The use of lean principles and simulation optimization in solving the Shojinka problem from the welding area of a high-end bicycle manufacturing system

• Main Authors: Wan-TingHou, 侯婉婷
• Other Authors: Ta-Ho Yang
• Format: Others
• Language: zh-TW
• Published: 2016
• Online Access: http://ndltd.ncl.edu.tw/handle/47626565171476591367

碩士 === 國立成功大學 === 製造資訊與系統研究所 === 104 === In this case, high-end bicycle manufacture presented here to be example, first, we use Value Stream Mapping（VSM）to find out the potential improvement opportunities in the system. The case company has long lead time, every products from the beginning of purchasing to finished product up to six months. From VSM that we can find out material took most of time in waiting, therefore center about the reason of these problems, we proposed appropriate lean principle after discuss with experts and line leader to design the scenario, there are three scenario in this study. And how to measure the performance of every scenario? We used discrete-event simulation to generate the value of performance index, and also used optimization tool to find out better operator allocation and number of each scenario in order to reach advantage of Shojinka. Because this case study was actually the author to participate the progress of improvement, the improvement rates were: work-in-process （WIP） and cycle time by 16%; field of space by 16% ; bottleneck station personnel do not need to work overtime, by approximately 1.5 hours earlier than in the past to work when throughput didn’t impacted, we also taken into account the improvement situation to one of our scenarios. Then we used discrete-event simulation to measure the performance of each scenario. After experiment, it proved that lean principles could improve the system performances, such as WIP、cycle time、service level when throughput didn’t impacted. Based on these reasons, it represents the true efficiency in the system. And at the end of the experiment, we use sensitivity analysis to see that when demand change if system need to meet the service level, the operator number of system and the throughput of system will how to change. From sensitivity analysis can conclude that the number of operator in system increase when demand increase, on the contrary, it decrease when demand decrease. From this point of view, the system have reached the advantage of Shojinka.