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研究生:王建能
研究生(外文):Wang Cheng Neng
論文名稱:固定流程生產作業製造彈性與生產績效之相關性研究
指導教授:耿伯文耿伯文引用關係
學位類別:碩士
校院名稱:國立成功大學
系所名稱:工業管理學系
學門:商業及管理學門
學類:其他商業及管理學類
論文種類:學術論文
論文出版年:1999
畢業學年度:87
語文別:中文
中文關鍵詞:固定流程生產作業暫存區配置瓶頸工作站系統模擬實驗設計製造彈性生產績效
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在目前少量多樣的需求環境中,提昇製造系統的彈性一直是廠商所努力追求的目標,然而在Gustavsson的研究中指出,系統的彈性與生產力常存在著一定的取捨關係,若一個製造系統事前沒有做好完善的規劃與評估,可能會使得系統的生產設備無法發揮其應有的生產力,造成投資成本的浪費。
而固定流程製造作業乃泛指上下游製程具有一定的相關性,而因為其製造的流程固定,所以一旦上游或下游某工作站遭逢不確定因素停工或當機,都會造成整條生產線全面的停工與當機,如此一來所造成的損失將更為巨大。
設置暫存區可使得工作站之間更具獨立性,具有平順生產變異的功能,而增加瓶頸工作站機台數量不但可以增加系統產出,也能因為途程選擇增加,使得系統上製造的彈性得到一定的提昇。
所以本研究擬在半導體封裝產品SOJ28生產線上,改變暫存區容量大小與瓶頸工作站機台數量,藉由實驗設計與系統模擬的方法產生出三種不同的生產績效指標:生產力(productivity)、在製品存量(WIP)、產線彈性(manufacturing flexibility),並對三種指標進行相關性分析,以瞭解此三種生產指標在固定流程生產作業彼此的關係。另外,本研究將針對因子實驗所模擬出來的結果,對三個投入變項與三個產出項之互動關係進行分析比較,期望能對此個案生產線提出可供參考的建議。

目錄
摘要.................................................................................................................................I
目錄...............................................................................................................................II
表目錄..........................................................................................................................IV
圖目錄...........................................................................................................................V
第一章 緒論..................................................................................................................1
1.1 研究背景與動機........................................................................................... 1
1.2 研究目的........................................................................................................3
1.3 研究範圍與假設........................................................................................... 4
1.4 研究架構與流程........................................................................................... 5
第二章 文獻探討......................................................................................................... 7
2.1 暫存區配置問題............................................................................................7
2.1.1 固定流程生產作業與暫存區.............................................................. 7
2.1.2 生產線緩衝存貨的相關研究.............................................................. 8
2.1.3暫存區之功能......................................................................................10
2.2 製造彈性......................................................................................................11
2.2.1 製造彈性的意義.................................................................................11
2.2.2 製造彈性的分類.................................................................................12
2.2.3 製造彈性的衡量.................................................................................16
2.3 生產力..........................................................................................................20
2.4 半導體封裝製程簡介..................................................................................24
2.4.1 IC封裝製程簡介.................................................................................24
2.4.2 IC封裝產品生管特性........................................................................ 27
第三章 研究方法........................................................................................................29
3.1 根據TOC理論建構出改善的模型.........................................................29
3.2 系統模擬...................................................................................................31
3.3 生產績效指標衡量...................................................................................34
第四章 實例驗證........................................................................................................37
4.1 SOJ28半導體封裝生產線製造環境.........................................................37
4.2 模型的建構與驗證...................................................................................39
4.2.1 模擬模型的建構..............................................................................39
4.2.2 模擬模型的驗證..............................................................................41
4.3 實驗設計.................................................................................................. 43
4.4 模擬結果.................................................................................................. 46
4.4.1 模擬各組實驗產生結果..................................................................46
4.4.2 換算之後的三種生產績效指標..................................................... 47
4.5 實驗結果分析...........................................................................................48
4.5.1 實驗因子與生產績效之相關分析..................................................48
4.5.1.1 WIP與實驗因子之相關分析...............................................49
4.5.1.2 生產力與實驗因子之相關分析......................................... 52
4.5.1.3 產線彈性與實驗因子之相關分析..................................... 55
4.5.2 生產績效之間的相關性分析......................................................... 58
4.5.2.1 產線彈性與在製品數量之相關性分析..............................59
4.5.2.2 產線彈性與生產力指標之相關性分析..............................60
4.5.2.3 在製品數量與生產力指標之相關性分析..........................61
4.5.3.1 WIP三因子MANOVA分析...............................................62
4.5.3.2 生產力MANOVA分析..................................................... 67
4.5.3.3 產線彈性MANOVA分析................................................. 69
第五章 結論與未來研究方向....................................................................................72
5.1 結論.......................................................................................................... 72
5.2 未來研究方向.......................................................................................... 73
參考文獻......................................................................................................................75
表目錄
表2.1 製造彈性的衡量方法整理表..........................................................................17
表4.1 工作站加工時間表..........................................................................................38
表4.2 工作站機台數量表..........................................................................................38
表4.3 當機時間與修復時間表..................................................................................38
表4.4 實驗處理表......................................................................................................45
表4.5 模擬實驗結果表..............................................................................................46
表4.6 各組績效指標表..............................................................................................47
表4.7 WIP複迴歸與偏相關分析表...........................................................................49
表4.8 WIP之ANOVA分析表...................................................................................49
表4.9 生產力指標複迴歸與偏相關分析表..............................................................52
表4.10 生產力ANOVA分析表................................................................................52
表4.11 產線彈性複迴歸與偏相關分析表.................................................................55
表4.11 產線彈性ANOVA分析表.............................................................................55
表4.12 產線彈性與在製品數量之相關性分析表....................................................59
表4.13 產線彈性與生產力相關係數分析表............................................................60
表4.14 WIP與生產力相關分析表.............................................................................61
表4.15 WIP MANOVA分析表...................................................................................62
表4.16 生產力MANOVA分析表............................................................................. 67
表4.17 產線彈性MANOVA分析表..........................................................................69

徐朝南『製造彈性的發展與衡量』台灣工業技術學院工業管理研究所碩士論文,民國八十三年
吳凱文『IC封裝廠之短期生產排程模式』清華大學工業工程研究所碩士論文,民國八十六年
戴于婷『IC封裝廠中期生產規劃系統之構建』交通大學工業工程與管理碩士論文,民國八十七年
謝文樂『IC構裝製程與設備簡介』機械工業雜誌,pp.187-194, 民國八十四年六月
湯玲郎、林啟芬、劉常勇『積體電路廠之生產系統模擬研究』工業工程學刊,第十卷,第二期,pp.95-103,民國八十二年
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