導入廠內成套零件供補模式於多種少量生產之汽車製造廠

Abstract

國內的汽車產業面臨市場飽和的瓶頸，為了維持市場佔有率，各家汽車公司持續不斷的推出新車種，以提高消費者的購買意願。台灣汽車製造廠生產線大部分皆採用多種少量混線生產方式，每增加一個新車種，生產線的零件種類往往得增加一倍，而在生產線擺放零件的面積無法增加下，此種現象使得生產效率也出現瓶頸。成套零件供補（Set Parts Supply, SPS）模式是由豐田生產方式中的及時生產衍生而來，是一個能有效降低生產線零件存放面積與提高生產效率的方法，它將所有的零件退出生產線邊，由專人以成套的方式，依生產車序及時的供應給生產線上的作業員。目前中、外文獻中探討SPS模式實際應用的例子非常少見，有鑑於此，本研究以豐田生產方式為工具，建構了一套適用於汽車製造業的廠內SPS模式之實施流程，以利於汽車製造廠在車種增加之下仍能有系統地規劃廠內零件供補上線方案，並藉由試行與效果確認的方法來作持續的改善。本研究將以此實施流程實際應用於台灣某汽車製造廠之生產線，驗證本研究所提出方法確實可幫助汽車製造廠實行SPS模式。

Domestic auto industry is facing a bottleneck of market saturation. In order to maintain market share, automobile companies have to continually introduce new models to enhance consumers’ purchasing willingness. In Taiwan, most auto manufacturers adopt a high-variety-low-volume mixed line mode of production. The number of types of parts often doubles as result of a newly introduced car model. When the production area is limited, the production efficiency is highly affected by the increasing number of parts. Set Parts Supply (SPS) Model, derived from the Just-in-time manufacturing of Toyota production methods, is an effective way in reducing the line-side storage space which often also leads to an improvement of production efficiency. SPS moves all components away from the production line and assigns specific operators to deliver parts with completed set based upon the car producing sequence to supply production line instead. There is very little literature that studied the implementation of SPS model. This research constructs a process for auto makers to implement the SPS model in practice. A real case drawn from a Taiwanese auto manufacturer is used to demonstrate the feasibility and effectiveness of the proposed process.