應用FlexSim模擬軟體提升生產效率-以高雄某傢俱工廠為例

Abstract

傳統木製傢俱產業需要大量人力進行製造與搬運還需有足夠的空間來儲存原料和成品，因此，有效利用工廠有限的空間並規劃完善的動線，才能得到最佳的生產流程。有鑑於此，本研究期望透過FlexSim模擬軟體對Y工廠進行建模，找出其瓶頸點並進行改善，以提升整體工廠生產效率。首先，本研究至Y工廠蒐集相關資料，例如，機台參數、機台數量、員工數量、場內動線以及生產方式，並將數據分別輸入至FlexSim模擬軟體中的Expertfit進行分析，得出各別機台最合適之製造時長與分配方式。其次，本研究透過Dashboard對工件於暫存區及貨架之停留時間、各機台稼動率以及A、B工件之CycleTime進行分析，結果顯示工件於Queue8、Rack1、Rack2之停留時間過長，間接拉長A、B工件之CycleTime，故本研究將Queue8、Rack1以及Rack2訂定為瓶頸點。再者，本研究提出兩項改善方案，第一，本研究認為Queue8停留時間過長是鑽孔機-1以及鑽孔機-2之加工時間過長所導致，故本研究針對鑽孔機之機臺參數透過實驗進行劇本模擬得出各別機台之最佳參數；第二，本研究推測Rack1以及Rack2貨物堆疊原因是搬運人員一次性只搬運一項貨物，故本研究基於衡量員工在長時間搬運的最大搬運負荷量下，透過實驗進行劇本模擬，得出一次性搬運兩項貨物為最佳參數。最後，根據上述改善方案結果顯示，第一，修改鑽孔機機臺參數後，將Queue8之停留時間縮短了0.99小時，第二，增加一次性的搬運數量皆有效減少Rack1及Rack2的停留時間約1.08小時，改善後的A、B工件之CycleTime也縮短了約1.43小時與2.53小時，每小時的產出量也提升約98個半成品。證實本研究所提出之改善方案確實能夠降低停留時間、CycleTime以及提高單位時間內產出量，為該工廠帶來更好地效益。

The traditional wooden furniture industry relies heavily on manual labor for manufacturing and handling, as well as on the availability of adequate storage space for raw materials and finished products. Therefore, effective utilization of the limited factory space and the development of efficient workflows are crucial for achieving the best production processes. To address these challenges, this study aims to model Factory Y using FlexSim simulation software, identify bottlenecks, and implement improvements to enhance overall factory production efficiency. Initially, relevant data was gathered from Factory Y, including machine parameters, the number of machines, workforce size, facility layouts, and production methods. This data was then input into the Expertfit module of the FlexSim simulation software for analysis, resulting in the determination of optimal manufacturing durations and allocation methods for individual machines. Subsequently, an analysis was conducted through the Dashboard module, focusing on workpiece dwell times in temporary storage areas, machine utilization rates, and the CycleTime of A and B workpieces. The results indicated that workpieces spent excessive time in Queue8, Rack1, and Rack2, indirectly causing longer CycleTimes for A and B workpieces. As a result, Queue8, Rack1, and Rack2 were identified as bottlenecks. This study proposed two improvement strategies. Firstly, it was found that the extended dwell time in Queue8 was due to prolonged processing times for Drilling Machine-1 and Drilling Machine-2. Therefore, this study conducted scenario simulations and experiments to determine the optimal parameters for each drilling machine. Secondly, it was hypothesized that the stacking of goods in Rack1 and Rack2 was a result of operators handling only one item at a time. Consequently, this study conducted scenario simulations to establish that handling two items at once was the optimal parameter, taking into consideration the maximum handling capacity of operators during extended handling periods. In conclusion, the results of the proposed improvement strategies demonstrated a reduction in dwell times, CycleTimes, and an increase in production output per unit time. These improvements confirm that the strategies proposed in this study effectively enhance efficiency for Factory Y.