheme which Compared with the push production system, the three pull strategies have significantly improved the current simulation, and the strategy is the best among the hybrid strategies, total WIP reduce 86% and average lead time reduce 9.8%.
論文目次 摘要 i
誌謝 iv
目錄 v
表目錄 vii
圖目錄 viii
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 拉式生產系統 8
2.3 限制理論 14
2.4 離散事件模擬 15
2.5 模擬最佳化 17
2.6 與相同產業導入精實生產的論文差異比較 19
3. 研究方法 20
3.1 案例公司簡介 20
3.2 現況價值流圖繪製 24
3.3 現況分析與訂定改善目標 31
3.4 導入拉式生產 31
3.5 建構現況系統與各策略之模擬模式 38
3.6 系統描述 39
3.7 模擬最佳化 40
4. 案例分析 42
4.1 現況系統分析 42
4.2 案例公司現況分析 42
4.3 策略產生 45
4.4 現況模擬模式建構 53
4.5 精實系統設計之模擬模式建構 68
4.6 模擬最佳化 72
4.7 實驗結果 75
4.8 敏感度分析 78
5. 結論與建議 83
5.1 結論 83
5.2 未來研究建議 84
參考文獻 85
附錄A 論文符號說明 89
附錄B產品需求百分比與分類 90
附錄C產品單件加工製程資訊 91
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