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研究生: 王正誼
Wang, Cheng-Yi
論文名稱: 以價值流圖與多準則決策方法進行需求不確定下之精實拉式系統設計
The use of value stream mapping and multiple criteria decision-making method to implement lean pull system design under demand uncertainty
指導教授: 楊大和
Yang, Taho
學位類別: 碩士
Master
系所名稱: 電機資訊學院 - 製造工程研究所
Institute of Manufacturing Engineering
論文出版年: 2009
畢業學年度: 97
語文別: 中文
論文頁數: 112
中文關鍵詞: 田口方法系統模擬拉式策略精實生產需求不確定理想解類似度順序偏好法
外文關鍵詞: Taguchi Method, VSM, TOPSIS, Demand Uncertainty, Lean Production, Simulation, MCDM, Pull Strategy
相關次數: 點閱:107下載:5
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  • 近年來在台灣政府大力栽培下,使得台灣TFT-LCD(Thin Film Transistor Liquid Crystal Display)產業蓬勃發展,這些高科技產業雖為台灣經濟之命脈,但因為顧客端需求波動大且需求不易預測,使用傳統推式生產容易造成大量的在製品(Work-in-process,WIP)與完成品庫存堆積,因此需要不同於以往多量少樣的生產方式。
    本研究針對TFT-LCD廠後段製程,在需求不確定的情況下,提出結合超級市場(Supermarket)與CONWIP(Constant Work-in-process)之精實拉式生產策略,藉由田口方法結合理想解類似度順序偏好法(Technique for Order Preference by Similarity to Ideal Solution,TOPSIS)求解最佳生產控制策略方案,用以改善製程中WIP過多導致的浪費,並且以生產週期時間(Cycle Time)與WIP來顯示出浪費的改善。
    本篇論文同時提出結合精實拉式概念與價值流圖(Value Stream Map,VSM)之指導程序,此程序從定義產品價值開始,經由現況價值流圖的繪製找出浪費所在,以此為改善的契機並繪製未來理想狀態價值流圖作為改善方案的依據。
    最後,導入精實拉式策略至一個實際的案例,經結果比較與分析發現,現況圖與未來圖在產出不變的情況下,系統的平均Cycle Time預期可以從8.80天縮減至4.82天,改善了45.20%。系統的平均WIP從50,342片縮減為25,795片,改善了48.76%。由此可知,藉由導入精實拉式策略來控制系統內的WIP水準,可有效改善系統中的浪費。

    Tendencies in today’s competitive high-technology environment, especially thin film transistor liquid crystal display (TFT-LCD) industry, it is difficult to forecast the customer’s demand and setup a production planning under lower work-in-process (WIP), shorter cycle time, and higher throughput requirement. This paper proposes a lean pull strategy, combining supermarket with constant work-in-process (CONWIP), which is applying value stream mapping methodoloty in a TFT-LCD manufacturing case study under demand uncertainty. The proposed multiple criteria decision-making (MCDM) method by using hybrid Taguchi and technique for order preference by similarity to ideal solution (TOPSIS) method to find the best scenario of production control policy to remove the waste of WIP and improve cycle time, simultaneously. In order to link the visualizing material and information flow in the whole picture, value stream mapping and Rother’s 7 guiding principles procedure also applying to the lean pull strategy, then to find optimum result from alternative scenarios were enhanced by simulation. Finally, a real-world TFT-LCD case study is used to demonstrate and test findings. After comparing current-state map and future-state map of the case study, the simulation results indicated that the average cycle time reduced from 8.80 days to 4.82 days as well as the WIP could be reduced from 50,342 panels to 25,795 panels without any loss of throughput.

    摘要 i Abstract ii 誌謝 iii 目錄 iv 圖目錄 vi 表目錄 viii 1. 緒論 1 1.1 研究背景與動機 1 1.2 研究目的 2 1.3 研究流程 3 1.4 論文架構 4 2. 文獻探討 5 2.1 精實生產系統 5 2.2 離散事件模擬 18 2.3 多準則決策方法 22 3. 研究方法 30 3.1 價值流圖 30 3.2 現況分析與導入精實拉式策略 38 3.3 建立現況模擬模式與未來理想狀態模擬模式 45 3.4 田口方法結合理想解類似度順序偏好法 48 4. 實例說明 60 4.1 現況分析與導入精實拉式策略 60 4.2 建立模擬模式 68 4.3 田口方法結合理想解類似度順序偏好法 82 4.4 情境分析 95 5. 結論與建議 98 5.1 結論 98 5.2 未來研究與建議 99 參考文獻 101 附錄A 機台相關資訊 106 附錄B 實驗參數設定 109 附錄C價值溪流符號說明 111

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