| Summary: | 碩士 === 國立雲林科技大學 === 企業管理系碩士班 === 101 === This study is mainly on investigating the batch production in manufacturing industry when a new plant is constructed, how to implement the Toyota Production System (TPS) practice and procedures to the new plants. In this study, the conclusions are obtained by the processes of actual participation, in depth interviews, on-site observation, data collection and analysis. The findings and conclusions are as follows.
1. The procedures of implementing TPS to new plant include: (1) education of TPS (2) top manager’s goal setting (3) building Organization (4) Deciding takt time (5) Deciding manufacturing capacity standards (6) Deciding facilities layout (7) Designing production processes (8) Integrating TPS operation. It’s an important thing to decide the takt time which will affect the planning of equipment capacity, layout, and process design. The takt time should be evaluated in details to find out a suitable management model of company .
2. When the new plant can be adopted a smaller scale, slower speed and multi-machine manufacturing models and by decreasing the accuracy, strength requirements, process simplifies, transferring the cooperation with first-tier vendors to second-tier vendors and local manufacturers to reduce the cost and customize of the equipments. As the equipments are installed their own customized monitoring system with production management system and the auto-detection equipments to grasp the effect of material flow, information flow and the quality assurance in the real-time status, the targets of “Just-In-Time” and “Jidoka” can be achieved.
3. The most important successful factors in the process of implementing TPS, are executives’ supports and full empowerment that can make more smooth-going of introducing new production system and management mode, and of purchasing the smaller size equipments which are complied with TPS. In addition, the members of the company more understand the benefits of the TPS, the more they accept the operations of TPS before the new plant is built. It will reduce the problems and difficulties on implementing TPS in an organization, if the details of executions and situations are considered.
4. After the new plant''s production goals (product types, specifications range) are determined, through the way to simplify the types of raw materials and to standardize the dimensions of semi-finished , can be achieved to reduce the frequency of changing molds and, the number of lines, as well as to get the advantages of easy to manage.
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