高新科技材料加工產業生產精進之方法： 永虹科技公司個案研究

Abstract

台灣高科技產業是台灣的經濟引擎，在科技創新研發方面近來也有長足的進步。但在高新科技材料產業這個重要的關鍵領域，可以說從來都不是台灣的強項！但近年來這個情勢已逐漸扭轉，以往高端科技材料及研發技術掌控於美、日及部份歐洲材料大國的情形雖仍然存在，但台灣在部份材料領域已慢慢突破，取得世界領先地位。但無可諱言，台灣在高新科技材料生產規模方面，與國際大廠相較，通常規模比較小，且對於生產管理的方法與管理制度的導入方面，仍屬落後。 所以，台灣企業如何在國際競爭激烈的環境下，殺出重圍，取得一席之地，除技術的突破與專利的取得外，高科技材料生產製程的良率提升、產量提升與生產成本的降低等生產管理手法，亦是重要關鍵。 本研究就是針對『高新科技材料產業』（以永虹公司碳纖維生產為例），探討生產管理精進方法，希望能產出一套方法，能夠迅速1. 增加良率 2. 提高產量 3. 降低成本，而且要能夠快速達成。由於『高新科技材料產業』設備依存度高，從業人員素質也較高，在面對高強度的研發競爭下，在生產管理工具的選擇與導入，就成關鍵。考量的重點包含：『管理成本』負擔不能太大，要導入容易，且必須迅速產生綜效。所以一個『整合性的管理工具』就是本研究的中心。 本研究針對研究對象『永虹科技股份有限公司』的實際運作，先經過分析討論後，選擇整合1.平衡計分卡(BSC) 2.品管圈(QCC) 3.人力資本管理(HCM)，經過導入之後， 從2012年12月到2013年5月，已經將良率提升27.92%( 從 58.8%提升到86.67%)，單位時間產能提升174% (從7.3公斤/小時 提高到 20.02公斤/小時)，成本更是下降了68.51% (從 3,326元/公斤的成本降低到 1,037元/公斤 )。成果證明本研究案方向正確，確實有效。

As the engine for economic growth in Taiwan, Taiwan’s high-tech industries have made considerable progress in technology, research and innovation. However, as we known, high-tech industry, as a critical area, is never the strength of Taiwan! But in recent years, Taiwan has turned its numbers around. Although high-end technology materials and their R&D technologies usually controlled by the US, Japan as well as a certain sum of European powers, Taiwan has made some breakthrough progresses in parts of such materials, and gotten front rank positions in such areas. And there is no hiding that, compared with various international companies, high-tech materials production in Taiwan is relatively small, and its production management methods and systems introduction are in the behind. With the globalization of economy, it becomes more severe in this market. Therefore, how to improve its international competitiveness is an urgent issue to be done. Except for technology breakthroughs and obtainment of patents, yield enhancement, production increase, cost reduction and such management methods in high tech production process are also deemed as the key points. This Study focuses on “High-tech materials industry” (taking UHT Unitech’s carbon fiber production as the example), explores through advanced management approaches and hopes to propose a set of method to quickly 1. increase yield; 2. Improve quality; 3. Reduce cost. Along with the high equipment dependence and personnel quality related to “High-tech materials industry” under high level of R&D competition, selection and introduction of production control tools became an important factor. Key points need consider include: we can not afford too much on “management cost”, with easy introduction to quickly achieve comprehensive result. For this reason, this Study’s core is an “Integrated management tool”. This Study directs at UHT Unitech Co., Ltd.’s actual operations, and after analysis and discussion, integrates 1. Balanced score card (BSC); 2. Quality control circle (QCC); 3. Human capital management (HCM). After the introduction, from December, 2012 to May, 2013, it has improved yield by 27.92% (from 58.8% to 86.67%), productivity per hour by 174% (from 7.3kg/h to 20.02kg/h), and reduced cost by 68.51% (from NTD3,326/kg to NTD1,037/kg). Results prove that this Study is valid and feasible.