| 研究生: |
王翔 Wang, Hsiang |
|---|---|
| 論文名稱: |
價值流方法4.0之應用與執行-以光學眼鏡製造為例 The Implementation of Value Stream Method 4.0-Case of Optical Glasses Manufacturing |
| 指導教授: |
楊大和
Yang, Ta-ho |
| 學位類別: |
碩士 Master |
| 系所名稱: |
電機資訊學院 - 製造資訊與系統研究所 Institute of Manufacturing Information and Systems |
| 論文出版年: | 2022 |
| 畢業學年度: | 110 |
| 語文別: | 中文 |
| 論文頁數: | 84 |
| 中文關鍵詞: | 價值流方法4.0 、自働生產管理環 、精實資訊系統 、目視管理 、生產現場控制 |
| 外文關鍵詞: | Value Stream Method 4.0, Jidoka-JIT Cycle, Lean Information System, Visual Management, Shop-Floor Control |
| 相關次數: | 點閱:124 下載:38 |
| 分享至: |
| 查詢本校圖書館目錄 查詢臺灣博碩士論文知識加值系統 勘誤回報 |
精實生產常以價值流圖(Value Stream Mapping)做為改善起點,用來分析生產流程中的浪費並找出改善機會。現今企業在進行數位化至工業4.0(Industry 4.0)的轉型過程時,常導入企業資源規劃 (Enterprise Resource Planning, ERP)系統或其他數位系統用以儲存大量的訂單相關資料,系統的導入使資訊流增加,也因此可改善之範圍從實體生產流程擴展至數位環境中的資訊流程。有別於傳統精實方法,精實4.0(Lean 4.0)所提出的價值流方法4.0(Value Stream Method 4.0, VSM 4.0)可因應轉型所帶來的環境改變,將整體流程詳細地分析並提出適切的改善方式,改善做法也從傳統精實方法導向VSM 4.0所採用的數位化改善方式。
辨識資訊浪費之方法可從精實資訊管理(Lean Information Management, LIM)理論說明,LIM是將精實生產理念應用於資訊管理中,目的為消除資訊流程的浪費以達成資訊連續流。消除浪費的過程中,可透過以精實理念來建構的資訊系統完成改善,其系統之建構目的是透過簡化與整合資訊流程,使系統中的資訊來源穩健並能直接支援產線或管理決策,此做法可從根本解決資訊浪費,並使資訊產生真正價值。
本研究以VSM 4.0分析案例現況的整體訂單作業流程,並建構一精實資訊系統輔助案例進行訂單流程的改善,促使管理層與生產線實踐更有效的生產現場控制(Shop-Floor Control, SFC)。本研究建構的精實資訊系統將參考過去研究之方法,並著重探討如何將系統提供之資訊,使管理者易於進行生產線的目視管理(Visual Management)。系統將提供合適的介面來輔助案例進行在製品(Work-In-Process, WIP)追蹤與齊料(Wait-To-Match)掌控,並促使產線逐步實踐生產連續流。本研究建構的系統將以Visual Basic Application (VBA)串接Microsoft SQL Server (MS SQL Server)完成,實踐一個低成本且高彈性之客製化系統,使案例能更有效掌控目前生產情況。
本研究為一實例探討之研究,為協助案例進行數位化轉型,並針對現況議題提出改善方法,包括改善整體訂單流程、簡化與整合資訊流及建構精實資訊系統來進行目視管理等,並在最終以VSM 4.0評估指標來分析各改善情境。從VSM 4.0評估指標可說明在訂單流程中主要的生產準備階段與生產執行階段之作業時間,分別改善約61%與73%,從其他指標亦可見顯著的改善成效。在系統導入後也能降低流程中的資訊浪費及達成資訊流的連續流,並使整體流程實踐高度自動化。本研究之目的在實踐一個具理論基礎的研究框架供後續學者探討外,同時奠定案例進行持續改善的基礎。
Value stream mapping is often used in lean manufacturing as a starting point for improvement, analyzing waste in the actual production process and identifying opportunities for improvement. As companies nowadays often implement Enterprise Resource Planning (ERP) or other systems in the process of Industry 4.0 or digital transformation, the scope of improvement can be extended from the production process to the overall order process. The Value Stream Method 4.0 (VSM 4.0) proposed in Lean 4.0 can expand the scope of analysis and extend the analysis of waste from logistics to information process, so the improvement method is also directed from the traditional lean improvement method to information process improvement.
Lean information management (LIM) is the application of the lean production concept to information management, with the aim of eliminating waste in the information process and achieving a continuous flow of information. In the improvement process of eliminating waste, the improvement can be facilitated by an information system constructed with the concept of lean.
This study analyzes the overall order process of the case study through VSM 4.0. The system is designed to improve the order process of the case study, and it provides information to facilitate better Shop-Floor Control (SFC) in the production line referring to the methodology of previous studies and focusing on how to make the information presentation easy for visual management (VM). The system assists the production line to achieve continuous flow in the production line that constructs by Visual Basic Application (VBA) connecting with Microsoft SQL Server (MS SQL Server) to implement a low-cost, highly flexible customized system. The system will provide an interface suitable for visual management to assist cases in Work-In-Process (WIP) tracking and Wait-To-Match control, so that managers can control the current production situation more efficiently.
This study is a case study that helps to improve the pressing issues faced by the case in the transformation process, including improving the overall order process, streamlining and integrating information flow, and building systems to assist visual management. In the end, the VSM 4.0 assessment metrics were used to analyze the improvement scenarios in each stage. From the VSM 4.0 evaluation indicators show the operation time of the main production preparation stage and production execution stage in the order process has been improved by 61% and 73% respectively, and other indicators have also shown significant improvement. The purpose of this study is to put into practice a research framework for subsequent studies and to lay the foundation for continuous improvement of the case.
財政部關務署 (2022),「海關進出口統計」,(取得日期:2022年4月16日), [available at https://portal.sw.nat.gov.tw/APGA/GA30]
經濟部統計處 (2022),「工業產銷存價值統計調查」,(取得日期:2022年4月16日),[available at https://dmz26.moea.gov.tw/GMWeb/investigate/InvestigateDA.aspx]
楊大和、李兆華(2021),精實管理4.0之自働生產管理環,工業工程雜誌,(取得日期:2022年2月16日),[available at https://sites.google.com/ciie.org.tw/column501/%E7%B2%BE%E5%AF%A6%E7%AE%A1%E7%90%864-0%E4%B9%8B%E8%87%AA%E5%83%8D%E7%94%9F%E7%94%A2%E7%AE%A1%E7%90%86%E7%92%B0?authuser=2]
Bevilacqua, M., Ciarapica, F. E., & Paciarotti, C. (2015). Implementing lean information management: the case study of an automotive company. Production Planning & Control, 26(10), 753-768.
Belkadi, S., Cherti, I., & Bahaj, M. (2018). Lean in information technology: Produce the human before the software. In International Conference on Advanced Intelligent Systems for Sustainable Development , 203-213. Springer, Cham.
Bartoszewicz, G., & Wdowicz, M. (2019). Automation of the process of reporting the compliance of the production plan with its execution based on integration of SAP ERP system in connection with Excel spreadsheet and VBA application. Digitalization of Supply Chains, 101-116. Spatium, Radom.
Chaudhry, A. K., Kalwar, M. A., Khan, M. A., & Shaikh, S. A. (2021). Improving the efficiency of small management information system by using VBA. International Journal of Science and Engineering Investigations, 10(111), 7-13.
Dombrowski, U., Richter, T., & Krenkel, P. (2017). Interdependencies of Industrie 4.0 & lean production systems: A use cases analysis. Procedia Manufacturing, 11, 1061-1068.
Greif, M. (1991). The Visual Factory: Building Participation through Shared Information. Portland, OR: Productivity Press.
Gupta, S., & Jain, S. K. (2013). A literature review of lean manufacturing. International Journal of Management Science and Engineering Management, 8(4), 241-249.
Hammer, D. K., & Piber, H. (1997). The rules of lean information management. In Proceedings, The 19h International Conference on Information Technology Interfaces, 33-47.
Hölttä, V., Mahlamäki, K., Eisto, T., & Ström, M. (2010). Lean information management model for engineering changes. World Academy of Science, Engineering and Technology, 42, 1459-1466.
Hopp, W. J., & Spearman, M. L. (2011). Factory Physics. Long Grave, Illinois: Waveland Press.
Hagedorn-Hansen, D., Hagedorn-Hansen, E., & Oosthuizen, G. A. (2016). Resource efficient process chain strategies for global competitive manufacturers. International Association for Management of Technology, 1-11.
Hartmann, L., Meudt, T., Seifermann, S., & Metternich, J. (2018). Value stream method 4.0: holistic method to analyse and design value streams in the digital age. Procedia CIRP, 78, 249-254.
Jung, H. S., & Kim, T. H. (2007). A methodology for construction information system for small size organization with excel/VBA. In Symposium on Human Interface and the Management of Information, 642-649. Springer, Berlin, Heidelberg.
Jaca, C., Viles, E., Jurburg, D., & Tanco, M. (2014). Do companies with greater deployment of participation systems use Visual Management more extensively? An exploratory study. International Journal of Production Research, 52(6), 1755-1770.
Jo, J., Huh, J., Park, J., Kim, B., & Seo, J. (2014). LiveGantt: Interactively visualizing a large manufacturing schedule. IEEE Transactions on Visualization and Computer Graphics, 20(12), 2329-2338.
Kahneman, D. (2011). Thinking, Fast and Slow. Farrar, Straus and Giroux, New York.
Kagermann, H., Helbig, J., Hellinger, A., & Wahlster, W. (2013). Recommendations for implementing the strategic initiative Industire 4.0: Securing the future of German manufacturing industry; final report of the Industrie 4.0 Working Group. Forschungsunion.
Koskela, L., Tezel, A. and Tzortzopoulos, P. (2018), “Why visual management?”, In 26th Annual Conference of the International Group for Lean Construction, 250-260.
Lewis, T. (2014). New Record for Human Brain: Fastest Time to See an Image. LIVESCIENCE, (Date of acquisition: June 12, 2022), [available at https://www.livescience.com/42666-human-brain-sees-images-record-speed.html]
Larteb, L., Benhadou, M., Haddout, A., & Nahla, H. (2016). The key to lean performance: Implementing a daily shop-floor control system using standardization and visual management. International Journal of Advanced Research in Management, 7(1), 34-43.
McDonald, T., Van Aken, E. M., & Rentes, A. F. (2002). Utilising simulation to enhance value stream mapping: a manufacturing case application. International Journal of Logistics, 5(2), 213-232.
Meudt, T., Metternich, J., & Abele, E. (2017). Value stream mapping 4.0: Holistic examination of value stream and information logistics in production. CIRP Annals, 66(1), 413-416.
Mayr, A., Weigelt, M., Kühl, A., Grimm, S., Erll, A., Potzel, M., & Franke, J. (2018). Lean 4.0-A conceptual conjunction of lean management and Industry 4.0. Procedia Cirp, 72, 622-628.
Ohno, T. (1988). Toyota Production System: Beyond Large-scale Production. Diamond. Inc., Tokyo.
Poppendieck, M., & Poppendieck, T. (2003). Lean Software Development: an agile toolkit. Addison-Wesley.
Rother, M., & Shook, J. (2003). Learning to See: Value Stream Mapping to Add Value and Eliminate Muda. Lean Enterprise Institute.
Rauen, H. Mosch, C., and Prumbohm, F.(2018), Industrie 4.0 Meets Lean, VDMA, Frankfurt, Germany.
Redeker, G. A., Kessler, G. Z., & Kipper, L. M. (2019). Lean information for lean communication: Analysis of concepts, tools, references, and terms. International Journal of Information Management, 47, 31-43.
Smith, R., & Ibbitson, A. (2011). The Lean Information Management Toolkit. Ark Group. London.
Sun, Y. Z. (2011). Realization of research management system based on OFFICE VBA technology. In Proceedings of 2011 Cross Strait Quad-Regional Radio Science and Wireless Technology Conference, 920-922. IEEE.
Soares, S., & Teixeira, L. (2014). Lean information management in industrial context: an experience based on a practical case. International Journal of Industrial Engineering and Management, 5(2), 107-114.
Senkuviene, I., Jankauskas, K., & Kvietkauskas, H. (2014). Using manufacturing measurement visualization to improve performance. Mechanical Technologies, 20, 99-107.
Steenkamp, L. P., Hagedorn-Hansen, D., & Oosthuizen, G. A. (2017). Visual management system to manage manufacturing resources. Procedia Manufacturing, 8, 455-462.
Schuh, G., Anderl, R., Dumitrescu, R., Krüger, A.and Hompel, M. (2020). Industrie 4.0 Maturity Index Managing the Digital Transformation of Companies, acatech STUDIE, München, Germany.
Tezel, A., Koskela, L., & Tzortzopoulos, P. (2016). Visual management in production management: a literature synthesis. Journal of manufacturing technology management, 27(6), 766-799.
Teixeira, L., Ferreira, C., & Santos, B. S. (2018). An information management framework to industry 4.0: a lean thinking approach. In International Conference on Human Systems Engineering and Design: Future Trends and Applications, 1063-1069. Springer, Cham.
Virginia, I. M., Vasile, K. C., & Liviu-Ion, R. O. S. C. A. (2015). Lean information management: Criteria for selecting key performance indicators at shop floor. ACTA Universitatis Cibiniensis, 66(1), 67-72.
Womack, J., Jones, D. T., & Roos, D. (1990). The Machine that Changed the World. New York: Rawson Associates.
Willis, T. H., & Willis‐Brown, A. H. (2002). Extending the value of ERP. Industrial Management & Data Systems, 102(1), 35-38.
Womack, J. (2004). Lean Information Management, Lean Enterprise Institute, (Date of acquisition: June 12, 2022), [available at https://www.lean.org/the-lean-post/articles/lean-information-management/]
Wan, H. D., & Chen, F. F. (2008). A Web-based Kanban system for job dispatching, tracking, and performance monitoring. The International Journal of Advanced Manufacturing Technology, 38(9), 995-1005.
Wagner, T., Herrmann, C., & Thiede, S. (2017). Industry 4.0 impacts on lean production systems. Procedia Cirp, 63, 125-131.
Żywicki, K., Rewers, P., & Bożek, M. (2017). Data analysis in production levelling methodology. In World Conference on Information Systems and Technologies, 460-468. Springer, Cham.