用六標準差法改善生產效率和良率

Abstract

很多企業或產業體，實際上都離不開製造與生產之環節，經常為了銷售上，業務上之績效，絞盡腦汁。但卻忽略了工廠段之基本功: 提升人均小時產能（Unit Per Person Per Hour, UPPH）和良率（Yield），使人、機、料、法、環最佳化。提升人時產能體現在適度之用工，適量之設備購置，即根據UPPH科學地計算出所需設備，依據標配進行購置，最優化之標準作業流程 (SOP)編制，高效之廠房利用率等。Yield 即為良率，為另一個提高利潤的關鍵因數。高良率意味高的品質合格率，節約了人力和材料損失，進而在有效時間內達成最佳的人均及良品產出，使B公司在製造業中更具競爭力。綜合UPPH和Yield之達成，能實現工業生產利潤的最大化。 一般的工業企業毛利潤率較低，在3%-4%之間，本研究為改變現狀，以豐富的製造業經驗為基礎，提出用六標準法改善生產效率和良率，通過降低成本使得企業獲利提升，讓公司在盈利的過程中逐步實現工業自動化，為公司轉型奠定紮實的基礎。 本研究將針對製造業，特別是大量生產管理之兩個關鍵因數（UPPH和Yield），並以實例個案分析，通過個案細分為子項目，每個項目都通過6 Sigma 之主要手法DMAIC，詳細闡述解決過程與分析方法，最終達到預期目標，提升產出及良率，進而提升公司利潤。

Many manufacturing companies pay more attention to sales strategies rather than the basic factors: Unit per Hour per Person (UPPH) and Yield; therefore they cannot optimize men, machines, materials, methods and environment. Rational labor standard arrangement, facilities purchase and arrangement management are calculated scientifically according to UPPH requirement. Effective standard operating procedure (SOP) and high usage ratio of factory are all considered in UPPH setting. Another factor affecting the profits is Yield. High Yield rate means high qualified products rate. It can decrease the cost of labor and attrition so that optimal UPPH and qualified products output come true in limit time that the contract demands. As a result, the company is more competitive in industrial companies. Combining UPPH and Yield can maximize profit in controllable aspects. Generally, the gross profit rate in many manufacturing companies is low as 3% to 4%. The Research desires to change this status and comes up with UPPH and Yield to promote profits increase by a large margin according to rich experience. This strategy provides the company transformation to automation manufacturing system with enough capital and makes this goal achieve gradually. This research is focusing on the two vital factors, UPPH and Yield, in manufacturing industry. Through studying practical cases which are divided by subprojects by DMAIC method of 6 Sigma and explicit illustration demonstrates these two factors can increase company’s profits substantially.