精益生产快速换模改善案例（经典作品

1、Confidential ManzoniSMED Stamping Workshop Apr, 12th16th 2010 现场改善现场改善 GK 129 1000T 快速换型快速换型 Confidential 2 Presentations Title GK129 team 改善团队改善团队 奔驰奔驰 Team members 团队成员团队成员 冲压主任冲压主任 龚小范龚小范 维修主任维修主任张建强张建强 模修领班模修领班王佑春王佑春 传播者传播者 王伟王伟 操作工操作工 张传有张传有 模修模修王树林王树林 维修计划维修计划刘景鹏刘景鹏 电子工程师电子工程师 刘伟东刘伟东 860项目组项目组

2、胡智平胡智平 860项目组项目组高洋高洋 巴西专家巴西专家Silviu 巴西专家巴西专家Evandro Speckhahn 巴西模修巴西模修Renato 精益精益 张春杰张春杰 Confidential 3 Presentations Title The source of the GK 项目来源项目来源 Kaizen 改善 SMED 1. VSM 价值流程图价值流程图 2. 860项目组项目组 Capacity Expansion project 8.6 M/y Confidential 4 Presentations Title Objective and Goal 目的与目标目的与目标

3、降低降低1000T换型时间换型时间 =从从35分钟至分钟至20分钟分钟 Decrease the setup model time (1000T) = From 35mins to 20 mins 人因工程改善人因工程改善 =1项项 Ergonomic Improvement =1 Item 安全改善安全改善 =1项项 Safety Improvement =1 Item 可视化管理可视化管理 =1项项 Visual Management=1 Item 5S改善改善 =1项项 5S Improvement =1Item Objectives and Goal 目的目的 与目标与目标 Confi

4、dential 5 Presentations Title Benefits of SMED 快速换型的好处快速换型的好处 Reduces unproductive time 减少非生产时间减少非生产时间 Allows to improve the client service (lead time, quantity) 有利改善客户服务有利改善客户服务(交交 货周期、数量等货周期、数量等) Enlarges real capacity of machines 扩大机器实际产能扩大机器实际产能 Reduce the investment and production cost 减少投资，降低成

5、本减少投资，降低成本 SMED 快速换型快速换型 Allows to reduce the stocks 有利降低库存有利降低库存 Shorter series becomes cheaper (reduce batch size) 产品系列更换时间更短产品系列更换时间更短 、成本更低、成本更低 (缩小批量缩小批量) Confidential 6 Presentations Title Step 1 步骤一步骤一 Step 2 步骤二步骤二 Step 3 步骤三步骤三 Step 4 步骤四步骤四 Step 6 Changeover method not rationalised 没有理顺换模方

6、法没有理顺换模方法 Study of the actual situation 研究实际情况研究实际情况 Separate internal work From external work 将内部工作与外部工作分开将内部工作与外部工作分开 Convert internal work in external work 将内部工作转化为外部工作将内部工作转化为外部工作 Step 5 步骤五步骤五 Reduce of internal work 减少内部工作减少内部工作 Absence of method 没有方法 没有方法 Preparation time with big variations

7、准备时间变化太大 准备时间变化太大 There is no distinction between external work and internal work 内部和外部工作没有什么区别 内部和外部工作没有什么区别 Improvement of logistic support 改善物流运输改善物流运输 Improvement serviceability 改善可用性改善可用性 Pre-assembly 预先装配 预先装配 Pre-adjustments 预先调整 预先调整 Pre-heating 预热 预热 Previous work before the machine stop 停机

8、前的准备工作 停机前的准备工作 Work to be done with the machine stopped 停机时要做的工作 停机时要做的工作 Work to be done after stopping 停机后要做的工作 停机后要做的工作 Register and classified all the necessary working elements 将所有必要的工作进行登记和分类将所有必要的工作进行登记和分类 Video 视频 视频 Chronograph 计时器 计时器 The 5 Steps of SMED 快速换型的五个步骤快速换型的五个步骤 Starting point

9、始点始点 SMED 快速换型快速换型 Eliminate adjustments and settings 消除调整和设定消除调整和设定 Simplify fixation and tightening 简化固定和上紧程序简化固定和上紧程序 Parallel work 平行作业平行作业 Internal Work: Operations which have to happen when the machine is not running 外外部工作：机器没有运作时要进行的工作部工作：机器没有运作时要进行的工作 External work: The operations which can

10、take place when the machine is running 内部工作：内部工作：机器运作时要进行的工作机器运作时要进行的工作 Reduce of external work 减少外部工作减少外部工作 Confidential 7 Presentations Title Step1: Study of the actual situation 步骤一：研究实际情况步骤一：研究实际情况 Make the list of setup step through film 观看录像列出换型步骤观看录像列出换型步骤(共共59步）步） Confidential 8 Presentation

11、s Title Step 2 Separate internal work From external work 步骤二：区分内部工作和外部工作步骤二：区分内部工作和外部工作 对对59步换型步骤进行内部外部工作的区分步换型步骤进行内部外部工作的区分 Confidential 9 Presentations Title After Kaizen改善后改善后 Before Kaizen改善前改善前 Step 3 Convert internal work to external work 将内部工作转换成外部工作将内部工作转换成外部工作 工具准备工具准备 Prepare and Organize

12、tools Photo 将换型工具按照模型摆放在车上，便于取将换型工具按照模型摆放在车上，便于取 放。同时增加放。同时增加1个套筒和个套筒和1个六角扳手个六角扳手 Put the tools in the car according the former in order to take easily and at the same time add 1 steel tube and 1 wrench 工具在车上摆放无序工具在车上摆放无序, 只有只有1个个套筒和套筒和 1个六角扳手个六角扳手 The tools were put without order in the car and the

13、re was 1 steel tube and 1 wrench Confidential 10 Presentations Title Nmero Atividades / Tarefas / Elementos Pessoa Passos Hora Tempo (Segundos) 0 000:00:45 1Operar desbobinador para nova bobinaOpA100:00:57 2Cortar fitaOpA200:01:17 3Introduzir chapa at o roloOpA300:02:0200:00:4500:00:45 49Abrir porto

14、 e limpar respingos de leoOpB400:01:1100:00:2300:00:23 19Regulagem dos 4 rolosOpA2200:09:0000:01:0900:01:09 50Aguardar desaceleraoOpB500:02:2500:01:1400:00:52 5aguardar chapa nova encostar na velhaOpA600:03:1000:00:3600:00:36 51Estampar final da bobina e retirar cavacoOpB700:07:2800:05:0300:02:31 10

15、Avanar chapa em manualOpA1200:06:0900:00:2300:00:12 11Estampar final da chapaOpA1300:06:1400:00:0500:00:05 12Retirar cavaco e avanar chapa em manualOpA1400:07:1200:00:5800:00:29 13Estampar final da chapaOpA1500:07:1800:00:0600:00:06 14Retirar ponta da chapaOpB1600:07:3500:00:1700:00:17 52Esvaziar fe

16、rramentaOpB1700:09:0200:01:3400:01:34 Trocar caixas de cavacoOpA18 00:01:0000:00:00 54Trocar carimboOpB3200:11:0900:02:0600:00:00 Avano da chapa em manualOpB5400:18:0300:00:3800:00:00 29Limpeza para troca no 7 estgioFerrA3400:11:3600:00:1900:00:00 31Retirar 1 parafuso e soltar outro, do anel do 7 es

17、tgioFerrA3600:12:3500:00:4800:00:48 56Retirar 2 parafusos lado de trazFerrB3800:13:1100:00:4800:00:00 57 Segurar anel do 7 estgio para retiradaFerrB3900:13:3500:00:2400:00:24 33Retirada do 2 parafuso do anel do 7 estgioFerrA4100:13:3600:00:1300:00:13 34Retirada do anel do 7 estgioFerrA4200:13:5000:0

18、0:1400:00:14 58Limpeza do alojamento do anelFerrB4300:13:5700:00:2200:00:22 35Colocar novo anel do 7 estiagio FerrA4400:14:3600:00:4600:00:00 59Colocar novo anel do 7 estiagio FerrB4400:15:0000:01:0300:01:03 60Apertar 4 parafusos do 7 estgioFerrB4500:15:1700:00:1700:00:17 62Trocar centradorFerrA4900

19、:17:2100:01:4300:00:00 63Fechar porto trazeiroFerrB5000:17:5000:00:2900:00:29 40Regular altura do 5 e 6 estgioFerrA5200:17:0700:00:5500:00:55 43Encher ferramenta com peasOpB5500:20:3600:02:3300:01:32 44Pegar pea para medioOpA5600:20:4700:00:1100:00:11 45Medir peasOpB5700:24:1100:03:2400:02:23 46Acio

20、nar prensa em automtico e atingir 25gpmOpB5800:25:2000:01:0900:00:48 64 1811900:18:00 对换型步骤进行排序对换型步骤进行排序 Define the better sequence: 统计每个人的工作时间统计每个人的工作时间 并确定可以同时做的工作并确定可以同时做的工作Sichronize activities: Operator A Operator B ToolMaker A ToolMaker B Confidential 11 Presentations Title After Kaizen改善后改善后

21、Before Kaizen改善前改善前 在校平机上安装支架，用于存放手柄在校平机上安装支架，用于存放手柄 同时将手柄加长同时将手柄加长 Make a support beside the machine to lay the handle and lengthen the handle 手柄放在控制台旁边小盒内手柄放在控制台旁边小盒内 The handle was in the box of console (1)制作存放手柄支架制作存放手柄支架 Make a support Confidential 12 Presentations Title After Kaizen改善后改善后 Befo

22、re Kaizen改善前改善前 (2) 拆除校平机护板拆除校平机护板 Remove the protective net 需将校平机护板拆下，用手柄调整参数需将校平机护板拆下，用手柄调整参数 Need to remove the protective net, adjust the parameter with handle 将护板更换为有机玻璃并开四个小窗口，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直接用手柄调整参数 Change the protective net into organic glass and open 4 small windows,Adjust the

23、 parameter with handle directly Confidential 13 Presentations Title After Kaizen改善后改善后Before Kaizen改善前改善前 (3) 可视化调整参数可视化调整参数 Make the parameter visual 操作工在调整参操作工在调整参4个调整轮参数时需来回到控个调整轮参数时需来回到控 制台查看制台查看POP The operator moved to the console to check the POP when he adjusted the parameter 将将4个调整轮的调整参数按照顺

24、序贴在校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平机上，调整时操作工无需来回走动 Put on the parameter card into the glass Confidential 14 Presentations Title After Kaizen改善后改善后Before Kaizen改善前改善前 (4)制作尼龙挡块制作尼龙挡块 Make nylon block 新料料头出校平机后向上弯，与旧料对接不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好，操作工必须用撬棍对接 The new coil was bent at the exit

25、of machine, and bad connect the end of old coil. The operator must using crowbar to press 在校平机出口安装尼龙挡块在校平机出口安装尼龙挡块 Make nylon block at the exit of machine Confidential 15 After Kaizen改善后改善后Before Kaizen改善前改善前 (5) 制作存放字头支架制作存放字头支架 Make a support to lay stamping punch 字头放在换型车上字头放在换型车上 The stamp punch

26、and the tool were on the setup model car 制作字头存放支架，放在冲床旁，换型时制作字头存放支架，放在冲床旁，换型时 方便取放，减少走动方便取放，减少走动 Make a support to lay the stamp punch and the tool beside the machine, in order to take Confidential 16 After Kaizen改善后改善后Before Kaizen改善前改善前 (6) 制作检具支架制作检具支架 Make a support to lay gauge 检具摆放不便于拿取检具摆放不便于

27、拿取 The gauge was put not easy to take 重新制作检具支架重新制作检具支架 Make a new support to lay the gauge Confidential 17 结果结果 Result HistoryResult Goal 以前 目标 结果 分钟 Confidential 18 Presentations Title 换型时间跟踪换型时间跟踪 Setup time control Confidential 19 Presentations Title 标准化标准化 Standardization 对换型过程对换型过程 进行标准化，进行标准化，

28、 编到编到POP中。中。 明确明确2名操作名操作 工和工和2名模修名模修 的分工的分工 Make a standard about the setup model and add this item into POP and define each operator and each toolmakers work Confidential 20 Presentations Title Training 培训培训 Training record 培训记录培训记录 培训三个班的操作工和模培训三个班的操作工和模 修修 Training the operators and toolmakers of

29、 3 shift Confidential 21 Presentations Title Safety Improvement 安全改善安全改善 After Kaizen改善后改善后 Before Kaizen改善前改善前 安全隐患安全隐患Accident risk 防护门打开时冲床可以冲活防护门打开时冲床可以冲活 The press is working with the opened gate 只有在防护门关上的情况下才可以冲活只有在防护门关上的情况下才可以冲活,在防护门上在防护门上 开推拉窗便于操作工钩三角废料开推拉窗便于操作工钩三角废料 The press is working wit

30、h the closed gate only， open a window on the gate easy to take out the scrap Confidential 22 Action 行动计划行动计划 共制定共制定17项行动计划，已全部完成项行动计划，已全部完成 Made 17action plan and finished all Confidential 23 Gemba Kaizen Results 改善结果改善结果 Gemba Kaizen Results (GK) 现场改善收益统计表现场改善收益统计表 Indicator项目项目 Before GK改改 善前善前 Goal GK目标目标Results of GK改善收益改善收益 Value%Value% 生产能力生产能力 Production Capacity (百万百万 台台/年年 Mi unidades / year) 换型时间换型时间 Change