臺灣博碩士論文加值系統

近年來企業為承接更大量的訂單，不斷的擴充產能，從企業成立之初單廠區模式，不斷的擴廠與合併，使得企業規模日漸增大，製造工廠也從一廠的模式擴充至多廠，為因應此生產環境的改變，以往單廠之生產規劃已不敷使用。所以，如何在現階段生產環境下，規劃多廠間跨廠產能規劃就顯得相當重要。
本研究針對多廠生產規劃問題，在廠與廠間歷史銷售量及既有的資源設備下，建立三階段規劃模式以生產總成本最小為目標。業務依據歷史銷售量統一接單，根據銷售量產能限制分配訂單，再以機器產能限制規劃工作站產能負荷，找出瓶頸工作站利用跨廠生產方式解決多廠區產能規劃問題。其中三階段模式並考量生產成本、製造成本、外包成本、延遲成本與運送成本等之總成本最小下，取得第一階段各廠區訂單產品需求量；第二階段各廠工作站產能負荷及瓶頸工作站；第三階段平衡瓶頸工作站需求量，取得工作站跨廠生產量、外包量與產能利用率。如此，可以依據最佳跨廠產能規劃結果安排生產細部規劃與排程規劃。

In order to satisfy the demand of increasing orders, a company must expand the production capacity to meet the orders. Due to the increasing production scale, a company must adopt a multi-plant manufacturing strategy to increase the capacity to satisfy the ordered demands. Under this consideration, it is important to develop a coordinated capacity planning in the manufacturing model to meet the change in such production environment.
The objective of this research is to develop three integrate capacity planning models in three phases. This model is aimed at minimizing the total production cost under the consideration of historical sales volumes among plants and constraints of resources and equipment. The multi-plant capacity planning model is analyzed according to the historical sales volume, order allocation by sales capacity constrain, workstation capacity load by machine capacity constrain to find the bottleneck workstation. In this model, we obtain the minimal integrated cost including production cost, manufacturing cost, out-sourcing cost, delay cost, and delivery cost. In phase one, we can obtain the amount of product order requirement of each plant. In phase two the workstation capacity load and bottleneck workstation of each plant is obtained. In phase three, we can obtain the workstation production amount, outsourcing amount and utilization of capacity by means of balancing the bottleneck workstation requirements. The multi-plant capacity is modeled and solved using the linear programming formulation and technologies. In this way, an optimal multi-plant capacity planning solution can be found. We can arrange the production planning and schedule planning according to the optimal solution of multi-plant capacity planning.

中文摘要……………………………………………………………………i
英文摘要………………………………………………………………………ii
誌謝…………………………………………………………………………iii
目錄…………………………………………………………………………iv
圖目錄………………………………………………………………………vii
表目錄…………………………………………………………………… viii
第一章 緒論……………………………………………………………1
1.1 研究背景………………………………………………………1
1.2 研究動機………………………………………………………2
1.3 研究目的………………………………………………………4
1.4 問題定義………………………………………………………5
1.5 論文架構………………………………………………………8
第二章 文獻探討………………………………………………………11
2.1 製造業的供應鏈管理………………………………………12
2.2 生產協調製造…………………………………………………15
2.3 工廠生產型態………………………………………………17
2.3.1 計畫式生產…………………………………………………18
2.3.2 訂單式生產…………………………………………………18
2.4 多廠生產計畫………………………………………………19
2.4.1 多廠生產規劃………………………………………………19
2.4.2 訂單分配……………………………………………………20
2.4.3 分配問題……………………………………………………22
2.5 產能規劃……………………………………………………24
2.5.1 粗略產能規劃………………………………………………25
2.5.2 產能規劃之相關研究………………………………………26
2.5.3 瓶頸資源生產規劃………………………………………29
2.5.4 外包管理…………………………………………………31
2.6 文獻探討結語…………………………………………………32
第三章 研究方法…………………………………………………………34
3.1 研究用語定義……………………………………………………34
3.2 問題定義…………………………………………………………36
3.3 研究範圍…………………………………………………………40
3.4 問題模式限制與假設……………………………………………41
3.4.1 第一階段之限制與假設條件………………………………41
3.4.2 第二階段之限制與假設條件………………………………42
3.4.3 第三階段之限制與假設條件……………………………43
3.5 問題模式之參數與變數…………………………………………43
3.6 問題架構與模式…………………………………………………45
3.6.1 第一階段問題架構與模式建立……………………………46
3.6.2 第二階段問題架構與模式建立……………………………49
3.6.3 第三階段問題架構與模式建立……………………………53
3.7 研究方法…………………………………………………………57
第四章 實例探討……………………………………………………58
4.1 例題假設說明……………………………………………………58
4.2 例題一—一般性生產模式………………………………………60
4.2.1 第一階段多廠區訂單分配求解……………………………61
4.2.2 第一階段多廠區訂單分配求解結果………………………62
4.2.3 第二階段各廠區工作站產能需求規劃求解………………63
4.2.4 第二階段各廠區工作站產能需求規劃求解結果……………64
4.2.5 第三階段跨廠產能規劃平衡求解…………………………67
4.2.6 第三階段跨廠產能規劃平衡求解結果……………………68
4.2.7 結果討論……………………………………………………71
4.3 例題二-應用在印刷電路板產業………………………………72
4.3.1 第一階段多廠區訂單分配求解……………………………74
4.3.2 第一階段多廠區訂單分配求解結果………………………75
4.3.3 第二階段各廠區工作站產能需求規劃求解………………76
4.3.4 第二階段各廠區工作站產能需求規劃求解結果……………79
4.3.5 第三階段跨廠產能規劃平衡求解…………………………82
4.3.6 第三階段跨廠產能規劃平衡求解結果……………………84
4.3.7 結果討論……………………………………………………90
4.4 例題三-應用在印刷電路板業但各規劃區間之需求量不穩定91
4.4.1 第一階段之結果分析……………………………………91
4.4.2 第二階段之結果分析…………………………………92
4.4.3 第三階段之結果分析…………………………………95
4.5 結論……………………………………………………………100
第五章 結論……………………………………………………………102
5.1 產能規劃之重要性與急迫性………………………………102
5.2 本研究方法之特性與貢獻……………………………………103
5.3 後續發展與建議………………………………………………105
參考文獻…………………………………………………………………107
附錄一例題三訂單資料………………………………………………111
附錄二例題一求解結果……………………………………………………112
附錄三例題二求解結果……………………………………………………115
附錄四Lingo執行程式……………………………………………124

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