汽車零組件向來是台灣出口貿易的大宗商品，但隨著中國的經濟崛起，台灣過去5年的汽車零件出口巳經面臨成長停滯和衰退的狀況。大陸製造商透過國家政策的扶持和外資企業的投資，不斷強化其生產技術和降低成本，逐步擴大在售後市場零件的市占率。國內的製造商一直思考要如何透過有效的管理來降低生產成本提高品質，以期在國內和大陸廠商的競爭下還能保有市場和獲利。
豐田生產系統強調即時生產的概念，生產剛好數量的產品，於滿足客戶需求的同時，維持原物料或半成品的最低庫存量或零庫存以杜絕生產過程的七大浪費。精實生產是以豐田生產系統為基礎，透過定義價值、確認價值溪流、暢流、拉式生產和完善的五大原則，減少生產浪費、增加生產效率。
本研究以豐田生產系統和精實生產為基礎，透過價值溪流圖的繪製及觀查和山積表等工具的使用，定義生產線的問題然後透過精實小組的共同討論，制定改善對策。經過生產線和作業人力的重新配置以及加工作業的取消、合併、重排和簡化之後，使得生產前置時間由改善前的26.4天降至改善後的16.8天;生產週期時間由改善前的2,093秒降至改善後的1,326秒;作業人力由改善前的8人減少至改善後的5人。
關鍵詞：售後市場零件、豐田生產系統、精實生產、價值溪流圖、山積表

Auto parts and components have always been the bulk exporting commodity in Taiwan. However with the rise of China's economy, auto parts in Taiwan have faced growth stagnation and decline in the past five years. Manufacturers in mainland China have continuously strengthened their production technology and reduced costs with the support of national policies in China and the investment of foreign companies, and gradually expanded the market share of aftermarket parts. Taiwan’s manufacturers have been thinking about how to reduce costs and improve product quality through more effective management in order to maintain the market and profit under the competition between Taiwan and mainland China.
Toyota production system emphasizes the concept of just-in-time production which defines the operation of producing just the right amount of products and maintaining a minimum inventory of raw materials, semi-finished products or zero inventory to eliminate the seven major wastes of the production process while meeting customer needs. Lean production is based on the Toyota production system. It reduces production waste and increases production efficiency through the five principles of defining value, confirming value, stream, smooth flow, and pull production.
This research is based on Toyota production system and lean production. After the discussions with the team, the problem of the production line is defined, and the improvement measures are formulated via the drawing of value stream maps and the use of tools such as the mountain plot table. After the reconfiguration of production lines and manpower, and the cancellation, consolidation, rearrangement and simplification of processing operations, the production lead time shortens from 26.4 days to 16.8 days, the production cycle time reduces from 2,093 seconds to 1,326 seconds, manpower decreases from 8 to 5 after improvement.
Keywords: Aftermarket parts, Toyota production system, lean production, value stream map, mountain plot table.

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