採取大量客製化策略之科技產品製造商，為了面對市場激烈的競爭及因應成本因素，需修正生產系統及作一連串的生產自動化改變。大量客製化之複雜度來自產品尺寸快速改變，軟體開發功能、治具設計、及自動化硬體擴充相容性，產品測試人機介面及產品轉換前置時間等，造成自動化之實質效益與期待結果有相當程度的差異。本研究探討製造商面對大量客製生產自動化之挑戰，如何重組製造系統關鍵技術以模組化提升彈性，並提出解決方案以修正建構彈性自動化系統。本研究藉由產品與製程模組化兩項核心技術應用至自動化解決方案，期望運用現場分析規劃產品導向及生產製程模組化。以生產績效比對模組測試自動化前後之差異，呈現模組化對大量客製化生產之成效。
藉由本研究現場實驗結果，以傳統人工生產及模組化自動化生產相比之下，模組化的效益將產品轉換的前置時間降低60%，設備稼動率由90%提升至95%，在產出效率由89%提升至93%。另外，在製造成本的基礎比較下，模組化的生產成本可降低30%。最終模組化評估步驟中，期望透過本研究案例期望提供製造業管理者運用模組化彈性製造系統技術，來達到彈性生產的決策參考。
關鍵詞：大量客製化、模組化、彈性、自動化

Facing intense competition in market and on cost factors, technology product manufacturers who adopt mass customization strategies need to amend a series of production processes and to change manufacture automation. Complexity in mass customization arises from products size changes; compatibility in software development, fixtures design, augmentation of automation hardware and human-machine interface in product testing; as well as lead time for switching production, and so on. These factors cause the actual results of automation significantly different from those expected. This research discusses facing the challenges in automation for mass customization, how the manufacturers may combine key techniques of reconfigured manufacture system to promote flexibility by modularization, and generate the solutions to reform and build flexible automation system. This research explores the use of product and process modularization for flexible automation in a case analysis of production site scenario with planned product and process modularization. Production performance measures for the test automation are compared before and after product and process modularization.
The results show that modularization can decrease 60% of lead time in product shift. Equipment utilization will raise from 90% to 95%. In addition, output rate will improve from 89% to 93%. Further, manufacture cost will be reduce 30%. Therefore, this research provides a systematic modularization solution as strategic decision support system to manufacturers in production reconfiguration and automation.
Keywords : mass customization, modularization, flexibility, automation

目錄
摘要 I
致謝辭 III
目錄 IV
圖目錄 VII
表目錄 VIII
第一章 緒論 1
1.1研究背景 1
1.2研究動機 1
1.3研究議題與目的 2
1.4研究範圍 4
第二章 文獻探討 5
2.1 大量客製化 5
2.1.1大量客製化定義 5
2.1.2大量客制化生產環境和特徵 7
2.1.3大量客製化的挑戰與目標 10
2.2生產自動化 11
2.2.1生產測試自動化 13
2.2.2生產自動化績效 14
2.3彈性生產自動化 16
2.3.1彈性製造 18
2.3.2彈性與模組化 22
2.3.3模組化概念及優缺點 27
2.3.4模組化應用 33
2.3.5模組化之成效 35
2.4文獻小結 38
第三章 研究方法 41
3.1研究策略與方法 41
3.2研究架構 43
第四章 個案公司生產測試自動化分析 45
4.1 個案公司簡介 45
4.1.1 發展背景 45
4.1.2 產品技術演進 46
4.2 個案公司五大生產自動化簡介 48
4.2.1 前端主機板測試自動化 48
4.2.2 前端主機板shielding cover組立自動化 50
4.2.3 成品雷射雕刻自動化 51
4.2.4 成品測試自動化 52
4.2.5 成品包膜自動化 54
4.3個案公司之生產自動化現況 55
4.4個案公司模組化規劃 56
4.5現場情境分析與彈性自動化規劃 57
4.5.1 問題分析與規劃 59
4.5.2 模組化解決方案建立 60
4.5.3 產品導向模組化(第一階段)效益評估 61
4.6模組化展開之成效驗證 63
4.7生產製程模組化(第二階段)原則展開 65
4.8模組化架構敏感度分析 71
4.9綜合討論 74
4.9.1 自動化成效 75
4.9.2 個案比較討論 76
4.9.3 模組化及彈性之評估步驟 79
第五章 結果與後續研究 81
5.1結論 81
5.2後續研究 82
參考文獻 83
附錄 90

圖目錄
圖3-1 研究步驟 42
圖3-2 研究架構 44
圖4-1 個案公司傳統人工測試圖示 48
圖4-2 個案公司測試自動化圖示 49
圖4-3 個案公司人工組立鐵蓋至主板圖示 50
圖4-4 個案公司SMT置件機組立鐵蓋至主板圖示 50
圖4-5 個案公司之供應商人工雷雕製程操機圖示 51
圖4-6 個案公司半自動雷雕製程操機圖示 52
圖4-7 個案公司成品人工測試操機圖示 52
圖4-8 個案公司成品測試自動化圖示 53
圖4-9 個案公司導入成品人工包膜操作圖 54
圖4-10 個案公司導入成品自動化包膜操作圖 54
圖4-11產品尺寸轉換次數為自變數之動態圖形 73
圖4-12產品功能規格改變次數為自變數之動態圖形 74
圖4-13 模組化評估建議流程 79

表目錄
表2-1 製造優勢之構面與意義 15
表2-2 彈性製造、大量製造及重新組配製造之比較表 21
表2-3 模組化成效之推演 39
表2-4 彈性成效之推演 39
表3-1 不同的研究策略之相關狀況 41
表4-1 個案公司產品技術演進年代表 47
表4-2 個案公司前端測試自動化導入前後人力配置表 49
表4-3 個案公司導入成品測試自動化前後人力配置表 53
表4-4 個案公司生產線自動化設備、治工具及換線時間 55
表4-5 產品設計及零件模組化架構表 56
表4-6 測試模組化架構原則 57
表4-7 個案公司傳統人工測試與生產自動化比較表 58
表4-8 大量客製測試生產自動化導入前後比較表 59
表4-9 傳統人工與自動化、產品導向模組化(第一階段)之效率評比表 61
表4-10 個案公司模組化效益分析 63
表4-11 ROC權重與屬性數量對照表 64
表4-12 自動化系統模組化設計展開 66
表4-13 自動化硬體模組化設計展開 66
表4-14 自動化軟體開發設計展開 67
表4-15 生產製程模組化(第二階段)展開生產數據表 69
表4-16 傳統生產與生產自動化之評比表 70
表4-17 生產製程模組化(第二階段)展開驗證結果評比表 71
表4-18 產品尺寸轉換次數為自變數之計算表 72
表4-19 產品功能規格改變次數為自變數之計算表 73
表4-20 個案公司生產自動化之比較表 77
表4-21 自動化生產績效：個案與文獻比較表 78

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