國內金屬製造企業面臨全球訂單動態性變化的挑戰，除須提高產能效率外，更須對物料存貨及採購進行精實的管理，以達成降低庫存及縮短交期時間的目標，進而提升企業競爭優勢。金屬五金加工業的生產製程主要可分為鍛造、加工、熱處理、組裝四大階段，各階段的生產特性與規劃邏輯都不盡相同，生產管理者須克服複雜背景的困難，規劃出具可執行性的排程計畫。許多企業雖然已導入企業資源規 劃(ERP)系統來協助生產，但仍以物料需求規劃(Material Requirements Planning; MRP)模組策畫生產與採購排程時，由於MRP仍有功能上的不足，管理者經常面臨物料管理效益不佳，而影響產能的問題。本研究針對國內某金屬五金掛鉤製造公司為案例，以該公司生產線及所面臨的問題為背景，利用先進物料規劃（Advanced Material Planning, AMP）邏輯，結合Excel VBA程式與Plant Simulation軟體工具，採用模型驅動架構（Model-Driven Architecture）系統設計程序，發展出整合性物料與產能模擬系統 (Integrated Material and Capacity Simulation System; IMCSS)。該系統經過實作驗證其系統的架構、邏輯、數學及因果的關係，確認IMCSS設計內容均能符合該公司的現況與需求。同時利用系統模型，模擬導入AMP及IMCSS方案對關鍵績效指標之改善效應，模擬結果顯示AMP及IMCSS具備實際運作之能力，並可解決個案公司物料與產能效率的問題。 The domestic metal manufacturing enterprises are facing challenges of the dynamic changes of global orders. They have to increase productive capacity and precisely manage the material inventory and procurement for targeting the decrease of inventory amount and product delivery time, thus promoting the competitive advantage of business. The manufacturing process of a metal ironmongery machining industry can be mainly divided into four stages (i.e., forging, machining, heat treatment, and assembling). Since each stage has its unique productive characteristic and planning logic, it is very difficult for a planner to propose a production schedule which is fully executable in shop floor. Although many companies have implemented the Enterprise Resource Planning (ERP) system, they still use Material Requirements Planning (MRP) module to plan the production and purchasing schedules; thus managers often have problems of material and capacity according to the deficiency of MRP.This paper uses a case study of a domestic metal-ironmongery-machining company to develop an integrated material and capacity planning system (IMCSS) for resolving the production problems of the case company. The IMCSS deploys several technologies including advanced materials planning (AMP) logic, combining with Excel VBA program and Plant Simulation software tools, as well as the model driven architecture (MDA) approach to develop the simulation system. During the process of development and verification on the IMCSS this study has confirmed that the operating system architecture, logic, mathematics and causal relationship of system model are all fitted in with the case company's operational situation and practical requirement. This paper utilizes the simulation model to predict the improving effects on key performance indicators by implementing AMP and IMCSS. The simulated results reveal that the AMP and IMCSS are available in practice and can resolve the material and production issues of the case company.
