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研究生： 杜冠傑
Du, Guan-Jie
論文名稱： 口罩裝盒機構設計開發
Design and Development of Mask Boxing Mechanism
指導教授： 周榮華
Chou, Jung-Hua
學位類別： 碩士
Master
系所名稱： 工學院 - 工程科學系碩士在職專班
Department of Engineering Science (on the job class)
論文出版年： 2024
畢業學年度： 112
語文別： 中文
論文頁數： 83
中文關鍵詞： 自動化 、口罩生產機 、口罩 、裝盒機 、田口方法
外文關鍵詞： Automation, mask production, face mask, packing machine, Taguchi method
相關次數： 點閱：83  下載：19 
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    • 在疫情(COVID-19)爆發時，嚴重影響了很多的產業，迫使很多工廠需要關閉，但也有些工廠卻擁有更多的訂單，口罩產業就是受益的產業之一。但口罩廠的自動化程度相對較低，隨著需求量的大增，為了減少人員接觸產品的次數、減少人工成本、提高生產效率與良率，口罩工廠也開始投入自動化，將原有的工廠只有口罩生產是自動化的狀態，提升至更多製程都靠自動化來完成。
    本研究主要是針對單片包裝的口罩，在塞入紙盒的製程，進行開發設計，並透過田口法找出最佳化的參數。塞盒製程主要是由口罩裝盒機的預壓塞盒模組與塞盒模組來完成，目的是減少原有需要較多人力的製程，藉此來達到減少人力、增加產量與提升良率。研究比較了預壓塞盒模組跟塞盒模原有的設計與改善後的設計，運用田口法進行分析與取得最佳化參數，並利用獲得的最佳化參數，進行大量的塞盒良率測試，塞盒的不良率在加入優化條件後，由原先的501.4 ppm (百萬分之一)降低至189 ppm以下，成功減少人力，也證明設備是能正式生產的。

    During the COVID-19 pandemic, many industries were severely impacted due to lock down and restriction of people movement. However, some industries experienced an increase in orders; the face mask industry is one of them. Despite the surged demand, the level of automation in face mask production was still relatively low. To reduce human contact with products, lower labor costs, and improve production efficiency and yield, mask factories began investing in automation. This involved in upgrading the existing partially automated production lines to achieve greater automation across various production stages.
    This study focuses on the design and implementation of automating the packing of individually sealed masks, specifically at the stage of inserting masks into carton boxes. The goal is to optimize the process by using the Taguchi method. The box-inserting stage is primarily carried out by the pre-press box-inserting section and the box-inserting section of the mask packing machine. The purpose is to reduce the labor-intensive nature of the original process, thereby decreasing manpower, increasing production output, and improving yield.
    Using the optimized parameters, extensive field testing of the box-inserting section shows that the defect rate of box insertion decreases from 501.4 ppm to 189 ppm. Furthermore, the manpower reduces from the original 11 workers to 4 workers, indicating the effectiveness of the present implemented automation system.

    摘要 I EXTENDED ABSTRACT II 誌謝 X 目錄 XI 表目錄 XIII 圖目錄 XIV 第一章 緒論 1 1.1 前言 1 1.2 研究動機與目的 1 1.3 文獻回顧 3 1.3.1 自動化與數位化工廠 3 1.3.2 疫情對自動化生產的影響 4 1.3.3 口罩介紹 5 1.3.4 口罩生產介紹 7 1.3.5 田口法介紹 8 1.4 論文架構 10 第二章 系統架構設計 11 2.1系統架構介紹 11 2.2自動流程規劃 11 2.3機構設計 12 2.3.1 產品規格 12 2.3.2 塞盒模組架構 14 2.3.3預壓模組設計 17 2.3.4塞盒模組設計 22 第三章 機構測試與改善 26 3.1盒裝機塞盒測試 26 3.2 盒裝機塞盒模組改善 26 3.2.1 問題確認 26 3.2.2 設計改善 27 第四章 結果與討論 33 4.1塞盒模組驗證 33 4.2 田口分析實驗 33 4.2.1 問題描述 33 4.2.2 設計實驗條件 33 4.2.3 控制因子與水準設定 34 4.2.4 直交表選擇 34 4.2.5 實驗數據 37 4.2.6 因子反應表與因子反應圖 39 4.2.7 最佳化設定 42 4.2.8 最佳化參數驗證 43 4.2.9 最佳化參數分析 45 4.3 ANASY模擬 45 4.3.1 模擬條件設定 46 4.3.2 模擬步驟 46 4.3.3 模擬結果 58 4.4 盒裝機的效率 59 第五章 結論與建議 60 5.1 結論 60 5.2 建議 60 參考文獻 62

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