There has been full of inefficiency and waste in current operation method of steel structure industries. This study hopes to utilize Toyota Just-in-time Production System for fabrication of steel structure to eliminate current each waste during the production process. The main purpose of this study is take case company as an example to discuss the following respects: 1.The current production process of steel structure industries. 2.The application of Toyota Just-in-time Production System in the steel structure fabrication. This study first introduces the framework of Toyota Just-in-time Production System to apprehend its spirit and then explains the concept and advantage of Toyota Just-in-time Production System explicitly. Also, this study compares Toyota Just-in-time Production System with current production method of steel structure industries. Second, according to the glancing of related document reference, this study discusses the application method and its profit for Toyota Just-in-time Production System in the manufacturing industries. As there are significant differences in structure or operation method between steel structure industries and manufacturing industries, thus this study utilizes gradual erection plan to match Toyota Just-in-time Production System during the period of fabrication process plan to eliminate the distinction between these two industries besides explaining the necessary rationalized operation when leading Toyota Just-in-time Production System in. Having visited the production line and made mutual communication with operation chief, this study has found the current problems existing in production management in case company. According to this discovery, this study uses bridge production line and built-up H section production line as pilot implementation to discuss the possible question and solution policy for Toyota Just-in-time Production System concept applied in steel structure fabrication so as to frame the procedures and criterion of Toyota Just-in-time Production System in fabrication of steel structure and also to evaluate its profit.

鋼結構業的現行作業方式充滿了無效率的工作與浪費。本研究希望藉由豐田及時生產系統導入鋼結構製造，以消除生產過程中現存的各項浪費。本研究的目的主要是以個案公司為例，探討鋼結構業現行生產過程及豐田及時生產系統應用於鋼結構製造。 本研究首先介紹豐田及時生產系統架構，以了解豐田式的精神所在，再詳細介紹及時生產系統的概念及優點，並比較豐田即時生產系統和鋼結構現行生產方式。 其次藉由相關文獻的回顧，探討豐田及時生產系統於製造業應用方式與其效益。由於鋼結構業與一般製造業無論在形態上或是作業方式上，都有顯著的差異存在，因此於製造規劃階段，除說明導入豐田及時生產系統所需具備的合理化作業外，擬配合漸進式吊裝規劃技術以消除兩者間之差異。 經由親自到生產現場去查訪並與作業主管做雙向溝通，瞭解個案公司在現行生產管理上存在的問題。利用橋樑及H組合型鋼兩條試驗生產線進行檢討，評估豐田及時生產系統觀念應用於鋼結構製造過程之中可能產生的問題與解決對策，以擬定豐田及時生產系統導入鋼結構之方式與注意事項，並評估其效益。 / There has been full of inefficiency and waste in current operation method of steel structure industries. This study hopes to utilize Toyota Just-in-time Production System for fabrication of steel structure to eliminate current each waste during the production process. The main purpose of this study is take case company as an example to discuss the following respects: 1.The current production process of steel structure industries. 2.The application of Toyota Just-in-time Production System in the steel structure fabrication. This study first introduces the framework of Toyota Just-in-time Production System to apprehend its spirit and then explains the concept and advantage of Toyota Just-in-time Production System explicitly. Also, this study compares Toyota Just-in-time Production System with current production method of steel structure industries. Second, according to the glancing of related document reference, this study discusses the application method and its profit for Toyota Just-in-time Production System in the manufacturing industries. As there are significant differences in structure or operation method between steel structure industries and manufacturing industries, thus this study utilizes gradual erection plan to match Toyota Just-in-time Production System during the period of fabrication process plan to eliminate the distinction between these two industries besides explaining the necessary rationalized operation when leading Toyota Just-in-time Production System in. Having visited the production line and made mutual communication with operation chief, this study has found the current problems existing in production management in case company. According to this discovery, this study uses bridge production line and built-up H section production line as pilot implementation to discuss the possible question and solution policy for Toyota Just-in-time Production System concept applied in steel structure fabrication so as to frame the procedures and criterion of Toyota Just-in-time Production System in fabrication of steel structure and also to evaluate its profit. / 目 錄 誌謝詞……………………………………………………………………一 中文摘要…………………………………………………………………二 ABSTRACT………………………………………………………………三 目錄………………………………………………………………………四 圖次………………………………………………………………………六 表次………………………………………………………………………八 第一章 緒論…………………………………………………………………1 第一節 研究動機與目的 …………………………………………1 第二節 研究步驟與範圍…………………………………………4 第三節 研究架構 …………………………………………………6 第二章 豐田及時生產系統之文獻探討………………………………….7 第一節 及時化（Just In Time）的基本觀念………………………7 第二節 豐田及時生產系統的主要目的……………………….12 第三節 豐田及時生產系統的執行方法……………………….14 第四節 豐田及時生產系統的構成因素……………………….31 第五節 實施豐田及時生產系統的優點及原則………………32 第三章 鋼結構業引進豐田及時生產系統之可行性分析……………36 第一節 鋼結構業生產方式概要………………………………36 第二節 鋼結構業生產方式與豐田及時生產系統比較………44 第四章 中國鋼鐵結構公司導入豐田及時生產系統個案……………58 第一節 生產製造現況與問題分析……………………………58 第二節 豐田及時生產系統導入及效益評估 ………………73 第三節 導入限制條件之評估 ……………………………109 第五章 結論與建議……………………………………………………110 第一節 結論……………………………………………………110 第二節 建議 …………………………………………………112 參考文獻…………………………………………………………….113 附錄-個案公司訪談說明……………………….……………………118 作者簡歷……………………………………………………………………123 表 次 表1-1 台灣市場鋼結構用量統計表……………………………………2 表2-1 自�C化與自動化的比較…………………………………………27 表4-1 鋼橋漸進式吊裝規劃表範例……………………………………80 表4-2 鋼橋單一循環每日作業規劃表範例…………………………80 表4-3 中國鋼鐵結構公司91年鋼架類別統計表…………………….82 表4-4 中國鋼鐵結構公司91年工程類別產量表……………………83 表4-5 鋼橋月生產計劃表範例…………………………………………91 表4-6 鋼橋日生產計劃表範例…………………………………………92 表4-7 鋼橋批量生產表範例…………………………………………..94 表4-8鋼橋鑽孔績效比較表…………………………………………..…97 表4-9鋼橋本體板組合績效比較表…………………………………….97 表4-10鋼橋本體板電銲績效比較表……………………………………97 表4-11鋼橋學習效益………………..………………………………….100 表4-12鋼橋作業面積使用比較表…………………………………….102 表4-13鋼橋庫存量績效比較表….……………………………………102 表4-14 H組合型鋼腹板加工分類表…………………………………106 表4-15切割火口與鋼材板厚對照表..………………………………… 106 表4-16電銲條件表………………………………………………………107 表4-17 切割作業面積及在製品庫存量比較表……………………108 表4-18 H組合型鋼品質標準比較表…………………………………108 圖次 圖1-1 研究架構圖…………………………………………………………6 圖2-1拉式生產系統流程圖……………………………………………11 圖2-2豐田及時生產系統架構圖………………………………………13 圖2-3及時化架構圖……………………………………………………16 圖2-4工作標準化要素圖………………………………………………19 圖2-5看板方式流程圖…………………………………………………24 圖2-6自�C化架構圖……………………………………………………28 圖3-1鋼架製造流程圖…………………………………………………39 圖3-2鋼橋製造流程圖…………………………………………………40 圖3-3鋼架吊裝流程圖…………………………………………………41 圖3-4鋼橋吊裝流程圖…………………………………………………42 圖4-1小板件加工流程圖………………………………………………59 圖4-2 H型鋼組立程序圖…………………………………………………60 圖4-3方型鋼組立程序圖………………………………………………61 圖4-4生產計劃流程圖…………………………………………………66 圖4-5鋼柱加工流程圖…………………………………………………67 圖4-6鋼樑加工流程圖…………………………………………………68 圖4-7橋樑加工流程圖…………………………………………………69 圖4-8鋼橋構段分區圖範例……………………………………………81 圖4-9中國鋼鐵結構公司91年鋼架類別統計圖……………………82 圖4-10中國鋼鐵結構公司91年工程類別圖…………………………83 圖4-11鋼橋單一作業循環甘特圖範例……………………………….84 圖4-12橋樑構段圖………………………………………………………85 圖4-13 橋樑生產流程圖………………………………………………86 圖4-14 改善後橋樑生產流程圖.………………………………………89 圖4-15 鋼橋主生產時程圖範例.………………………………………90 圖4-16 鋼橋工作圖範例………………………………………………93 圖4-17 H組合型鋼圖……………………………………………………103 圖4-18H組合型鋼生產流程圖…………………………………………105