以基於D-DANP-mV之品質機能展開定義生產汽車零件之塑膠射出企業精實生產策略

Abstract

精實生產是將生產系統化的一種有效方法，主要概念是以最小的資源投入，在最少的浪費下創造出最大的價值。塑膠在較輕的重量下擁有可塑性與強韌性，且有各式各樣不同的顏色與透明度，使許多汽車機車零件與相關用品都以塑膠為優先選擇。而在塑膠射出產業的生產產品種類多元且多變的，因此生產策略對於塑膠射出企業非常的重要。為提升企業生產效率以及減少各種浪費，達到提升企業競爭力之效果，本研究導入基於網路決策實驗室分析法(Decision Making Trial and Evaluation Laboratory，DEMATEL)之分析網路流程(DEMATEL based Analytic Network Process,，DANP)，整合折衷排序法(VlseKriterijumska Optimizacija I Kompromisno Resenje，VIKOR)，結合為DEMATEL-based Analytic Network Process with modified VIKOR model (D-DANP-mV)，並融合品質機能展開法，分析客戶需求與零件規格之關聯性，以萃思法推演適合之發明策略，藉以改善生產線。本研究首先依據實際情況，歸納客戶需求，並且將生產規格導入品質屋。其次本研究以多準則決策分析法，找出相關企業精實生產實施的優先順序，其中透過DEMATEL法推衍需求間的影響關係，並以DANP法計算各需求之權重，後續以VIKOR法，計算需求優先改善之規格參數。最後以萃思法(TRIZ)結合VIKOR，針對衝突嚴重之優先參數，訂定精實生產策略。根據研究結果，本研究得到了四個衝突點，並利用萃思法矛盾矩陣和VIKOR推演適合的解決方案。包括分割，丟棄和回收，機械系統更換為主要的解決方案。可用於分割區段中的工作空間。機械臂和自動化生產可用於解決機械系統更換部件的衝突點。一般來說，標準化、降低成本和製造與裝配設計(Design for Manufacture and Assembly，DFMA)是最合適的精實策略。未來，本研究所提出的框架也可以在其他製造企業中採用。

Lean production is an effective method to systematize production. The main concept is to create maximum value with minimum resource input and minimum waste. Plastic has plasticity and toughness under the lighter weight, and has a variety of different colors and transparency. So many vendors of automobile and motorcycle prioritize plastic as the major materials for parts. In the plastic injection industry, the types of products produced are various and changeable. So production strategies are very important for plastic injection companies.Thus, this research aims to improve the production efficiency of the enterprise and reduce various wastes, so as to enhance the competitiveness of the enterprise. To achieve the purpose, the Decision Making Trial and Evaluation Laboratory (DEMATEL) based analytic network analysis (ANP), or DANP, integrated with the VlseKriterijumska Optimizacija I Kompromisno Resenje (VIKOR) method, i.e., the D-DANP-MV, is introduced. Moreover, the quality function deployment (QFD) method was introduced to analyze the correlations amongst customer needs and part specifications, and derives suitable invention strategies by the TRIZ methods to improve the production line.This research first summarized customer needs based on actual conditions, and introduces production specifications into the Quality House of the QFD. Then, this study introduced hybrid multiple criteria decision making (MCDM) methods to find out the priority order of lean production implementation in related enterprises, among which used DEMATEL to deduce the influence relationship between requirements, and calculates the weight of each requirement by the DANP. Then, the VIKOR was introduced to calculate the parameters on the manufacturing process, which are prioritized for improvement. In the end, combining TRIZ with VIKOR, lean production strategies were formulated for the priority parameters with serious conflicts.According to the research results, four conflict points are known as a result of this research, and the recommended solutions are discovered using the TRIZ and VIKOR contradiction matrix. Segmentation, discarding and recovery, and mechanical system replacement are the primary solutions. It can be utilized to split the work space in the section for division. The robotic arm and automated production can be used to resolve the conflict point in the mechanical system's replacement component. In general, standardization, cost reduction, and Design for Manufacture and Assembly (DFMA) are the most suitable lean strategies. In the future, the proposed framework can also be adopted in other manufacturing firms.