汽車產業的蓬勃發展帶動了臺灣汽車零件的產業，許多公司投入技術與資本開發，並積極加入各國車廠的供應鏈。近年來，受到關稅與各式貿易協定的影響，汽車零件產業受到的衝擊遠大於汽車廠，相較於創新設計，節省成本成為了主要的課題。個案公司產品的製程主要有4個製程，布簾、射出、塗裝和組立，選擇塗裝製程作為本研究主要是因為漆料原料成本較其他製程高，且良率與其他製程比低了20%以上。本研究旨在塗裝製程良率不穩定、顆粒缺陷比例高的問題，提出一套以TRIZ(Theory of Inventive Problem Solving)創新理論結合因子實驗搭配反應曲面法的系統性製程改善。首先，TRIZ是一種系統性創新方法論，從全球的專利資料庫中尋找具有創新性與意義重大的發明進行分析，得到能有效解決的對應技術性矛盾的有創意原則，稱為矛盾矩陣，而本研究透過這個方法進行有系統並快速的歸納問題，找出技術矛盾後根據矛盾矩陣得到創新原則，進而選出相對應的實驗因子。接著，在有限的時間與成本之下，面對多因子的實驗，使用部分因子實驗與田口直交表，有效篩選出顯著因子與交互作用，以縮小實驗規模並提升因子判別效率。結果顯示，落塵數與漆量旋鈕為影響塗裝顆粒缺陷的關鍵因子。為進一步找出最佳參數組合，本研究使用反應曲面法建立二階迴歸模型透過數學模型求解。經過驗證實驗後與模型預測相符，證實模型準確性，將該參數應用至實際生產後，不良率下降從20%至10%。本研究成果證明，結合TRIZ與實驗設計的製程改善方法能在不增加額外設備投資的情況下，快速篩選顯著因子並進行最佳化，達到降低塗裝顆粒缺陷、提升良率的目標。此方法具備實務應用價值與可複製性，未來可擴大應用於其他塗裝製程或關鍵製造參數的優化。

The rapid growth of the automotive industry has stimulated Taiwan’s auto parts sector, motivating companies to invest resources and join global supply chains. In recent years, however, trade agreements and tariffs have affected the auto parts industry more severely than automakers, shifting emphasis from design innovation to cost reduction. The case company has four key manufacturing processes: fabric, injection, coating, and assembly. The coating process is selected for this study because it has the highest material costs and lowest yield rate. To improve unstable yields and a high proportion of particle defects, this research proposes a systematic improvement approach that combine TRIZ(Theory of Inventive Problem Solving) with factorial design and response surface methodology. Technical contradictions are identified and matched with inventive principles from the contradiction matrix through TRIZ, enabling to select experimental factors. To reduce cost, partial factorial design and Taguchi orthogonal arrays are applied to screen significant factors and interactions. The results indicated that environmental dust and paint flow parameter are the key contributors to particle defects. A second-order regression model is established by using response surface methodology to determine optimal parameter combinations. Validation experiment confirms the predictive accuracy of the model. After implementation, the defect rate decreased from 20% to 10%. This study demonstrates that combining TRIZ with experimental design enables screening factor rapidly without additional equipment, and reducing coating defects effectively. This method can also be replicated in other coating or manufacturing processes, too.

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