應用緩衝管理提升裝配廠作業績效之研究 - 以G公司為例

Abstract

個案公司是一個消費性電子產品的裝配工，產品種類少量多樣，大多為功能相近，只是在模組、外型、電子元件上的些微差異，屬於 Mixed SKU Production 的裝配生產系統。由於在 Mixed SKU Production 的作業環境下，加上以「人」為主的裝配作業現場，人員作業上的變異，整個系統的瓶頸作業，則會在各 SKU 間移動，並使得生產線流量(Flow)難以完全被平衡，而每日的有效產出，也將隨之產生變異與不穩定。由於各工作站將會隨著系統瓶頸站的節奏產出，因此瓶頸生產速率決定了整個系統的產出，根據限制理論 (Theory of Constraints, TOC) 所延伸出的緩衝管理 (Buffer Management) 概念，是藉由瓶頸的控制與保護，透過緩衝區的建置，讓瓶頸資源受到保護，並使的其他非瓶頸的資源，可以全力作業，不受限於瓶頸生產的速率，以達到生產線流量(Flow)平衡，來提升整個生產線的效率。本研究方法將個案公司的裝配線工廠，以傳統改善與Buffer Management 兩種不同方式來分析，藉由裝配工廠的實際導入，逐步分析實際生產運作的結果，驗證 Buffer Management對於Mixed SKU Production 的裝配生產系統，改善有效產出的顯著效果。

The case study is a consumer electronics product assembly factory, a small variety of product categories, mostly similar functions, but there are something slightly different from the module, appearance and electronic components. It is belong to Mixed SKU production assembly systems. The operating environment of Mixed SKU Production and the operator is the key factor for this environment since the operation variation and the bottleneck will move in each SKU to make the production line (the flow) is hard to be completely balanced and the effective daily outputs subsequently have a variation and be unstable. Since the output of each station will along with the bottleneck station, the production rate of bottleneck station determines the output of whole system. The theory of constraints extending out of the buffer management concept, by bottleneck resource protection and the buffer management built so the other non-bottleneck resources that can do best operation. It will not be limited to the production rate of the bottleneck and achieve the production line flow balance to improve the efficiency of the entire production line. The case study via G-company assembly line to analyze two different improved ways, one is traditional method and the other is buffer management. The result would be verified by two different ways. And the buffer management implement for mixed SKU production assembly system could get a significant effect for throughput.