进入新世纪以来，新工业革命风起云涌，信息技术日新月异。代表着新工业 革命基石的制造业，其生产方式、组织形态、商业模式和生产流程正在发 生着显 著变化。尤其是电子加工制造业，在面对当前机遇与挑战的同时，优化生产流程、 提升生产效率已经成为电子加工制造业面临的紧迫问题。 捷普电子（广州）有限公司（ 以下简称：捷普公司）是捷普集团在境外投资 的全球最大的制造生产基地。本文以捷普公司变频器产品为研究对象，首先，通 过对变频器现有生产流程的研究与分析，找出其中 存在的主要问题，即：贴片机 换线时间长；贴片机和波峰焊工站在制品库存高；组装生产线人力资源浪费严重 等；其次，运用鱼骨图和因果矩阵从人、机、料、法、环等几个方 面分析了导致 上述问题产生的主要原因，即：换线体制不完善；流程设计不合理；生产线的柔 性差。然后，根据生产流程优化理论和方法，提出了变频器产品生产流程优化策 略 ，即从人员方面，提出加强对员工作业技能的培训；从机器方面，提出加强设 备保养及引入自动化；从方法方面，通过ECRS方法消除流程浪费；环境方面，改 进生产线布局；接 着通过具体的行动来解决主要问题，如重新设计备料区域、程 序调用自动化、导轨宽度调整自动化、加强设备保养来缩短换线时间；通过导入 空中导轨、重新设计双边插件、优 化测试流程减少产品的在制品库存；通过优化 组装生产线布局，从直线生产线改为“U”型生产线，使变频器产品组装生产线 达成率明显得到提升，减少人力资源浪费。最后，结 合公司生产指标对优化后的 生产流程进行了预期效果分析。 生产流程优化是企业提高自身竞争力的重要方法之一，可以有效的缩短生产 周期、减少过程浪费、提升产品品质。捷 普公司变频器生产流程的优化研究，不 仅对工业产品有着直接的指导价值，也对国内外同行企业的生产流程优化有着一 定的借鉴意义。 关键词：流程优化；精益生产；生产周期 ；产品合格率MBA 学位论文 作者：何海胜 捷普公司变频器生产流程优化研究 II RESEARCH OF OPTIMIZATION PRODUCTION PROCESS OFVFD IN JABILINCORPORATION Abstract Since the beginning of the new century, great changes have taken place in the new industrial revolution and information technology. The manufacturing industry, which represents the cornerstone of the new industrial revolution, is changing greatly in the way of production, the form of organization, the models of business and the production process. Faced with the opportunities and challenges, the electronic processing and manufacturing industry has to solve some urgent problems like optimizing the production process and improving production efficiency. Jabil Circuit (Guangzhou) Ltd , Jabil Incorporation in short form, is the biggest oversea processing and manufacturing base of Jabil Group. This paper mainly studies the Variable-Frequency Drive Products of Jabil Incorporation. Firstly, by studying and analyzing the current production process of the Variable-Frequency Drive Products, the author tries to find out some problems in the process: long time in the changeover of SMT, high storage in the station of SMTand wave soldering, serious waste of human resources in assembly line, etc. Secondly, by using cause-effect diagram and cause- effect matrix, the author analyzes the reasons for the above problems from humans, machines, materials, method and the environment. The reasons are mainly as the following: imperfect changeover line, irrational process design, and the poor flexibility in production line. Thirdly, based on the theories and methods of production optimization, the author puts forward some strategies in optimizing the production process of the Variable-Frequency Drive Products. from the aspect of personnel, to strengthen the staff skills training; From the aspect of machine, it is proposed to strengthen the maintenance of equipment and introduce automation. In terms of method, ECRS method is used to eliminate process waste. Environment, improve production line layout; Through specific actions to solve the main problems, such as redesigning the material preparation area, program call automation, guide rail width adjustment automation, strengthening equipment maintenance to shorten the line changing time; Reduce the WIP inventory of the product by introducing the air rail, redesigning the bilateral plug-in, and optimizing the test process; By optimizing the layout of theMBA 学位论文 作者：何海胜 捷普公司变频器生产流程优化研究 III assembly line and changing from the linear production line to the "U" production line, the realization rate of the inverter product assembly line is obviously improved and the waste of human resources is reduced. Finally, the expected effect of the optimized production process is analyzed with the company's production index. The optimization of the production process is one of the important methods for the enterprise to enhance its competitiveness. It can efficiently shorten the production period, reduce the waste in the procedure and improve the quality of the products. Not only do the study on the production process optimization of Variable-Frequency drive products in Jabil Incorporation guide the industrial products, it will also provide some help in the production optimization for both domestic and foreign counterparts. Key Words: Process Optimization; Lean Production Theory; Manufacturing lead time; First pass yield.MBA 学位论文 作者：何海胜 捷普公司变频器生产流程优化研究 IV 目 录 中文摘 要.................................................I Abstract ................................................ II 第一章 绪论 ..............................................1 1.1 研究背景与意义..............................................1 1.1.1 研究背 景................................................1 1.1.2 研究意义................................................2 1.2 研究思路与方 法..............................................3 1.2.1 研究思路................................................3 1.2.2 研究方 法................................................5 1.3 研究内容....................................................6 第二章 相关理论与文献综述 ................................7 2.1 关键概念界定................................................7 2.1.1 生产流 程................................................7 2.1.2 生产周期................................................7 2.1.3 产品合格 率..............................................7 2.1.4 在制库存................................................8 2.1.5 自动贴片换线时 间........................................8 2.2 相关理论介绍................................................8 2.2.1 目标管理理 论............................................8 2.2.2 理特尔理论..............................................9 2.2.3 精益生产理 论............................................9 2.2.4 戴明环理论..............................................9 2.3 工业工程的文献综 述.........................................10 2.3.1 国外研究现状...........................................10 2.3.2 国内研究现 状...........................................12MBA 学位论文 作者：何海胜 捷普公司变频器生产流程优化研究 V 第三章 捷普公司变频器生产流程现状及问题分析 .............14 3.1 捷普公司事业部及产品分析...................................14 3.1.1 能源事业部分析.........................................14 3.1.2 变频 器产品分析.........................................15 3.2 生产流程变频器现状描述.....................................16 3.2.1 前工序流程现状描 述.....................................16 3.2.2 后工序流程现状描述.....................................18 3.3 变频器生产流程中存在的问 题.................................20 3.3.1 换线时间长.............................................21 3.3.2 在制品库存 高...........................................21 3.3.3 人力资源浪费严重.......................................22 3.4 变频器生产流程中存在问题的原因分 析.........................23 3.4.1 换线体制不完善.........................................23 3.4.2 前工序流程设计不合理...................................26 3.4.3 组装生产线的柔性差.....................................28 第四章 捷普公司变频器生产流程的优化策略 .................31 4.1 优化目标、原则和思 路.......................................31 4.1.1 优化