應用TPS提升扣件生產作業安全與效率—以A公司為例

Application of TPS to Improve the Safety and Efficiency of Screw Manufacturing – A Case Study of A company

盧昆宏、陳姿吟
K. H. Lu and C. Y. Chen

國立高雄科技大學 工業工程與管理系

摘要

TPS(Toyota Production System, TPS)並不是縮減開支、裁員或是壓榨員工,而是改變「製造方法」讓生產流程變的更合理更順暢,並消除七大浪費,提升作業安全與效率進而降低成本。因此,本研究將以個案研究法,應用TPS及ECRS(Eliminate, Combine, Rearrange, Simplify, ECRS)分析法,來提升個案A公司的生產效率並消除不必要的浪費,並推行6S(Seiri, Seiton, Seiso, Seiketsu, Seiketsu, Safety, 6S)運動,改善工作環境條件,打造一個安全的工作場所,俾達到降低生產人員受傷的風險。

經過本研究針對個案A公司廠區環境整理整頓和設備改善二方面的改善,在廠區環境整理整頓的2個提案改善,於作業安全、容易管理、整潔明亮、易取易用、空間釋放與減少浪費提升等皆有明顯的改善效益。另外,在設備改善提出了1個提案改善,解決了作業人員勞力負荷的問題,降低了人力數量,並降低人力成本的支出,平均每月可節省2,772分鐘。

關鍵字:豐田生產系統(TPS)、七大浪費、6S、ECRS。

ABSTRACT

TPS (Toyota Production System, TPS) is not about reducing expenses, layoffs, or exploiting employees, but about changing the "manufacturing method" to make the production process more reasonable and smoother and reducing costs by eliminating the seven wastes and improving safety and efficiency. Therefore, this study will use the case study method and apply the TPS and ECRS (Eliminate, Combine, Rearrange, Simplify, ECRS) analysis methods, aiming to eliminate unnecessary waste in the production of Case A company, promote the 6S(Seiri, Seiton, Seiso, Seiketsu, Seiketsu, Safety, 6S) movement, which improves working conditions, creates an orderly and safe workspace, and therefore, reduces the risks of the operators’ being injured.

After this study, regarding enhancements in two main aspects as 6S and equipment amelioration, firstly, the research proposes 2 improvement measures according to the former. There are significant benefits in terms of operation safety, efficient management, cleanliness, convenience, space release, and reduction of waste. Secondly, one proposal for improving equipment is put forward, solving the problem of labor load for the operators and reducing the quantity of employees and HR cost, with an average monthly savings of 2,772 minutes.

KEYWORDS: Toyota Production System (TPS); 7wastes; 6S; ECRS.