利用資料分析結合六標準差進行生產損耗改善

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潘昀楷(Yun-Kai Pan) 查詢紙本館藏

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工業管理研究所在職專班

論文名稱

利用資料分析結合六標準差進行生產損耗改善

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摘要(中)

塑膠產業為一個相對成熟的行業，近年來面臨中國和東南亞國家的競爭影響，因此需要在製造成本上有更好的競爭力，以保有在台灣生產的優勢，並實現利潤最大化。對於塑膠射出製造業而言，原材料成本佔製造成本很大比例，因此降低生產損耗是一個重要的策略。這不僅可以降低原材料成本，還可以提高生產效率，從而增強競爭力，維持業務盈利能力。
由於塑膠射出產業大多為中小企業，沒有過多的人力資源能夠執行太過於複雜的專案改善計畫。本文以標準差中常用的六標準差中的DMAIC方法，從定義問題開始，接著利用現有系統蒐集數據，利用要因分析圖與迴歸與決策樹模型的建立找到影響損耗的因子，改善階段分為兩個階段執行。第一階段為即時性改善，第二階段為預防性改善，最後在控制階段可以利用推播通知作為參數超出範圍的提醒功能，以達到即時性的生產改善。

摘要(英)

The plastic industry is a relatively mature sector that has faced increasing competition from China and Southeast Asian countries in recent years. To maintain its production advantage in Taiwan and maximize profits, it needs to enhance competitiveness in manufacturing costs. For plastic injection molding, raw material costs constitute a significant portion of production expenses. Therefore, reducing production losses is crucial. This not only lowers material costs but also enhances production efficiency, thereby strengthening competitiveness and sustaining business profitability.
Given that many plastic injection molding businesses are small or medium-sized enterprises with limited human resources for complex improvement projects, this paper adopts the DMAIC method. Starting from problem definition, it utilizes existing systems to collect data and establishes cause-and-effect analysis, regression, and decision tree models to identify factors affecting losses. The improvement process is divided into two stages: immediate improvement and preventive improvement. Finally, in the control stage, push notifications are used as reminders for exceeding limits to achieve real-time production improvement.

關鍵字(中)

★ 迴歸模型
★ 決策樹模型
★ 六標準差
★ 損耗率

關鍵字(英)

★ Regression model
★ Decision tree model
★ Six sigma
★ Production losses

論文目次

1 中文摘要 ............................................................................................................................................... i
2 Abstract ............................................................................................................................................... ii
3 目錄 ..................................................................................................................................................... iii
4 圖目錄 .................................................................................................................................................. v
一、緒論 ................................................................................................................................................ 1
1-1 研究背景與動機 .......................................................................................................................... 1
1-2 研究目的 ...................................................................................................................................... 2
1-3 研究範圍與限制 .......................................................................................................................... 2
1-4 研究流程與步驟 .......................................................................................................................... 3
二、文獻回顧 ......................................................................................................................................... 4
2-1 產品開發流程 .............................................................................................................................. 4
2-2 品管七大手法 .............................................................................................................................. 5
2-3 精實六標準差相關文獻探討 ....................................................................................................... 6
2-4 精實六標準差與工業4.0的結合 ................................................................................................ 8
2-5 原料損耗率 .................................................................................................................................. 9
三、研究方法 ....................................................................................................................................... 10
3-1 特性要因圖 ................................................................................................................................ 10
3-2 六標準差與DMAIC .................................................................................................................. 11
3-3 損耗率 ........................................................................................................................................ 12
3-4 迴歸分析 .................................................................................................................................... 13
3-5 決策樹 ........................................................................................................................................ 15
四、個案研究分析 ............................................................................................................................... 17
4-1 產業介紹與問題定義背景 ......................................................................................................... 17
4-2 Define：問題定義階段 .............................................................................................................. 18
4-3 Measure：資料收集與衡量階段 ............................................................................................... 19
4-4 Analyze －分析階段 .................................................................................................................. 19
4-5 Improve：改善階段 ................................................................................................................... 29
iv
4-6 Control：管控階段 .................................................................................................................... 30
五、結論與未來研究方向 ................................................................................................................... 31
5-1 研究結論 .................................................................................................................................... 31
5-2 未來研究方向與建議................................................................................................................. 32
參考文獻 ............................................................................................................................................... 33

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指導教授

曾富祥

審核日期

2024-5-21

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