GK129-1000T快速换型课件.ppt

ManzoniSMEDStampingWorkshop,Apr,12th16th2010,现场改善GK129,1000T快速换型,2,PresentationsTitle,GK129team改善团队奔驰,Teammembers团队成员冲压主任龚小范维修主任张建强模修领班王佑春传播者王伟操作工张传有模修王树林维修计划刘景鹏电子工程师刘伟东860项目组胡智平860项目组高洋巴西专家Silviu巴西专家EvandroSpeckhahn巴西模修Renato精益张春杰,3,PresentationsTitle,ThesourceoftheGK项目来源,1.VSM价值流程图,2.860项目组CapacityExpansionproject8.6M/y,4,PresentationsTitle,ObjectiveandGoal目的与目标降低1000T换型时间=从35分钟至20分钟Decreasethesetupmodeltime(1000T)=From35minsto20mins人因工程改善=1项ErgonomicImprovement=1Item安全改善=1项SafetyImprovement=1Item可视化管理=1项VisualManagement=1Item5S改善=1项5SImprovement=1Item,ObjectivesandGoal目的与目标,5,PresentationsTitle,BenefitsofSMED快速换型的好处,Reducesunproductivetime减少非生产时间,Allowstoimprovetheclientservice(leadtime,quantity)有利改善客户服务(交货周期、数量等),Enlargesrealcapacityofmachines扩大机器实际产能,Reducetheinvestmentandproductioncost减少投资，降低成本,SMED快速换型,Allowstoreducethestocks有利降低库存,Shorterseriesbecomescheaper(reducebatchsize)产品系列更换时间更短、成本更低(缩小批量),6,PresentationsTitle,Step1步骤一,Step2步骤二,Step3步骤三,Step4步骤四,Step6,Changeovermethodnotrationalised没有理顺换模方法,Studyoftheactualsituation研究实际情况,SeparateinternalworkFromexternalwork将内部工作与外部工作分开,Convertinternalworkinexternalwork将内部工作转化为外部工作,Step5步骤五,Reduceofinternalwork减少内部工作,Absenceofmethod没有方法,Preparationtimewithbigvariations准备时间变化太大,Thereisnodistinctionbetweenexternalworkandinternalwork内部和外部工作没有什么区别,Improvementoflogisticsupport改善物流运输,Improvementserviceability改善可用性,Pre-assembly预先装配,Pre-adjustments预先调整,Pre-heating预热,Previousworkbeforethemachinestop停机前的准备工作,Worktobedonewiththemachinestopped停机时要做的工作,Worktobedoneafterstopping停机后要做的工作,Registerandclassifiedallthenecessaryworkingelements将所有必要的工作进行登记和分类,Video视频,Chronograph计时器,The5StepsofSMED快速换型的五个步骤,SMED快速换型,Eliminateadjustmentsandsettings消除调整和设定,Simplifyfixationandtightening简化固定和上紧程序,Parallelwork平行作业,InternalWork:Operationswhichhavetohappenwhenthemachineisnotrunning外部工作：机器没有运作时要进行的工作,Externalwork:Theoperationswhichcantakeplacewhenthemachineisrunning内部工作：机器运作时要进行的工作,Reduceofexternalwork减少外部工作,7,PresentationsTitle,Step1:Studyoftheactualsituation步骤一：研究实际情况,Makethelistofsetupstepthroughfilm观看录像列出换型步骤(共59步）,8,PresentationsTitle,Step2SeparateinternalworkFromexternalwork步骤二：区分内部工作和外部工作,对59步换型步骤进行内部外部工作的区分,9,PresentationsTitle,AfterKaizen改善后,BeforeKaizen改善前,Step3Convertinternalworktoexternalwork将内部工作转换成外部工作,工具准备PrepareandOrganizetools,Photo,将换型工具按照模型摆放在车上，便于取放。同时增加1个套筒和1个六角扳手Putthetoolsinthecaraccordingtheformerinordertotakeeasilyandatthesametimeadd1steeltubeand1wrench,工具在车上摆放无序,只有1个套筒和1个六角扳手Thetoolswereputwithoutorderinthecarandtherewas1steeltubeand1wrench,10,PresentationsTitle,对换型步骤进行排序Definethebettersequence:,统计每个人的工作时间并确定可以同时做的工作Sichronizeactivities:,Step4Reduceofinternalwork减少内部工作,11,PresentationsTitle,AfterKaizen改善后,BeforeKaizen改善前,在校平机上安装支架，用于存放手柄同时将手柄加长Makeasupportbesidethemachinetolaythehandleandlengthenthehandle,手柄放在控制台旁边小盒内Thehandlewasintheboxofconsole,(1)制作存放手柄支架Makeasupport,Step4Reduceofinternalwork减少内部工作,12,PresentationsTitle,Step4Reduceofinternalwork减少内部工作,AfterKaizen改善后,BeforeKaizen改善前,(2)拆除校平机护板Removetheprotectivenet,需将校平机护板拆下，用手柄调整参数Needtoremovetheprotectivenet,adjusttheparameterwithhandle,将护板更换为有机玻璃并开四个小窗口，直接用手柄调整参数Changetheprotectivenetintoorganicglassandopen4smallwindows,Adjusttheparameterwithhandledirectly,13,PresentationsTitle,Step4Reduceofinternalwork减少内部工作,AfterKaizen改善后,BeforeKaizen改善前,(3)可视化调整参数Maketheparametervisual,操作工在调整参4个调整轮参数时需来回到控制台查看POPTheoperatormovedtotheconsoletocheckthePOPwhenheadjustedtheparameter,将4个调整轮的调整参数按照顺序贴在校平机上，调整时操作工无需来回走动Putontheparametercardintotheglass,14,PresentationsTitle,Step4Reduceofinternalwork减少内部工作,AfterKaizen改善后,BeforeKaizen改善前,(4)制作尼龙挡块Makenylonblock,新料料头出校平机后向上弯，与旧料对接不好，操作工必须用撬棍对接Thenewcoilwasbentattheexitofmachine,andbadconnecttheendofoldcoil.Theoperatormustusingcrowbartopress,在校平机出口安装尼龙挡块Makenylonblockattheexitofmachine,2019/12/14,15,可编辑,16,Step4Reduceofinternalwork减少内部工作,AfterKaizen改善后,BeforeKaizen改善前,(5)制作存放字头支架Makeasupporttolaystampingpunch,字头放在换型车上Thestamppunchandthetoolwereonthesetupmodelcar,制作字头存放支架，放在冲床旁，换型时方便取放，减少走动Makeasupporttolaythestamppunchandthetoolbesidethemachine,inordertotake,17,Step4Reduceofinternalwork减少内部工作,AfterKaizen改善后,BeforeKaizen改善前,(6)制作检具支架Makeasupporttolaygauge,检具摆放不便于拿取Thegaugewasputnoteasytotake,重新制作检具支架Makeanewsupporttolaythegauge,18,结果Result,History,Result,Goal,以前,目标,结果,分钟,19,PresentationsTitle,换型时间跟踪Setuptimecontrol,20,PresentationsTitle,标准化Standardization,对换型过程进行标准化，编到POP中。明确2名操作工和2名模修的分工MakeastandardaboutthesetupmodelandaddthisitemintoPOPanddefineeachoperatorandeachtoolmakerswork,21,PresentationsTitle,Training培训,Trainingrecord培训记录,培训三个班的操作工和模修Trainingtheoperatorsandtoolmakersof3shift,22,PresentationsTitle,SafetyImprovement安全改善,AfterKaizen改善后,BeforeKaizen改善前,安全隐患Accidentrisk防护门打开时冲床可以冲活Thepressisworkingwiththeopenedgate,只有在防护门关上的情况下才可以冲活,在防护门上开推拉窗便于操作工钩三角废料Thepressisworkingwiththeclosedgateonly，openawindowonthegateeasytotakeoutthescrap,23,Action行动计划,共制定17项行动计划，已全部完成Made17actionplanandfinishedall,24,GembaKaizenResults改善结果,25,GembaKaizenResults改善结果,26,PresentationsTitle,Monito