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研究生:鍾蕙嬪
研究生(外文):Huei-pin Jhong
論文名稱:應用等候線系統於串聯與裝配式生產之DBR分析
論文名稱(外文):Analysis of Serial and Assembly DBR Production System - Using Queueing Theory
指導教授:郭雅玲郭雅玲引用關係
指導教授(外文):Yar-lin Kuo
學位類別:碩士
校院名稱:國立雲林科技大學
系所名稱:工業工程與管理研究所碩士班
學門:工程學門
學類:工業工程學類
論文種類:學術論文
論文出版年:2009
畢業學年度:97
語文別:中文
論文頁數:119
中文關鍵詞:在製品存貨連續型馬可夫鏈DBR(drum-buffer-rope)系統
外文關鍵詞:DBR(drum-buffer-rope) systemWIP bufferMarkov process
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生產製程中瓶頸機台的存在主導著整體的生產效益,組織的營運應著重在系統的瓶頸管理,本研究將DBR排程系統應用於生產流程上,探討如何控管在製品(work in process;WIP )存量,給予瓶頸適當的緩衝,以達最大期望淨利為生產目標。研究中考量的生產流程為串聯式生產及裝配式生產,以連續型馬可夫鏈(Markov Process)分別求算系統內在製品存量的穩定狀態機率,並建構最大期望淨利之目標式,探討機台不故障、非瓶頸機台會故障狀態以及瓶頸機台會故障狀態下之最適在製品存量的差異。

研究結果顯示在製品存量的控管受到機台平均服務速率、機台平均故障率及機台平均維修速率的影響,尤其以機台平均服務速率之影響最大。依據串聯式生產與裝配式生產製程特性不同,控管在緩衝區存量的特性亦不相同。串聯式生產模式中,非瓶頸機台生產速率越快,則需降低緩衝區的存貨量;裝配式生產模式中,非瓶頸機台產端生產速率越快,則需提高瓶頸機台產端的緩衝區存貨量,兩種生產模式的目的皆為求生產作業之流暢以達淨利最大。
The bottleneck of machines in the production process dominates the overall production efficiency. Organizations should focus on the operations of the bottlenecks in the system. In this study, DBR system was used in the production process to explore the controlling of the WIP (work in process), and provide the bottleneck with the optimal size of WIP buffer that could achieve the maximum net profit of output. The Markov Process was used to calculate the steady-state probability of the WIP in the serial and in the assembly production system respectively. Both production system was discussed under these three cases: The machines with no failure, non-bottleneck machine with failure and the bottleneck machine with failure.

The research results showed that the size of WIP buffer was affected by the average machine service speed, average machine failure rate and average repair rate. The average service rate of machine was the most influential factor. Based on different characteristics of series and assembly production systems, inventory control methods in the buffer were not the same. In series production system, when the productions of non-bottleneck machine run faster, the size of WIP buffer should be smaller. In assembly production system, when the productions of non-bottleneck machine run faster, the bottleneck machine buffer stock should be bigger. The purposes of these two of production systems are both used to make the production smooth and to achieve the maximum net profit.
中文摘要 i
Abstract ii
誌謝 iii
目錄 iv
表目錄 vi
圖目錄 vii
第一章 緒論 1
1.1研究背景 1
1.1.1限制理論(Theory of Constraints;TOC) 1
1.1.2 Drum-Buffer-Rope(DBR)排程系統 4
1.1.3 在製品緩衝與時間性緩衝 5
1.1.4 V-A-T產出鏈分析模式 6
1.1.5串聯與裝配式生產之緩衝區型態 7
1.2 研究動機與目的 8
1.3 研究方法與步驟 9
第二章 文獻探討 12
第三章 串聯型生產模式 17
3.1問題描述 17
3.2機台二模式建構1─機台不會故障 19
3.2.1基本假設 19
3.2.2符號定義 19
3.2.3系統狀態圖 20
3.2.4模型的描述與基本建構 20
3.2.5數值分析 22
3.3機台二模式建構2─考量非瓶頸機台會故障,瓶頸機台不會故障 28
3.3.1基本假設 28
3.3.2符號定義 28
3.3.3系統狀態圖 29
3.3.4模型的描述與基本建構 29
3.3.5數值分析 32
3.4機台二模式建構3─考量非瓶頸機台不會故障,瓶頸機台會故障 41
3.4.1基本假設 41
3.4.2符號定義 41
3.4.3系統狀態圖 42
3.4.4模型的描述與基本建構 42
3.4.5數值分析 45
3.5研究小結 53
第四章 裝配型生產模式 59
4.1問題描述 59
4.2模式建構1─機台不會故障 61
4.2.1基本假設 61
4.2.2符號定義 61
4.2.3系統狀態圖 62
4.2.4模型的描述與基本建構 62
4.2.5數值分析 65
4.3模式建構2─考量非瓶頸機台會故障 72
4.3.1基本假設 72
4.3.2符號定義 72
4.3.3系統狀態圖 73
4.3.4模型的描述與基本建構 73
4.3.5數值分析 78
4.4模式建構3─考量瓶頸機台會故障 86
4.4.1基本假設 86
4.4.2符號定義 86
4.4.3系統狀態圖 87
4.4.4模型的描述與基本建構 87
4.4.5數值分析 92
4.5研究小結 101
第五章 結論 107
參考文獻 109
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[3]Kent, R., Optimised production technology. Scheduling Technology Group.
[4]Koh, S. G. & Bulfin, R. L., (2004). Comparison of DBR with CONWIP in an unbalanced production line with three stations. International Journal of Production Research, 42(2), 391–404.
[5]Louw, L. & Page, D. C., (2004). Queuing network analysis approach for estimating the sizes of the time buffers in Theory of Constraints-controlled production systems. International Journal of Production Research, 42(6), 1207–1226.
[6]Radovilsky, Z.D., (1998). A quantitative approach to estimate the size of the size of the time buffer in the theory of constraints. International Journal of Production Economics, 55, 113-119.
[7]Rahman, S., (1998). Theory of constraints:a review of the philosophy and its applications. International Journal of Operations and Production Management, 18, 336-355.
[8]Tu, Y. M., & Li, R. K., (1998). Constraint time buffer determination model. International Journal of Production Research, 36(4), 1091-1103
[9]Wu, H. H. & Yen, M. L., (2006). A DBR scheduling method for manufacturing environments with bottleneck re-entrant flows. International Journal of Production Research, 44(5), 883-902.
[10]Ye, T. & Han. W., (2008). Determination of buffer size for drum-buffer-rope (DBR) controlled production system. International Journal of Production Research, 46(10), 2827-2844.
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