應用遊戲與強化生產模型來克服SDBR導入生產管理實務的兩個障礙

Abstract

自2000年起，限制理論簡化型限制驅導式排程方法(Simplified Drum-Buffer-Rope, S-DBR)，已經獲得廣泛的重視。數百個成功的SDBR生產管理個案中，也已證實工廠可以在極短的生產前置時間(PLT)以及極少的在製品數量下得到高度可靠的交期績效(DDP)。然而，在實務界的推動上，還是有兩個障礙阻礙著SDBR的導入。第一個是從事生產管理的人員，不相信只簡單的改變生產管理方法(SDBR方法)，就可以顯著的改善生產交期績效，得到極短的生產前置時間。第二個是從本研究以及某些導入SDBR公司的經驗中，發現有些生產環境存在著幾種特性會阻礙SDBR成功導入。因此本研究首先設計工廠管理遊戲情境，透過收集兩百四十五位生產管理實務人士的實驗數據，來克服第一個障礙。結果顯示：“生產管理模式”是主因，改變生產管理模式，就能顯著改善DDP和PLT。其次進行克服第二個障礙，研究中定義出三種普遍存在於生產環境的特性：CCR的位置、多個CCR或者交互作用的CCR以及緊急插單。進一步的研究指出，只要針對SDBR做小幅的修正，就可完全適用於這些生產環境下。

Since 2000, TOC of the Simplified Drum-Buffer-Rope (SDBR) has received considerable attention. Hundreds of successful SDBR cases have achieved highly reliable due date performance (DDP) with short production lead-time (PLT) and minimum WIP. However, two obstacles have remained, blocking the introduction of SDBR to production management society. The first one is from production management practitioners, who have been less than confident that DDP and PLT can be significantly improved by simply changing the way to manage production (SDBR way). The second is from our study and experiences of implementing SDBR in local companies, we found out there are such environments include several characteristics which may block the success implementation of SDBR. Proceedings of the study, we first used job-shop games of scenario design and collect 245 production management practitioners that make experiment to verify how to overcome the first obstacle. Results show that: the “mode of managing production” was the root cause, and changing the mode of managing production could significantly improve DDP and PLT. Continuously to overcome the Second SDBR obstacle, we defined three environments include those with the following characteristics: the CCR location, multiple CCR or interactive CCR and frequent order insertion are existing commonly. Further study of these environments indicated that SDBR with the minor modification that SDBR applies perfectly in these environments.