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研究生:張元榛
研究生(外文):CHANG, YUAN-CHEN
論文名稱:以最小化完工時間為目標含單站重工之生產排程 -以某鞋業製造商為例
論文名稱(外文):Minimizing Makespan with Production Scheduling of Single Workstation Rework for Manufacturing Firm of Footwear
指導教授:柳永青柳永青引用關係林君維林君維引用關係
指導教授(外文):LIU, YUNG-CHINGLIN, CHUN-WEI
口試委員:柳永青林君維傅家啟王泰裕
口試委員(外文):LIU, YUNG-CHINGLIN, CHUN-WEIFU, JA-CHIHWANG, TAI-YU
口試日期:2017-06-01
學位類別:碩士
校院名稱:國立雲林科技大學
系所名稱:工業工程與管理系
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:2017
畢業學年度:105
語文別:中文
論文頁數:64
中文關鍵詞:重工生產排程製鞋業
外文關鍵詞:ReworkManufacturing proceduresShoe manufacturing industry
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製鞋業為勞力密集產業,自動化導入較為緩慢,至今還是以半人工半機器作業為主,以個案研究公司為例,針車製程的不良率有8到10%,如果將不良品透過重工(rework)方式成為良品,即可減少原物料的浪費及物料成本的損失。
但是現場作業人員未必願意重工,若不願意重工,則須多補原物料來增加生產數量,導致完工時間的增加;若願意重工,在沒有一套好的重工的排程方式下,依人員經驗法則判斷往往會造成不良品擱置一旁暫存區導致存貨堆積。
所以本研究考量含單站重工的流程式生產(Flow Shop)排程問題,建立數學模式並利用基因演算法進行求解,希望找出好的排程方法,使整個生產排程的最大完工時間(Makespan)最小化。然後透過案例分析,將現行無重工增加生產量的方法與方法一達總流程時間的50%時啟動重工排程及方法二達不良率的50%時啟動重工排程比較在變動重工站數及不良率時的績效表現,最後進行方法一與方法二達多少比例時啟動重工排程的敏感度分析,觀察完工時間之變化。
Shoe manufacturing industry belong to labor-intensive industry, which still mainly depends on semi mechanical processing nowadays since the introduction of automation is relatively slow. Take the case study company as example, the defective rate of sewing machine manufacturing procedures is from 8% to 10%. The wastes of materials and the losses of material costs could be decreased via rework approach that makes defective products into good products.
However, workers on site may not be willing to choose rework approaches. If they do not want to rework, more materials would be needed to increase the production amounts, which increases the completion time. Even though workers are willing to rework, it is not uncommon to see that workers may set the defective products aside in the storage cache according to their rule of thumb, which may cause the inventory accumulation without good scheduling approaches of reworks.
Therefore, this study considered the scheduling problems of flow shop for rework procedures in single stop to establish mathematics models taking advantage of genetic algorithm in hope of finding solutions for good scheduling approaches, which could minimize the maximal makespan in the manufacturing scheduling. Through case analyses, approaches of production amount without rework, launching rework scheduling once reaching 50% of total scheduled time (method 1), and launching rework scheduling once the defective rate reaching 50% (method 2) could be compared to understand the performances under varying rework stop numbers and defective rates. Finally, the optimal ratio between method 1 and method 2 to launch the sensibility analyses of rework scheduling was calculated to observe the alteration of completion time.
摘要 ................................................................................................................................................ i
Abstract ......................................................................................................................................... ii
誌謝 .............................................................................................................................................. iii
目錄 .............................................................................................................................................. iv
表目錄 ......................................................................................................................................... vii
圖目錄 ........................................................................................................................................ viii
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研究範圍與限制 ................................................................................................................. 4
1.4研究流程 ............................................................................................................................. 5
第二章、文獻探討 ....................................................................................................................... 6
2.1文獻架構 ............................................................................................................................. 6
2.2製鞋業現況 ......................................................................................................................... 7
2.2.1運動鞋製程介紹 .......................................................................................................... 7
2.2.2針車重工定義 .............................................................................................................. 8
2.2.3針車重工範例 .................................................................................................................. 9
2.3生產排程 ........................................................................................................................... 11
2.3.1生產排程類型 ............................................................................................................ 11
2.3.2平行機類型 ................................................................................................................ 12
2.3.3排程績效衡量準則 ........................................................................................................ 13
2.3.4生產排程求解方法 .................................................................................................... 14
2.3.5小結 ............................................................................................................................ 15
2.4重工排程 ........................................................................................................................... 15
2.4.1重工的排程相關文獻 ................................................................................................ 16
2.4.2重工排程時間點之選定 ............................................................................................ 17
2.4.3小結 ............................................................................................................................ 18
2.5基因演算法 ....................................................................................................................... 18
2.5.1基因演算法之應用 .................................................................................................... 20
第三章、研究方法 ..................................................................................................................... 21
3.1問題描述 ........................................................................................................................... 21
3.2問題假設 ........................................................................................................................... 21
3.3符號定義 ........................................................................................................................... 22
3.4數學模式 ........................................................................................................................... 22
3.5數學模式驗證 ................................................................................................................... 24
3.5.1參數設定 .................................................................................................................... 24
3.5.2結果驗證 .................................................................................................................... 25
3.6基因演算法之建構 ........................................................................................................... 27
3.6.1染色體編碼方式 ........................................................................................................ 28
3.6.2產生初始族群 ............................................................................................................ 28
3.6.3適應值函數 ................................................................................................................ 29
3.6.4複製 ............................................................................................................................ 29
3.6.5交配 ............................................................................................................................ 30
3.6.6突變 ............................................................................................................................ 31
3.6.7取代 ............................................................................................................................ 32
3.6.8終止條件 .................................................................................................................... 32
第四章、績效評估與案例分析 ................................................................................................. 34
4.1實例應用-以某鞋業製造商為例 ...................................................................................... 34
4.1.1結果分析 .................................................................................................................... 36
4.1.2變異數分析 ................................................................................................................ 38
4.2變動重工站數&不良率 .................................................................................................... 39
4.2.1結果分析 .................................................................................................................... 39
4.3敏感度分析 ....................................................................................................................... 46
第五章、結論與建議 ................................................................................................................. 50
5.1結論 ................................................................................................................................... 50
5.2研究建議 ........................................................................................................................... 51
參考文獻 ..................................................................................................................................... 52
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