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研究生: 謝秉軒
Bing-Xuan Xie
論文名稱: 少量多樣產品於自動化測試機台進行單一機台模擬 — 最小化產品循環時間之生產規劃問題
Small Batches High Variety Products in Auto Test Handler Machine Execute Single Machine Simulation — Minimize Product Cycle Time Production Planning Issues
指導教授: 周碩彥
Shuo-Yan Chou
郭伯勳
Po-Hsun Kuo
口試委員: 周碩彥
Shuo-Yan Chou
郭伯勳
Po-Hsun Kuo
游慧光
Hui-Kuang Yu
學位類別: 碩士
Master
系所名稱: 管理學院 - 工業管理系
Department of Industrial Management
論文出版年: 2020
畢業學年度: 108
語文別: 英文
論文頁數: 71
中文關鍵詞: 模擬循環時間單一機台少量多樣
外文關鍵詞: simulation, cycle time, single machine, small batches high variety
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  • 本研究著眼於單一自動化測試機台的變數設置的問題,許多變量值變化會影響機器性能,產品循環時間和生產成本的問題。 根據這些變量的不同設置,就像每種不同種類的產品都應在不同的處理時間中進行測試一樣,不同的單一機台可能會發生不同的錯位頻率,這可能是不確定的。 然而,目的是最小化完工時間,即減少週期時間並降低生產成本。 通過使用模擬軟體Flexsim來執行單一機台模擬。 通過對不同參數,變量和設備狀態設置的分析,可以找到適合每種產品類型的更好配置,並在單台機器上找到準確的循環時間計算,從而提高生產測試效率。然而,本研究透過Flexsim進行模擬與實驗分析後,得出每種產品最合適的測試環境,包含在哪個機台進行測試,其機台的測試孔數量分別為多少。並考量到如果將測試孔擴增後,機台的測試環境會有何變化。同時也考量產品在進行測試時,可能會發生錯位,針對這個不確性因素發生的頻率與造成的影響進行描述與分析。此外,針對每個單一產品,根據機器循環時間的定義,除了產品在測試孔內進行測試所耗費的加工(處理)時間,亦可得出每個產品在機器手臂運送時所耗費的運送時間,以及在測試過程中因為錯位的發生所造成的等待時間與閒置時間。
    最後,根據得出產品運送時間與等待時間的資訊以及歷史產品測試資料,可用來推估新產品的加工(處理)時間。此外,當已知每種產品最合適的測試孔數量設置,也考慮了錯位可能造成的影響。針對每個客戶訂單中有不同種類的產品,能給予最合適的測試環境配置,以達到最佳化與最有效率的運作。


    This research focus on the problem that the variables setting of auto test handler single machine, the value variations of many variables will affect the performance of machine, the production cycle time, and the production cost. According to the different setting with these variables, like every different item types of products should be tested in different process time, and the different single machine may happen different frequency of misplacement, which may be uncertain. However, the objective is to minimize makespan, that is, to reduce cycle time and to reduce production costs. By using simulation software, Flexsim, to perform single machine simulation. The analysis of different parameters, variables and equipment condition settings is used to find the better configurations that fit each product type and find the accurate cycle time computing in single machine to improve the production efficiency. However, after conducting simulation and experimental analysis through Flexsim, this research obtained the most suitable testing environment for each product, including test in which machine, and the number of testing slots of the machine. Also consider how the testing environment of the machine will change if the testing slot is expanded. At the same time, it also considers that when the product is tested, misplacement may occur. The frequency and impact of this uncertainty factor will be described and analyzed. In addition, for each single piece product, according to the definition of machine cycle time, besides the process time spent by the product in the testing slot, the traveling time spent by each product with the robot arm transportation, and the waiting time and idle time caused by misplacement during the testing process. Finally, it can be used to estimate the process time of new products based on the information of product traveling time, waiting time, and historical product testing data. In addition, when it is known that the most suitable setting of the testing slots number for each product, the limitation of the number of machines, and the possible impact of misplacement is also considered. For each customer order, there are different types of products, and the most suitable testing environment configuration can be given to achieve optimized and most efficient operation.

    Abstract iv Acknowledgement v Chapter 1 Introduction 1 1.1 Background and motivation 1 1.2 Objective and scope 2 1.3 Organization 3 Chapter 2 Literature Review 4 2.1 Advanced Planning and Scheduling (APS) 4 2.2 Definition of time 5 2.2.1 Cycle Time 6 2.2.2 Process Time 8 2.3 Uncertain Variable & Uncertain Factors 9 Chapter 3 Methodology 14 3.1 General Study Framework 14 3.2 Develop Simulation Models 16 3.2.1 Original Simulation Models 16 3.2.2 Modified Simulation Models 17 3.2.3 Testing Process 18 3.3 Simulation Model Verification 20 3.4 Develop Experiment Design 20 3.5 Run Simulation Models & Generate Results 21 Chapter 4 Experiment 25 4.1 The setting of testing slot number 27 4.1.1 Without considering additional installation of testing slots 27 4.1.2 Within considering additional installation of testing slots 34 4.2 The occurrence of Misplacement 38 4.3 The cycle time of product 44 4.4 Estimating of the product process time 45 4.5 Optimization of machine setting with work order 51 Chapter 5 Conclusion and Future Work 56 5.1 Conclusion 56 5.2 Future Work 57 References 58

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