目前台灣汽車及其零件製造業之生產價值有逐年成長的趨勢，其中汽車零件製造業於2018年的生產價值為新台幣1908億元，為汽車產業的52.84%，係一重要產業。其中汽車用電燈組又佔了汽車零件製造業產品項目44%，非常具有代表性。然而汽車零組件產業無法避免的是市場的淡季與旺季，如何利用精實生產相關的工具與方法來降低成本為一重大議題，對於勞力密集的汽車零組件產業而言，人力成本為該產業生產成本的重要參考指標，本文將以車燈組裝線為案例進行探討。
製造現場能否因應需求量來進行生產，最直接影響的是企業的現金流。因此必需利用產能規劃方法來生產的決定投入與產出，當需求變動的情況下，可以減少人員或設備的投入，藉此節省非必要支出的成本。另外，在大部分的傳統產業中，生產順序都是依照員工過去的經驗而進行安排生產，此種生產方式可能造成當下所生產的產品並不是現在顧客所需要的，因此造成存貨堆積。
而目前案例公司現況所面臨的問題有兩點，第一點為當顧客需求或生產量產生變化時，主管該如何決定人力水準以達到當天的需求量，第二點為如何安排生產順序可以使生產的總流程時間最小化，或是使設備的閒置時間最小化。
因此本研究提出一套產能規劃與生產排序之研究方法，首先利用 RCCP 之途程法粗略估計各製程站所需作業人數，後續利用生產線平衡方法進行作業的合併，再藉由 Microsoft Office Excel 內建之規劃求解工具進行混合整數規劃模型求解合併後各產品作業的人力配置，當完成人力水準之產能規劃後，則利用排程軟體 Lekin Schedule Software 進行生產排序求解最佳之生產順序，而實驗情境設計主要是為了設計出符合案例公司現況的少量多樣生產方式，經由實驗結果發現導入少人化模式後績效表現未必比現況定員制佳，其中必須考慮產品的組合，若是將少人化模式結合批量分割的方式則可以得到較佳的績效表現。因此案例公司可透過導入少人化結合批量分割的方式來提升生產效率與降低生產成本，以增加其企業競爭力。

At present, the production value of Taiwan's automobile and parts manufacturing industry is growing year by year. Among them, the production value of the automobile parts manufacturing industry in 2018 was NT $ 190.8 billion, 52.84% of the automobile industry, and it occupies a pivotal position. Among them, the automobile electric light group accounts for 44% of the auto parts manufacturing products project, which is very representative.
The automobile and parts manufacturing industry can not avoid the low and high seasons of the market. How to use lean production-related tools and methods to reduce production costs is a major issue. For the labor-intensive industry, the labor cost is is an important reference index for the production cost of automobile and parts manufacturing industry. To deal with the problems, this study proposes a set of methods for capacity planning and optimization production sequencing. First, the RCCP route method is used to roughly estimate the number of operators required for each work center, and then create the logic to deciede whether combine operations or not. Through Microsoft Office Excel's built-in solver to solve the manpower allocation of each operation after operation combined. After completing the manpower level capacity planning, the next step is use the Lekin scheduling software to optimize the production sequencing. The design of the experimental is want to create a multiproduct and low volumes production environment.
The experimental results show that labor linearity doesn’t have significant influence at performance of manufacturing when it didn’t consider the proportion of product.It needs to combine with lotsplitting method so that can have more better performance.Therefore, the company can increase production efficiency and reduce production costs by the method of labor linearity with lotsplitting to increase company’s competitiveness.

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