臺灣博碩士論文加值系統

摘要
資訊與電腦科技的快速變革，使得今日的製造系統，形成自動化、整合性及迅速反應之生產要求與型態，更導致持續改變與非預期之改變成為生產製造之常態。然而現今的製造系統，部份屬於大量生產時代所延展至今的推式生產系統（Push system），另一部份則為受多方探討的豐田拉式生產系統（Pull system），此兩系統各自擁有絕佳的優點亦各有重大之缺陷存在。有鑑於此，本研究藉由運用限制理論整合推式與拉式生產系統，擷取兩系統的精髓，期望發展出具有高效率、整合性的生產製造系統以符合敏速製造系統（Agile manufacturing system）之特性，達到迅速反應市場變化及顧客的需求。
本研究經由限制理論建構整合模式，並運用模擬的方式驗證整合之後的系統績效。研究方法中，主要建立一研究案例以配合模擬作業之進行，根據此研究案例求得的產能規劃與排程的結果數據，再以此結果數據作為模擬作業所需的輸入資料，執行模擬並比較MRP系統、JIT系統及整合性生產系統的績效差異。比較的績效指標為產品產出率、在製品數量及產能利用率，希望藉此能提供製造業者作為進入廿一世紀產製模式與生產控管之依據。

ABSTRACT
Due to the rapid revolution of information and computer technology, the manufacturing systems nowadays have been transformed to be the automated, integrated and quick responding conditions. These are also deemed normality with the characteristic of continuous and unanticipated change for such manufacturing systems. Hence, the main purpose of this research is to apply concepts of Theory of Constraints（TOC）to study the possibility of integrating the so-called push and pull production systems for developing a highly efficient, and integrated production systems. We entitle the integrated model and environment as an Agile manufacturing system, which can respond the market change and customer changing demand quickly.
In this research, we developed a virtual case to work as the basic environment for the simulation processes. Based on the case established, the production capacity planning and scheduling results can be obtained and are used as input data for the simulation. Simulations were performed and the differences of performance from those three system models known as MRP, JIT and the integrated production model were compared and tabulated. The performance evaluation indices for comparison are production throughput, amount of WIP and the utility of production capability. We tend to provide manufacturers a basis of manufacturing model and production control to get into 21st Century.

目 錄
中文摘要……………………….…………………………………Ⅰ
英文摘要……………………….……………………………...Ⅱ
誌謝……………………….………………………………………Ⅲ
目錄……………………….………………………………………Ⅳ
圖目錄……………………….……………………………………Ⅵ
表目錄……………………….……………………………………Ⅶ
第1章 緒論………………………………………………………1
1.1 研究背景與動機………………………………………1
1.2 研究目的………………………………………………2
1.3 研究步驟與架構………………………………………3
1.4 研究範圍與限制………………………………………5
第2章　文獻探討…………………………………………………6
2.1 生產系統的發展與演進………………………………..6
2.2 MRP、JIT與OPT系統…………………………………9
2.2.1 MRP系統………………………………………9
2.2.2 JIT系統………………………………………11
2.2.3 OPT系統………………………………………14
2.2.4 MRP、JIT與OPT之比較………………………19
2.3 限制理論之探討………………………………………23
2.3.1 TOC/OPT之九大原則與五個基本步驟………24
2.3.2 限制驅導式排程方式之探討…………………26
2.4 敏速製造系統…………………………………………31
2.4.1 敏速製造系統的定義…………………………31
2.4.2 傳統製造與敏速製造之比較…………………35
2.5 相關模擬探討…………………………………………37
第3章 研究方法………………………………………………41
3.1 整合性生產系統建構符合敏速製造系統特性之研…41
3.2 模擬工具之選擇………………………………………43
3.3 模擬作業實施之步驟…………………………………44
3.4 生產系統績效指標衡量………………………………46
第4章 模擬過程與結果分析…………………………………49
4.1 模擬案例描述…………………………………………49
4.2 模擬模式之建構………………………………………50
4.2.1 生產模擬作業…………………………………50
4.2.2 產品製造途程…………………………………54
4.2.3 標準工時檔……………………………………55
4.2.4 主生產排程……………………………………56
4.2.5 產能負荷分析…………………………………57
4.3 生產排程控制作業……………………………………58
4.3.1 MRP生產排程控制作業………………………58
4.3.2 JIT生產排程控制作業………………………59
4.3.3 整合模式生產排程控制作業…………………60
4.4 模擬結果分析…………………………………………66
4.4.1 產品產出率……………………………………66
4.4.2 在製品數量……………………………………67
4.4.3 產能利用率……………………………………68
4.4.4 綜合績效比較分析…………………………….70
第5章 結論與建議……………………………………………72
5.1 結論……………………………………………………72
5.2 建議……………………………………………………73
參考文獻…………………………………………………………75
附錄……………………………………………………………….85
作者簡介………………………………………………………….93
圖 目 錄
圖 1-1 研究步驟與架構圖……………………………………4
圖 2-1 MRP系統之基本架構…………………………………11
圖 2-2 JIT系統之基本架構……………………………………13
圖 2-3 OPT系統之基本架構…………………………………17
圖 2-4 TOC瓶頸改善觀念步驟圖……………………………26
圖 2-5 限制驅導式排程法基本概念圖………………………27
圖 3-1 整合性生產系統建構符合敏速製造系統特性之實施步驟圖……………………………………………………41
圖 3-2 模擬作業流程圖………………………………………46
圖 4-1 產品結構圖……………………………………………49
圖 4-2 MRP模擬流程圖………………………………………51
圖 4-3 JIT模擬流程圖…………………………………………52
圖 4-4 整合模式模擬流程圖…………………………………53
圖 4-5 各產品製造途程………………………………………54
圖 4-6 整合模式瓶頸資源排程之甘特圖…………………….64
圖 4-7 整合模式繩排程之甘特圖…………………………….65
圖 4-8 產品產出率比較圖……………………………………66
圖 4-9 在製品數量比較圖……………………………………67
圖4-10 各製造資源產能利用率比較圖……………………….69
圖 4-11 瓶頸資源產能利用率比較圖…………………………..69
圖4-12 整合模式瓶頸緩衝區之在製品存貨量………………70
表 目 錄
表 2-1 生產系統的演進歷史…………………………………...9
表 2-2 OPT相關文獻彙總表…………………………………19
表 2-3 MRP、JIT與OPT之比較………………………………23
表 2-4 敏速製造的定義………………………………………33
表 2-5 三種不同生產系統概念之比較………………………36
表 2-6 傳統製造與敏速製造的觀點比較……………………37
表 2-7 相關模擬文獻彙總表…………………………………40
表 3-1 整合性生產系統建構符合敏速製造系統特性之實施步驟與運用方法彙總表…………………………………42
表 4-1 模擬模式之參數與條件異同比較表…………………50
表 4-2 產品製造途程表………………………………………55
表 4-3 產品標準工時…………………………………………55
表 4-4 主生產排程……………………………………………56
表 4-5 產能負荷分析表………………………………………57
表 4-6 MRP物料發放排程表…………………………………59
表 4-7 JIT物料發放排程表……………………………………60
表 4-8 邊際利潤分析表………………………………………62
表 4-9 整合模式瓶頸資源排程………………………………62
表 4-10 整合模式繩排程………………………………………63
表 4-11 三種模式生產績效綜合比較分析……………………71

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