精密塑膠射出成型製造系統整合與製程參數最佳化

INTEGRATED MANUFACTURING SYSTEM AND OPTIMIZATION OF PROCESS PARAMETERS ON PRECISION PLASTIC INJECTION MOLDING

10.6220/joq.2016.23(2).04

駱景堯(Chin-Yao Low)；林松農(Sung-Nung Lin)

精密塑膠射出成型 ； 製程參數 ； 田口方法 ； 派翠網路 ； 生產模擬 ； precision plastic injection molding ； production parameters ； Taguchi methods ； Petri net ； produce simulation

品質學報

23卷2期（2016 / 04 / 30）

143 - 157

繁體中文

精密塑膠射出成型屬於高階塑膠產品生產的一環，產品本身具備高附加價值同時有著嚴格的品質規格要求。臺灣中小企業在轉型生產高階塑膠產品上往往因為無力負擔鉅額的產線建置成本而無法成功轉型。本研究以北臺灣H公司為研究對象。透過田口方法與工作研究，消除製程變異並訂定最佳製程參數組合，以現有機臺輔以機器手臂建構生產合乎品質規格產品的產線。另外，派翠網路及生產模擬應用於製造系統整合，目的在於達到產能需求，最後得到4-2-1的產線最佳人機數量比。整合完成產線的產品品質規格、產能均合乎客戶要，而且較原產線節省10.4%的生產成本，並縮短7.2%的生產時間。本研究幫助H公司成功轉型為精密塑膠射出成型生產線，轉型投入成本預估在投產後18個月可以攤提完畢。

Precision plastic injection molding is a high-end production process of plastic products. The products are with high added value and stringent quality requirements. Taiwan SME restructuring of production on high-end plastic products are often encountered difficulties because the huge cost of equipments. In this study, the company H is located in northern Taiwan as study object. Combining Taguchi methods and work study, the optimal production parameters combination is obtained and process capability and variation are within specifications with present machines and additional robotic arms. Petri net model and produce simulation in this study are applied in order to take into account the capacity and cost. Finally, 4-2-1 is the best number combinations of machinerobotic arm-operator. The improved manufacture system can achieve the quality and productivity requirements. In addition, the new manufacture system reduces production costs 10.4% and 7.2% production time simultaneously. The costs of manufacture system transformation can be repaid by saved money in 18 months.

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