臺灣博碩士論文加值系統

螺絲雖小卻是生活各樣器具組成所不可或缺的零件。舉凡各種機器設備、電腦通訊、醫療器材等均少不了螺絲。螺絲的生產係從盤元抽成線材、打頭、成型、搓牙、熱處理、電鍍烤漆等表面處理到成品的包裝，這些製程可以在一個大型的工廠一貫作業，但螺絲工廠大都為中小企業，藉著群聚且完整的供應鏈，因此螺絲生產的每一個製程也可由各個專業分工廠商來進行。在螺絲的專業包裝工廠中，原物料倉庫存放著有待包裝的螺絲、包裝材料（未開之紙箱紙盒、塑膠盒、塑膠袋）、標籤、膠帶、及空棧板等，當包裝生產線要進行螺絲包裝時，這些原物料一般由堆高機從原物料倉庫運搬至包裝生產線。包裝人員依據工令進行包裝，包裝完成後即將一箱箱的成品堆疊在棧板上，該堆棧好的成品棧板亦需由堆高機運搬至成品倉庫暫存以等待裝運出貨。因少量多樣之訂單型態，廠內原物料及成品的運搬頻率很高所以需要許多堆高機，堆高機出入迴轉空間大且與人員動線交錯易衍生工安問題。在本研究中運用萃智理論（TRIZ, Teoriya Resheniya Izobreatatelskikh Zadatch）的基本原理，將系統性創新的方法應用於工廠配置(Layout)之改善，設計在迴圈式軌道上走行的叉牙式電動有軌無人車RGV (Rail Guided Vehicle)，以此自動運搬系統來取代多數的柴油堆高機，不但可節省空間，使包裝生產線及運搬能力倍增，同時在原有工廠中使產能及營業額倍增，並創造了更為安全及環保的工作環境。

Although the screw is a small peanut, it is really basic and necessary in our living. It is an integral part of almost all the industrial products. In screw manufacturers, each stage of manufacturing process can be divided then subcontracted to other individual companies. In the case of a screw packaging factory, raw materials in storage including the screws to be packaged, package materials, labels, tapes, and empty pallets should be moved to the packaging line. Workers, after the completion of packaging, need to stack the cases of the finished goods on the pallets. And these pallets also need to be transported to a finished goods warehouse to wait for shipping. Because the customer's orders are usually composed of small quantities of items with many varieties, high throughput in the handling of materials is usually required. Therefore, many forklift trucks are needed in this kind of factory. Because the aisle for forklift trucks to turn always wastes a lot of space and the intersections between forklift trucks and workers are inevitable, accidents are most concerned issues. In this study, a systematic and innovative approach that use TRIZ (Teoriya Resheniya Izobreatatelskikh Zadatch) will be applied to solve the layout problems of an existing screw packaging factory. In this TRIZ approach, the layout of the factory is modified and an electrical closed loop type RGV (Rail Guided Vehicle) system with forklift device is applied. Most of diesel forklift trucks will be replaced by this automatic material handling system. The advantages of this modification will increase the numbers of packaging lines and double the yield of production and revenue. In addition, it can also improve the industrial safety and make the environment more eco-friendly.

Chinese Abstract --------------------------------------------------------------------- i
English Abstract --------------------------------------------------------------------- ii
Acknowledgement --------------------------------------------------------------------- iii
Contents --------------------------------------------------------------------- iv
List of Tables --------------------------------------------------------------------- vi
List of Figures --------------------------------------------------------------------- xii
Chapter 1 Introduction ------------------------------------------------------ 1
1.1 Research Background ------------------------------------------- 1
1.2 Research Motivation -------------------------------------------- 2
1.3 Research Objective ---------------------------------------------- 3
1.4 Literature---------------------------------------------------------- 3
1.5 Structure of Chapters-------------------------------------------- 4
Chapter 2 Methodology ----------------------------------------------------- 5
2.1 TRIZ Development Background------------------------------- 5
2.2 Contradiction Matrix and Inventive Principles-------------- 9
2.3 9-Windows and Problem Explorer---------------------------- 13
2.4 Function Attribute Analysis------------------------------------ 15
2.5 S-Field Analysis and Inventive Standards-------------------- 16
2.6 Ideal Final Result ------------------------------------------------ 18
2.7 Resources --------------------------------------------------------- 20
Chapter 3 Realistic Study Case and Result Analysis ------------------- 22
3.1 Brief of the Study Case------------------------------------------ 22
3.2 Define issues------------------------------------------------------ 25
3.3 Select Tools------------------------------------------------------ 26
3.4 Technical Analysis and Contradiction Matrix--------------- 28
3.5 Result Comparison----------------------------------------------- 38
Chapter 4 Conclusion-------------------------------------------------------- 39
4.1 Summary and Contribution------------------------------------- 39
4.2 Future Work------------------------------------------------------ 41
Reference --------------------------------------------------------------------- 42
Appendix --------------------------------------------------------------------- 44

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