臺灣博碩士論文加值系統

臺灣機械產業中射出成型機為出口貿易型重點產業之一，但目前臺灣射出成型機產業生
產方式仍停留在運用預先生產機台來應付產業之接單生產型態，因此，面對工業4.0浪潮如
何縮短生產週期達成真正接單生產型態，實為射出成型機產業的重要議題之一。本研究旨在
應用精實管理手法整合系統模擬於射出成型機現場組裝流程改善，以達到縮短生產週期。本
研究以臺灣射出成型機組裝廠為例；首先透過精實管理手法中的價值溪流圖（Value Stream
Mapping , VSM）分析並尋找改善之目標，並結合生產成本協同分析，其後再利用模擬軟體
驗證改善前後的公司生產流程時間之差異。藉由本研究結果可改善射出成型機於組裝產品族
機台時組裝流程改善，並可衍生為新產品開發組裝時程預估模式，做為射出成型機組裝廠於
接單後生產之現場之參考依據。研究結果經價值溪流圖發現問題後，透過工站分割及生產平
準化能有效降低製程等待浪費並提高生產率，於直接人力成本中也足以降低四成的成本，因
此建議企業能模仿此方式來改善生產線。

The injection molding machine in Taiwan’s machinery industry is one of the major industries in export trade, but the current manufacturing method of injection molding machine industry in Taiwan still uses pre-production machine table to cope with industry’s order receiving production pattern. Therefore, it has become one of the important issues of injection molding machine industry how to shorten production cycle to achieve the real order receiving production pattern in face of industry 4.0. This research aims to apply lean manufacturing method to integrate system simulation to improve the field assembly procedure of injection molding machine to shorten the production cycle. With Taiwan’s injection molding machine assembly plant as the example, this research firstly used the Value Stream Mapping （VSM） in the lean manufacturing method to analyze and seek for the improvement goal and combined Production Cost to conduct the cooperative analysis. Afterwards, the simulation software was used to verify the difference in the time of company’s production flow before and after the improvement. Based on the research results, the assembly flow can be improved when the injection molding machine is used to assemble the product family machine table and the estimation model of development and assembly time-history of new products can be derived, which will be used as the reference basis of production field after the injection molding machine assembly plant receives the orders.

摘要....................................................................i
Abstract...............................................................ii
誌謝...................................................................iv
目錄....................................................................v
表目錄.................................................................vii
圖目錄................................................................viii
符號說明................................................................ix
第一章 緒論.............................................................1
1.1研究背景..........................................................1
1.2研究動機..........................................................1
1.3研究目的..........................................................2
1.4論文架構..........................................................2
第二章 文獻探討...........................................................4
2.1生產方式的演進.....................................................4
2.1.1手工藝生產....................................................4
2.1.2大量生產......................................................5
2.1.3多樣少量生產..................................................5
2.2精實管理之內涵.....................................................6
2.3生產成本..........................................................15
第三章 研究方法...........................................................17
3.1價值溪流圖分析.....................................................17
3.2生產成本計算.......................................................19
3.3研究方法架構.......................................................21
第四章 個案研究...........................................................22
4.1個案簡介...........................................................22
4.2射出型機製程流程分析................................................22
4.3現況價值溪流圖分析..................................................24
4.3.1資料整合......................................................24
4.3.2資料分析......................................................24
4.4改善目標...........................................................27
4.5未來理想價值溪流圖..................................................27
4.6系統導入模擬.......................................................29
4.6.1系統假設......................................................29
4.6.2模擬建構程序..................................................29
4.6.3模擬輸出資料蒐集...............................................32
4.7成本比較...........................................................33
第五章 研究結果與建議......................................................36
5.1研究結果與建議......................................................36
附錄A價值溪流圖十一項改善目標...............................................37
附錄B價值溪流圖改善範圍.....................................................37
附錄C57篇於價值溪流圖改善問題資料整理........................................38
附錄D製程流程圖示..........................................................42
附錄E改善前系統模擬輸出圓餅圖...............................................43
附錄F改善後系統模擬輸出圓餅圖...............................................43
參考文獻..................................................................44
Extended Abstract.........................................................47

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