臺灣博碩士論文加值系統

在當前競爭激烈的全球市場環境中，國際及國內客戶越來要求品質及成本為主軸。對提高生產力的追求導致需要對生產過程進行嚴格定義的性能測量方法。本文探討整體設備效率(OEE)是測量及識別工廠瓶頸站有效工具的方法。它可以與其他持續改善工具技術結合與應用。適合於半自動和全自動化製造過程，它起源於高度自動化的半導體產業。根據定義，OEE 是對時間稼動率、性能效率和良品率的計算。運用OEE三大指標(A/P/Q)架構及TPM&TPS 方法應用於被動元件MLCC (Multi-layer Ceramic Capacitor, MLCC)疊層機(Stacker)的生產中基本損失進行分類及改善，被動元件產業所追求的生產目標不外乎是低成本、高產出率、短生產週期、良率高及準時交貨等。本研究結果顯示，整體OEE 從 56.5% 提升至76.4% 增加15%以上生產量，從這項研究中所建立的改善15%以上效率，可增加設備利用率、可提高產能及降低生產作業成本，減少採購機台數量及提高工廠資源運用效率，協助工廠提升製程與產能控管能力。
OEE是一個成功可行的改善流程優化方法，實績說明了 OEE 不僅可提升15%以上並有效將製程的 Lead Time縮短，並顯示此改善方法是可以提供給高科技相關不同的產業之經營管理者，未來在解決遇到相關產業瓶頸問題時作為有效且有力的實證參考方法。
關鍵詞：TPM、TPS、整體設備效率(OEE)、積層陶瓷電容(MLCC)、Lead Time

Abstract
In today's highly competitive global environment, international and domestic customers are increasingly demanding quality and cost issues. The quest to increase productivity has led to the need for strictly defined performance measurement methods for production processes. This thesis develops the methods for overall equipment effectiveness (OEE) as an effective tool for measuring and identifying factory bottlenecks. It can be combined with other continuous improvement tool technologies. Suitable for semi-automatic and fully automated manufacturing processes, it originated in the highly automated semiconductor industry. By definition, OEE is a calculation of availability, performance efficiency, and quality rate. Using the OEE three indicators (A/P/Q) formula and TPM&TPS method applied to the production of passive component (Multi-layer Ceramic Capacitors, MLCC), especially to classify and improve loss items for stacker. The passive component industry pursues production goals are nothing more than low cost, high output rate, short production cycle time, high yield and on-time delivery. The results show that the OEE increased from 56.5% to 76.4% to increase production by more than 15%, and the improvement of efficiency established from this study by more than 15% can increase equipment utilization, increase production capacity and reduce production operation costs, reduce the number of purchased machines and improve the efficiency of factory resource utilization, and help factory improve process and capacity control capabilities.
OEE is a successful and feasible way to improve the process, which shows that OEE can not only improve by more than 15% and effectively shorten the lead time of the process, but also shows that this improvement method can be provided to managers of high-tech related industries as an effective and powerful empirical reference when solving related bottlenecks in the future.
Keywords：TPM、TPS、OEE、MLCC、Lead Time

目錄
中文摘要........................................................................................................................ i Abstract......................................................................................................................... ii
誌謝.............................................................................................................................. iii
目錄.............................................................................................................................. iv
圖目錄.......................................................................................................................... vi
表目錄........................................................................................................................ viii
專有名詞中英文對照.................................................................................................. ix
第一章 緒論................................................................................................................. 1
1.1背景與動機............................................................................................... 2
1.2研究目的................................................................................................... 3
1.3研究目標................................................................................................... 4
1.4研究流程................................................................................................... 5
第二章 文獻探討......................................................................................................... 6
2.1全員生產維護 (TPM).............................................................................. 6
2.2豐田式生產系統 (TPS).......................................................................... 11
2.3整體設備效率 (OEE)............................................................................. 12
2.4相關文獻探討彙整................................................................................. 16
第三章 研究方法....................................................................................................... 21
3.1研究架構................................................................................................. 21
3.2個案公司介紹......................................................................................... 22
3.3現況描述................................................................................................. 28
3.4導入TPM流程........................................................................................ 29
3.5 OEE指標的運用..................................................................................... 32
3.6 MES系統導入OEE計算....................................................................... 37
第四章 導入個案研究成果....................................................................................... 42
4.1資料收集與分析..................................................................................... 42
4.2設立改善目標......................................................................................... 46
4.3效果確認................................................................................................. 56
第五章 結論與未來研究方向................................................................................... 66
參考文獻..................................................................................................................... 68



















圖目錄
圖1-1 研究流程....................................................................................................... 5
圖2-1 TPM 基礎架構及目標................................................................................. 6
圖2-2 TPM 自主管理體制建立流程..................................................................... 8
圖2-3 TPM 展開的支柱與品質保養相互關係..................................................... 9
圖2-4 OEE定義.................................................................................................... 15
圖3-1 研究架構..................................................................................................... 21
圖3-2 MLCC產品生產流程圖............................................................................. 23
圖3-3 MLCC 疊層後成品示意圖........................................................................ 24
圖3-4 疊層機作業流程示意圖............................................................................. 26
圖3-5 TPM八大支柱............................................................................................ 31
圖3-6 疊層機--六大損失分類.............................................................................. 36
圖3-7 MES控管範圍流程圖................................................................................ 37
圖3-8 製造執行系統架構圖................................................................................. 39
圖3-9 MES建立OEE數據之流程架構.............................................................. 40
圖3-10 OEE 指標系統介面圖............................................................................... 41
圖4-1 TPM 實現自主管理的個別改善活動步驟............................................... 42
圖4-2 疊層機整體設備效率(OEE)圓餅圖.......................................................... 43
圖4-3 Stacking OEE - APQ Trend Chart.............................................................. 44
圖4-4 Cycle time 未達目標分析關聯圖............................................................. 46
圖4-5 改善後-疊層機整體設備效率(OEE)圓餅圖 ............................................. 56
圖4-6 改善後Stacking OEE - APQ Trend Chart................................................. 56
圖4-7 EG37改善後OEE 系統圖示.................................................................... 57
圖4-8 EG39改善後OEE 系統圖示.................................................................... 58
圖4-9 EG41改善後OEE 系統圖示.................................................................... 58
圖4-10 EG44改善後OEE 系統圖示.................................................................... 59
圖4-11 EG45改善後OEE 系統圖示.................................................................... 59
圖4-12 機台保養之過程管控與查核工具............................................................. 61
圖4-13 疊層保養時間改善(One Point Lesson) ..................................................... 62





















表目錄
表2-1 OEE評估指標一覽表................................................................................ 13
表2-2 相關文獻彙整一覽表................................................................................. 16
表3-1 疊層機停機狀況一覽表............................................................................. 32
表4-1 疊層機六大損失分類................................................................................. 45
表4-2 Cycle time 分析後項目改善對策............................................................. 47
表4-3 疊層機作業秒數監控表............................................................................. 49
表4-4 快速換模分析改善表-1.............................................................................. 49
表4-5 快速換模分析改善表-2.............................................................................. 52
表4-6 專案改善實施計畫表................................................................................. 55
表4-7 改善後根因改善總表................................................................................. 57
表4-8 TPM有形效果各項指標整理表................................................................ 60
表4-9 六大損失管理手法與各部負責人員權責................................................. 63
表4-10 A廠40台疊層機改善前後OEE指標......................................................65











專有名詞中英文對照
全員生產維護：Total Productive Maintenance (TPM)
三現主義：現場(Real Place)、現物(Real Objects)、現實(Real Situation)
TPM三零目標：零故障(Zero Failures)、零缺陷(Zero Defects)、零傷害(Zero Injury)
6S管理：整理(Seiri)、整頓(Seiton)、清掃(Seiso)、清潔(Seiketsu)、素養(Shitsuke)、安全(Safety)
整體設備效率：Overall Equipment Effectiveness (OEE)
平均故障間隔時間：Mean Time Between Failures (MTBF)
保養週期：Time Base Maintenance (TBM)
豐田式生產系統：Toyota Production System (TPS)
即時化生產技術：Just In Time (JIT)
循環式品質管理：Plan-Do-Check-Act (PDCA)
製造執行系統：Manufacturing Execution System (MES)
物料需求計劃：Material Requirement Planning (MRP)

參考文獻
英文文獻：
[1]SEMATECH, “Overall Equipment Efficiency Guidebook Revision 1,” SEMATECH Technical Reports, 1995.
[2]Richard Hedman, Mukund Subramaniyan and Peter Almstrom, “Analysis of critical factors for automatic measurement of OEE,” 49th CIRP Conference on Manufacturing Systems, pp.128-133, 2016.
[3]Yogi Tri Prasetyo and Felix Concepcion Veroya, “An Application of Overall Equipment Effectiveness (OEE) for Minimizing the Bottleneck Process in Semiconductor Industry,” 2020 IEEE 7th International Conference on Industrial Engineering and Applications, 2020.
[4]Jose Arturo Garza-Reyes, “From measuring overall equipment effectiveness (OEE) to overall resource effectiveness (ORE),” Journal of Quality in Maintenance Engineering, pp.506-527, 2015.
[5]Miguel Saez, Francisco Maturana, Kira Barton and Dawn Tilbury, “Real-time Manufacturing Machine and System Performance Monitoring Using Internet of Things,” IEEE Transactions on Automation Science and Engineering, 2018.
[6]Klint Allen A. Mariñas, Yung-Tsan Jou and Riana Magdalena Silitonga, “Investigating the Overall Equipment Effectiveness (OEE) of Die Casting Injection Machines using Productivity Analysis,” Second Asia Pacific International Conference on Industrial Engineering and Operations Management, pp.2312-2320, 2021.
[7]Okpala Charles Chikwendu, Anozie Stephen Chima and Mgbemena Chika Edith, “The optimization of overall equipment effectiveness factors in a pharmaceutical company,” Journal of Heliyon, 2020.
[8]Vandana Sonwaney and Rohit Kumar Singh, “Measurement of overall equipment effectiveness to improve operational efficiency,” International Journal of Process Management and Benchmarking, pp.246-261, 2018.
[9]Chetan Patel and Vivek A Deshpande, “A Review on Improvement in Overall Equipment Effectiveness,” International Journal for Research in Applied Science & Engineering Technology, pp.642-650, 2016.
[10]M.A. Chik, M.S.A. Abd Malik and M.D.Y. Faizah, “Capacity Improvement for 200mm PVD Cluster Equipment CMOS Technology,” 2020 4th IEEE Electron Devices Technology & Manufacturing Conference, 2020.
[11]R.W. Freck, “Using overall equipment effectiveness (OEE) and the equipment improvement process (ET) to improve Fab throughput,” 2000 IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop, 2000.
[12]Xiaoyan Li, Guangfu Liu and Xinyu Hao, “Research on Improved OEE Measurement Method Based on the Multiproduct Production System,” Journal of Applied Sciences, 2021.
[13]SEMI, “Standard for Definition and Management of Equipment Reliability, Availability, and Maintainability,” SEMI E10, 1996.




中文文獻：
[14]凌國榮 編著，「設備綜合效率改善之研究」，淡江大學高階主管管理碩士學程碩士論文，2002。
[15]日本設備維護協會 編著，財團法人中衛發展中心 翻譯，「新TPM加工組立」，財團法人中衛發展中心，2016。
[16]陳文哲 編著，「現場管理與改善」，中興管理顧問公司，pp.99-102，2002。
[17]鍾明鴻 編著，「設備管理」，超越企管工商叢書，pp.136-141，1997。
[18]劉承元 編著，「TPM與工廠全面改善」，廣東經濟出版社，2006。
[19]大野耐一 編著，國瑞協力會TPS自主研究會 翻譯，「豐田生產方式」，財團法人中衛發展中心，2005。
[20]中衛中心功能技術部 編著，「躍向全球的全面生產管理之路-TPM的台灣經驗」，財團法人中衛發展中心，2010。