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1、製程規劃,1,製程規劃的意義,指企業在其有限的內部資源及外在因素等限制條件下，從事生產過程的規劃，規劃出適合自己公司的製程技術及製程系統，俾達到以最低的成本及最有效率的方法/技術來生產出令顧客滿意的產品/服務之品質。,製程規劃,2,製程選擇與系統設計,預測,產品與 服務設計,產能規劃,設施與設備,佈置,工作設計,製程 選擇,技術變動,製程規劃,3,主要的製程決策,製程選擇(process choice) 垂直整合(vertical integration) 由廠商自己的生產系統或服務設備，操縱處理整個供應鏈的程度。 資源彈性(resource flexibility) 指員工和設備在處理多樣化
2、產品、產出水準、職責和功能的能力。 顧客參與(customer involvement) 資本密集程度(capital intensity),製程規劃,4,Processes at manufacturing organizations,High,Low,Volume,Project process Selecting location for new plant in Europe Installing ERP for a manufacturing firms business processes,Job process Machining precision metal tubes In
3、ternal consulting team at manufacturing firm,Batch process Forging process to make fittings for pressure vessels access Producing a batch of textbooks at R. R. Donnelleys plant,Line process Auto assembly King Soopers bread line,Continuous process Oil refining process Bordens pasta making process,製程規
4、劃,5,Processes at service providers,High,Low,Volume,Project process Real estate process for leasing and constructing facilities for large insurance company Student teams field project,Job process Customer service process at financial services firm General medical practice,Batch process Order fulfillm
5、ent process of importer/distributor Placing purchase orders at public relations agency,Line process Cafeteria line Teller line at bank,Continuous process Power generation plant Providing telephone line access,製程規劃,6,PROJECT BATCH MASS CONTINUOUS Product Unique Made to order Made to stock Commodity C
6、ustomer One-at-a-time Few individuals Mass market Mass market Demand Infrequent Fluctuates Stable Very stable Volume Very low Low to med High Very high No. of different Infinite Many, varied Few Very low products Production Long-term Discrete, job Repetitive, Process industry System Project assembly
7、 lines Equipment Varied General-purpose Special-purpose Highly automated Type of work Contracts Fabrication Assembly Mix, treat, refine Skills Experts, Wide range Limited range Equipment craftspeople of skills of skills monitors Advantages Custom work, Flexibility, Efficiency, Highly efficient techn
8、ology quality speed, low cost large capacity Dis- Nonrepetitive, Costly, slow, Capital investment, Difficult to advantages small customer difficult to lack of change base, expensive manage responsiveness Example Construction, Machine shops, Autos, TVs, Paint, chemicals, shipbuilding printing, bakery
9、 fast food food,Types of Processes,製程規劃,7,垂直整合的優點,規模經濟 品質較能掌控 有效利用人力資源設備和空間 提高生產效率 適合市場需求量大之公司,製程規劃,8,資源彈性,彈性勞動力(flexible work force) 能兼具原本及不同工作崗位之工作量和能力之員工。 專用設備 vs. 泛用設備,製程規劃,9,顧客參與,自助式服務(self-service) 產品選擇(買房子) 客製化程度 時間和地點 由顧客決定服務的時間和地點,製程規劃,10,資本密集程度,自動化 vs. 人工作業 自動化的優點 提高生產力 改良品質 缺點 不適合低產出量之作業，
10、其所需投資成本非常龐大。,製程規劃,11,產出量與製程決策之關聯性製造業,Less vertical integration More resource flexibility More customer involvement Less capital intensity/ automation,More vertical integration Less resource flexibility Less customer involvement More capital intensity/ automation,Low volume, make-to-order process,Hig
11、h volume, make-to-stock process,Project process Selecting location for new plant in Europe Installing ERP for a manufacturing firms business processes,Job process Machining precision metal tubes Internal consulting team at manufacturing firm,Line process Auto assembly King Soopers bread line,Continu
12、ous process Oil refining process Bordens pasta making process,Process design choices,製程規劃,12,Process design choices,Less vertical integration More resource flexibility More customer involvement Less capital intensity/ automation,More vertical integration Less resource flexibility Less customer invol
13、vement More capital intensity/ automation,Low volume, customized-service process,High volume, standardized-service process,Project process Real estate process for leasing and constructing facilities for large insurance company Student teams field project,Job process Customer service process at finan
14、cial services firm General medical practice,Batch process Order fulfillment process of importer/distributor Placing purchase orders at public relations agency,Line process Cafeteria line Teller line at bank,Continuous process Power generation plant Providing telephone line access,產出量與製程決策之關聯性服務業,製程規
15、劃,13,案例,Maxwell vs. Coffee shop,製程規劃,14,Process Selection with Break-Even Analysis,cf = fixed cost v = volume (i.e., number of units produced and sold) cv = variable cost per unit p = price per unit,Total cost = fixed cost + total variable cost TC = cf + vcv Total revenue = volume x price TR = vp Pr
16、ofit = total revenue - total cost Z = TR - TC = vp - (cf + vcv),製程規劃,15,Solving for Break-Even Volume,製程規劃,16,Break-Even Analysis,製程規劃,17,製程設計之考慮問題,木製椅 vs. 台灣涼椅 vs. 藤椅 年需求120 vs. 年需求12000 汽車製造廠是否需自製輪胎、座椅、燈具？ 點焊採用機械臂或半自動化？,製程規劃,18,製程設計應考慮之因素,物料規格分析 產品分析 自製或外購分析 製程技術的選擇 設備選擇 製程規劃與分析 設備佈置規劃 成本因素分析,製程規劃
17、,19,物料規格分析,物料之類別(type) 物料之型式(form) 尺寸、形狀 物料之物理/化學特性 所產生的廢料及下腳料(可利用度) 物料成本 物料來源 搬運之難易程度 存貨之預估 收料方式,製程規劃,20,產品分析,總產銷量 生產率 投入生產所需時間 生產方法 連續 間斷 批次 壽命期望值 改變之可能性 使用機能 消費者需求分析,品質水準 加工之條件及規格 品質 精確度(accuracy） 公差 外觀 表面加工 特殊性 標準化之程序 定價政策 產品市場定位,製程規劃,21,自製或外購分析,成本 品質 交期 數量 技術 設備 資金 專利,是否有充足而穩定的需求量 自製之零件，是否能發展至對
18、外銷售 零件自製時，有無該零件生產之管理能力 若投資自製零件，是否可達到一定的投資報酬率,製程規劃,22,製程技術的選擇1,專業技術因素 工作設計 工具設計 產能 質能平衡 生產線平衡 工作簡化,操作分析 可靠性 品質能力 價值分析與價值工程 安全性分析 彈性與擴充可行計劃。,製程規劃,23,製程技術的選擇2,成本與效益因素 機器、設備、存貨所需的資金 人力規劃 外包項目 生產標準時間 生產成本 廢品率 投資報酬率,勞動因素 勞工、技術人員及管理人員的供應情況 勞動的誘因(含薪資、福利制度)。,製程規劃,24,製程技術的選擇3,市場因素 市場需求量 市場產品廣度、深度之需求 市場所需求的品質
19、管理因素 管理制度 中、高階管理人才,廢棄物與防污因素 廢棄物之來源 數量防污方法 防污設備 防污系統設計 控制管理計劃 環境影響評估,製程規劃,25,設備選擇,Purchase cost Operating cost Annual savings Revenue enhancement Replacement analysis Risk and uncertainty Piecemeal analysis,製程規劃,26,通用設備與專用設備之比較,製程規劃,27,製程規劃之文件,Blueprints Bill of material (物料清單) Assembly chart / produ
20、ct structure diagram Operations process chart Routing sheet,製程規劃,28,Assembly Chart,製程規劃,29,電腦輔助製程規劃 (computer-aided process planning, CAPP),CAPP is a specialize software system for process planning. Type of CAPP Variant system A variant system retrieves a standard process plan from a CAPP database a
21、nd allows the planner or engineer to modify it for the new part. Generative system A generative system uses a knowledge base of rules gathered from expert machinists to create an individual process pan from scratch.,製程規劃,30,製程分析,The systematic examination of all aspects of a process to improve its o
22、peration Faster More efficient Less costly More responsive Basic tools Process flowchart Process diagrams Process maps,製程規劃,31,Process Flowchart Symbols (流程程序圖),製程規劃,32,Process Flowchart,製程規劃,33,Process Diagram,製程規劃,34,Process Map,製程規劃,35,途程(Routing)1,描寫了一物從它的初始狀況到它的最終狀況的程序 也描寫了何物將被生產、如何被生產、以及以何種方法來
23、生產 建立一途程時，首先依據由產品設計與開發部門所提供的產品資訊，將其轉成生產或服務的指令,製程規劃,36,途程(Routing)2,在途程中定義了作業(Operation)，並以順序描寫了作業在生產或服務發生的先後步驟。 將生產設施、工作中心、生產工具等分派給各個作業，維護各作業之處理時間。 途程的使用上，有時有其時間性，因此須將途程的有效起、訖時間加以界定，有時又因不同的生產批量會採用不同的途程，因此須將不同批量與途程間之使用關係加以界定，以幫助系統更迅速與正確地找出適合的途程。,製程規劃,37,途程單(Process Sheet)範例,製程規劃,38,設備佈置規劃,設備佈置係對於現場各部
24、門、製程、機器、支援等各種不同功能之單元，選擇一適當的位置予以安排。,製程規劃,39,成本因素分析,成本因素是較間接影響製程設計的因素，其所考慮的成本因素除了設備選擇中費用因素外，尚有融資成本、投資報酬率等。,製程規劃,40,製程規劃之步驟1,步驟一：收集所需資料。 步驟二：零組件分析。 步驟三：建立作業說明單。 步驟四：將加工單元組合成作業程序。 步驟五：收集有關設備與工具之資料。 步驟六：設備選擇與指定。 步驟七：設計製程作業計劃單並將作業標準化。,製程規劃,41,製程規劃步驟2,步驟八：製作生產途程單。 步驟九：製作操作程序圖。 步驟十：計算所需之機器與人員數目。 步驟十一：估計產品成本
25、。 步驟十二：購置所需設備。 步驟十三：安置設備。 步驟十四：試車。 步驟十五：量產。,製程規劃,42,設備數量計算範例1,假設油壓控制器每年之生產量為134000件，每年假設可利用之生產時間為2000小時，由操作1至5之期望廢品率分別為4%、5%、2%、3%、2%其生產效率90%，則各設備所需之數量為何?,製程規劃,43,設備數量計算範例2,製程規劃,44,設備數量計算解答,90%,製程規劃,45,設備數量之決策因素,當計算出來機器數非為整數時之考慮因素 在工作週期裡，人所能控制之比率如何?是否能得到更高之效率?更低之廢品率? 工作方法是否能改變以減低標準時間? 加班之成本是否低於增加機器設
26、備之成本? 一件機器之損壞是否妨礙整條生產線之生產?,製程規劃,46,現代輔助製程規劃之技術,Information Technology Artificial Intelligence Advanced Communications Manufacturing Technology,製程規劃,47,Information Technology,Management Information Systems (MIS) Move large amounts of data Decision Support Systems (DSS) Add decision making support Exp
27、ert System Recommend decision based on expert knowledge,製程規劃,48,Decision Support System,製程規劃,49,Artificial Intelligence,Neural networks Emulate interconnections in brain Genetic algorithms Based on adaptive capabilities in nature Fuzzy logic Simulate human ability to deal with ambiguity,製程規劃,50,Adva
28、nced Communications,Electronic data interchange (EDI) Internet, extranets Wireless communications Teleconferencing & telecommuting Bar coding, RFT Virtual reality,製程規劃,51,Manufacturing Technology,Numerically controlled (NC) machines Controlled by punched tape Computer numerical controlled (CNC) Cont
29、rolled by attached computer Direct numerical control (DNC) Several NC machines controlled by single computer Automated Material Handling Robotics Flexible manufacturing systems (FMS) Includes automated material handling,製程規劃,52,Automated Material Handling,Conveyors Automated guided vehicle (AGV) Aut
30、omated storage & retrieval system (AS/RS),製程規劃,53,Flexible Manufacturing Systems (FMS),Programmable machine tools Controlled by common computer network Combines flexibility with efficiency Reduces setup & queue times,製程規劃,54,Flexible Manufacturing System,製程規劃,55,Robotics,Programmable manipulators Fo
31、llow specified path Better than humans with respect to Hostile environments Long hours Consistency Adoption has been slowed by ineffective integration and adaptation of systems,製程規劃,56,e-Manufacturing,Real-time sharing of data with trading partners and customers to drive collaborative decisions CAD - uses software to create & modify designs GT- classifies designs to benefit from prior experience STEP - sets standards for communication CAPP - creates processing instructions for CAM CAM - uses programmable automation in manufacturing,製程規劃,57,Components of e-Manufacturing,