实习报告ppt版本.

1、B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P 张支亮张支亮 2011/08/202011/08/20 B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 2 2011年7月13日我正式步入了博西华公司生产部门 （TB2M-L2）开始了我的实习生涯，这次能有机会进入博西 华公司实习，我感到非常荣幸,十分感谢学校和公司给我提供 这

2、样一个难得的机会锻炼自己。在这一个半月里，对于一些 平常理论的东西，有了感性的认识，受益匪浅，学到了很多， 感触也有很多。 I officially enter the production sector (TB2M-L2) of BSHHA to start my practice career on July 13, 2011.I am of great honor to have the opportunity to practice in the BSHHA. I appreciate my college and the company very much for giving me

3、 the chance that I could practice in the company. During one and half months，Ive learned many things which are in theory，I also I benefited a lot and there are still some special feelings which appeared in my mind . B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAM

4、E, Year w 了解企业文化，了解企业的管理模式及方法 To know the enterprise culture and management mode and method of the enterprise w 认识冰箱生产基本流程以及每个工位的工作 To realize the refrigerator production process and the work of each workstation w 分析冰箱主要焊点的焊接缺陷 To analyse the main defects of welding point of refrigerators w 学习与社会接触和

5、为人处事的方法 To learn how to contact with society and learn the methods of communicating with people B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 博西华是国际性的博世-西门子集团的成员，集团的年营 业额已超过了88亿欧元。目前，博世和西门子家电电器集团 的销售额，在欧洲排名第一，世界排名第三。因为拥有了先 进和完善的生产技术，博西华已成为了这个行业的创新先导。 博西华

6、家用电器有限公司位于中国安徽省滁州市，占地面积 144,250平方米，拥有员工近3500名。目前公司年产 1,700,000台普通冰箱，新落成的双开门冰箱工厂预计年产量 将达160,000台。博世和西门子冰箱以质量优良享誉市场， 产品型号多达200种以上，满足了中国市场不同消费者多样 化的消费需求。公司坚持技术创新，重视研发，每年申请专 利近50项，2009年被评为高科技企业。 B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year BSHHA is a member

7、 of the international Bosch and Siemens Household Appliances Group with a turnover of more than 8.8 Billion Euro. At present, the turnover of BSH group ranks first in Europe, third in the world. BSHHA is the innovation leader of this industrial sector because of creativity and excellent technique. C

8、overing an area of 144,250 square meters, the BSHHA with almost 3500 employees is located in Chuzhou, Anhui province. The annual production capacity is more than 1,700,000 units BF and over 160,000 units SBS. Siemens and Bosch refrigerators have the highest quality standard and are pioneering innova

9、tions in the market. More than 200 variants of refrigerators are satisfying the consumers needs. In 2009 BSHHA has been granted Hi-Tech Enterprise status among others due to an average of around 50 patents B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 冰箱

10、生产基本流程： The basic process of refrigerator production: 冰箱壳体 Case of refrigerator 配 件 Fittings 预装 Preassembly 发泡 Foaming 总装 Final assembly 门体发泡 Door foaming 箱体发泡 Case foaming 门体装配 Door assembly 包装 Packing B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year （一）预装

11、线 （1）Preassembly line 预装线使冰箱产生基本雏形，其工序主要包括：冷藏室内胆压合、零度室内 胆压合、内胆装配（左，右）、顶盖板藏线盒装配、电线排布、防露管装配、藏 线盒装配、零度密封件装配、右侧板装配、左侧版装配、排水管装配（左，右）、 背板装配（左，右），箱体翻转以及螺丝固定。 The refrigerator basic shape will be produced on the Preassembly line. The main processes of Preassembly line includes: Zero-Innerliner Pressing, Coo

12、ler- Innerliner Pressing, Innerliner assembly (left, right), The wire house of top panel assembly，Fix the wires，Heater assembly，The wire house pannel assembly， Zero seals assembly，The board of right side assembly, The board of left side assembly,The drain tube assembly(left, right),Rear pannel assem

13、bly, Cabinet flip and Screwing. 防露管装配的目的是防止冰箱由于内外温差而使表面产生小水珠,同时防止 冰箱门封条结冰，使冰箱门无法打开。预装线由于各道工序的不确定性，故自动 化程度不高，仅在箱体翻转的时候使用了箱体翻转机。至预装线结束冰箱箱体内 部配件装配结束。 Heater assembly is to prevent refrigerator surface appear water droplets because of the temperature difference inside and outside of refrigerators surfac

14、e and to prevent the refrigerator door gasket being freezed and make the door cant be opened. The automation level of Preassembly line is not high because each working procedure time is uncertainty. Only when box is flipped over we use cabinet flip machine. Internal parts assembly of refrigerator is

15、 over at the end of Preassembly line. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year （二）箱体发泡 (2)Body foaming 箱体发泡，向冰箱箱体内部注入两种化学原料:黑料（化学成分为：异氰酸酯） 与白料（化学成分为：组合聚醚），使二者在箱体内发生反应产生填充物，充满 整个腔体，产生的填充物具有绝热、保温以及支撑的作用。 Body foaming is pouring two kinds of chemical m

16、aterials into the refrigerators which are called black material(Chemical composition: isocyanate) and white material (Chemical composition: combination of polyether).And the two kinds of chemical materials will react in the body of refrigerators.Then the body of refrigerator will be filled by the pr

17、oduct of the reaction.The product of the reaction could prevent the loss of heat and support the body. 在箱体发泡时，发泡之前要对箱体进行预热处理，箱体经过烘道预热。对箱体 进行预热的目的包括两个：一个是提高发泡环境的温度加快发泡速率，另一个是 防止在发泡过程产生的高温使冰箱箱体因为骤热而产生裂纹或损伤。 The bodies need to be preheated before the body foaming. The refrigerators will be preheated wh

18、en they pass bake oven.There are about two reasons of the body-preheating.On the one hand,that could increase the environment temperature of the reaction and quick the reaction speed,on the other hand,the aim is to prevent the damage of refrigerator body because of the temperature deference of insid

19、e and outside. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 发泡过程的相关参数： Parameters of foaming process: w料灌温度：1722 Container temperature:Container temperature: 17221722 w料灌压力：2.04.0 bar Container pressure:Container pressure: 2.04.0 bar2.04.0 bar w泵前预压力：2.

20、04.0 bar Pre- pumping preloading pressure: 2.04.0 barPre- pumping preloading pressure: 2.04.0 bar w泵压力：130180 bar Pumping preloading pressurePumping preloading pressure： 130180 bar130180 bar w充注头压力：13010 bar Filling head pressure: 130Filling head pressure: 13010 bar10 bar w充注头温度：2228 Filling head te

21、mperature: 2228 Filling head temperature: 2228 w烘道温度：4050 Bake oven temperature:Bake oven temperature: 4050 4050 w小样重量：114040g Sample weight: 1140Sample weight: 114040g40g w小样密度：22.525.0g/cm3 Sample thickness Sample thickness：22.525.0g/cm22.525.0g/cm3 3 w模机温度：4050 Molding machine temperature: Moldin

22、g machine temperature: 40504050 箱体发泡后经过420s的固化，清洁后进入下一道工序。 There will be 420 seconds for solidifying after Case Foaming and the refrigerators will be sent to the next process after cleaning. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year （三）门体装配线 (3) Door

23、 assembly line 门体装配线包括门体内部的电子元件的装配和门体发泡，门体发泡与箱体发 泡不同，其不同之处在于门体发泡时发泡料直接放入门体内部而不是采用冲头注 入的方式。 Door assembly line includes the electronic components assembly and door foaming, Door foaming is different from Case foaming.The materials of Door foaming is put into the door body directly instead of squeezin

24、g into. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year （四）总装线 （4）Final assembly line 经过预装线和发泡之后的冰箱进入总装线，总装线主要包括的工序有：灯泡 装配、前置动力装配、下铰链装配、装零度室风扇、蒸发器装配、焊接配冷凝管、 焊毛细管，电磁阀、氦气检漏、压缩机焊接、抽真空，R600a充注。 The refrigerators will be sent to the Final assembly line after Bo

25、dy foaming and Door assembly. The main process of Final assembly line includes: Bulb assembly, Lead power assembly, Fix base hings,Assembly 0 degree fan,Evaporator assembly,Solder condenser tube,Solser capillary tube and vavle,He-leakage testing,Solder compressor, Vacuuming and R600a charging. R600a

26、作为冷媒，具有蒸发潜热大，冷却能力强，流动性能好，输送压力低， 耗电量低。负载回升温度慢，与各种压缩机润滑油都兼容的特点。R600a在制冷 系统中含量不足时会造成压力值过大，机器声音异常，压缩机寿命缩短。 R600a as a kind o refrigerant, with a large latent heat of evaporation, good cooling ability, good fluidity, low delivery pressure, low power consumption. loading temperature rise slowly,has charac

27、teristics of compatible features with all kinds of compressor lubricants. If R600a is not enough in refrigeration system, it will cause too much pressure, machine abnormal voice, and short the compressor life. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Yea

28、r (五)车间设备、人员管理方法以及物流方法的学习 (5)Learning of workshop equipment, personnel and logistics management methods： 对于车间现场管理，公司采用的是5S现场管理法，5S现场管理法主要包括：整理、 整顿、清扫、清洁、素养。5S”活动的核心和精髓是修身，如果没有职工队伍修身 的相应提高，“5S”活动就难以开展和坚持下去。 For workshop management，what the company use is 5S management. 5S management includes:Sorting,

29、Set in order,Shine,Standardize,Sustain. The core of 5S activities is cultivate ones morality. 5 S activities will be difficult to carry out and stick to if workers morality cant be raised. 对于设备的维护及维修方面，公司采用TPM（全员生产维修）管理方法。TPM： 利用包括操作者在内的生产维修活动，提高设备的全面性能。TPM具有三个特点：全 效率、全系统和全员参加。TPM的目标可以概括为四个“零”，即停机为零

30、、废品为 零、事故为零、速度损失为零。 For equipment maintenance and servicing, what the company use is TPM(Total Productive Maintenance) management. TPM is using maintenance activities include the operator of the production to improve the overall performance of the equipment. TPM has three characteristics: the effici

31、ency, the whole system and overall attend. TPMs goal can be summarized as four zero: stop is zero, zero waste, accident is zero, zero speed loss. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 对于设备效率方面，公司采用OEE（全局设备效率）计算方法。OEE是一个独 立的测量工具，它用来表现实际的生产能力相对于理论产

32、能的比率。它由可用率， 表现性以及质量指数三个关键要素组成。OEE=可用率X 表现性 X质量指数。其中： 可用率=操作时间 / 计划工作时间；表现性=（总产量/操作时间）/理想周期时 间=（总产量 / 操作时间）*生产速率；质量指数=良品/总产量。 For equipment efficiency,what the company use is OEE (Overall Equipment Efficiency) calculation method,.OEE is a kind of independent measuring tool. It is used to show the act

33、ual production capacity relative to the theory of production capacity ratio. It consists of three key components: Availability, Performance and Quality index.OEE= Availability X Performance X Quality index and Availability =Operating time/Plan work time, Performance =(Production/Operation time) / Id

34、eal cycle time = (Production/Operation time) * Production rate, Quality index=Good quality products/Total output. 对于生产方式方面，公司采用的是精益生产的生产方式。即：利用杜绝浪费 和无间断的作业流程，而非分批和排队等候的一种生产方式。精益生产方式的基 本思想可以用一句话来概括，“旨在需要的时候，按需要的量，生产所需的产 品”。精益生产核心追求以下两个方面；一，追求零库存；二，跪求快速反应， 即快速应对市场的变化。 For the way for production, what

35、the company use is lean production. It is a kind of production mode to use preventing waste and continuouing work process rather than partial production and lined up waiting. The basic ideas of lean production can be summed up in one sentence, aims to need, according to the need of the amount requir

36、ed to produce the products, The core pursue of lean production has two aspects; one is zero inventory; another is fast reaction, that is reacting to the change of the market fast. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 14 对于生产过程

37、中的物流管理方面，公司采用的是SAP、直接喂料和 看板管理方法。看板管理是一种为了达到精益生产方式控制现场生产流 程的工具。看板的信息包括：零件号码、品名、制造编号、容器形式、 容器容量、发出看板编号、移往地点、零件外观等。 For logistics management of production process, what the company used is SAP、Feeding line and Kanban management. Kanban management is a kind of tools of controlling the production process

38、 in order to achieve lean production. The information of Kanban includes: number of parts, name of commodity, manufacturing numbers, container form, container capacity, numbers of Kanban sending, place to be sent, parts appearance, etc. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S

39、 G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 15 焊接是总装线中关键的一部分,主要包括：冷凝管焊接，电磁阀焊接， 蒸发器焊接以及压缩机焊接。压缩机焊接包括：高压管焊接和回气管焊 接。冷凝管焊接和压缩机焊接需要加焊剂，焊后需要清洗，加焊剂的目 的是使焊接过程的焊液可以均匀分布，焊后清洗的目的有两个：一个是 清洗焊接处表面的杂质，另一个是起到冷却的作用。 Soldering is a very important part of the Final assembly line. It includes: Soldering Condenser T

40、ube, Soldering Capillary Tube, Soldering Evaporator and Soldering Compressor. Soldering Compressor includes: high-pressure tube soldering and Return-air duct soldering. The welding points should be added soldering flux before soldering and cleaned after soldering when solder Condenser Tube and solde

41、r Compressor. There are two points about adding soldering flux to the welding points, one is to make weld liquid can be evenly distributed and another is to cold the pipe. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 16 B/S/H B O S C

42、H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 17 根据焊堵焊点的统计可知，造成堵的主要原因是脏堵，造成脏堵的主 要问题在于来料管内部有赃物，造成在压缩机工作使赃物堆积在毛细管 焊点处，堵点主要在在7.3.1，7.3.2，9，三个焊点，根据跟踪观察，其原 因主要是因为在配管时装配的不到位，焊接时焊剂堆积在焊点处，造成 焊堵。 According to the welding blocking statistics, we can know that

43、 the main reason of welding blocking is dirty blocking, because the pipes which are sent to factory is not pure and there are some impurities in the pipes, and when compressor works impurities are sent to the welding point of capillary tube that cause blocking. Point 7.3.1, point 7.3.2 and point 9 a

44、re main points of blocking points. According to observing, the main reason of capillary tube blocking is that the pipes do not reach the designated position when butting welded pipes and flux piles up in solder joints and cause welding blocking. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I

45、A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 18 造成焊堵缺陷的主要原因有： Reasons of welding blocking defects: 管与管的对接不到位，容易使焊液流进管内，造成焊堵。 When butting welded pipes, the pipes do not reach the designated position and its easy to make welding liquid flow into the tube and cause blocking. 配管时由于应力作用，毛细管弹

46、出一定距离，“弹管现象”，使 焊液流进管内，造成焊堵。 Capillary pops up a certain distance due to the stress when butting welded pipe and causing blocking and we called it as “popping up tube phenomenon”. 在涂抹焊剂时，涂抹的不均匀，导致焊条液体流的不均匀，产生 堆积，造成焊堵。 When we daub soldering flux onto pipes, the welding liquid might be non-uniform and

47、 cause accumulation and blocking. 焊接时加热时间过长，同时填料过多，使焊液沿焊缝往下流，降 温后凝固，造成焊堵。 Welding time is too long and adding too much welding rod，the welding liquid flows along the weldingline, causing welding blocking after cooling. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANY

48、NAME, Year 6/11/2021 I Slide: 19 焊堵缺陷的预防方法： Welding blocking defects prevention methods: 装配时，保证焊接头的套接长度，以使毛细管插入到位。 Ensure the length of welding head is long enough to make sure that capillary can be inserted as set length when butting welded pipes. 装配时，检查接头间隙是否偏大。 Check gap of joint is too large or

49、not when butting welded pipes. 用内焰尾料加热母材，控制好保温时间和温度，以及填料量 Heat the mother material by inner flame and control the heat preservation time, temperature and the amount of welding rod properly. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide:

50、 20 B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 21 根据统计结果显示可知，主要漏点在：6.10，1.1，10.1,这几个焊 点都是由蒸发器供货商焊接的，可见焊漏缺陷主要在于来料不良，所以 在选择供货商时，应该考虑来料质量的问题。 According to the result of statistics, we can know the main leakage points are point 6.10，poi

51、nt 1.1 and point 10.1.These welding points are soldered by evaporator suppliers. So the main reason of leakage defects is poor incoming part, and when we choose suppliers we should consider the incoming quality. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Y

52、ear 6/11/2021 I Slide: 22 造成焊漏缺陷的主要原因有： Reasons of welding leakage defects: 在焊接过程，填料不足，造成焊漏。 Welding rod is not added enough and cause welding blocking in the process of soldering. 加热不均匀，钎缝无致密性地填满钎料。 The pipes is not heated uniformity and welding gap can not be filled compactly. 接头间隙的钎料在液相变固过程中受到震动或

53、移动，使接头产生裂纹。 The joint of welding point is moved or shook when soldering fluid is cooling so flaw appeared. B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 23 焊漏缺陷的预防方法： Welding leakage defect prevention methods: 均匀加热接头附近，使填料时钎料流动性良好并均匀的填

54、缝。 Heat joint uniformly and keep the welding fluid flowing and filling the welding gap uniformly. 接头完成焊接、冷却、凝固过程要避免受到震动，待接头完全凝固才能 移动。 Avoid moving and shaking the joint of welding point when welding fluid is cooling. 焊接过程中，保证填料次数 Make sure the times of adding welding rod when soldering the pipes. B/

55、S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 24 （1）预装线，箱体漏泡主要在螺丝孔处，其原因是腻子在装配时漏 装或者没有装配到位，根据跟踪观察主要原因是腻子脱落，由于流水线 较长，腻子变干，在螺丝固定时由于拍打的过猛，容易使腻子脱落，造 成在发泡时发泡料从螺丝孔漏出。建议在装配腻子时，在腻子上面加一 道海绵条。 （1）Preassembly line ：Bubble leak of case is from screw

56、holes. The reason for this is the putty is neglected loading or not assembled in position. According to observing the putty become dry because of long assembly line and when screwing cabinet is flapped heavily and putty falls off, when case is foaming the foaming materials leak out from screw holes.

57、 It is recommended that we should add sealing stripe of rubber latex foam on the putty when assembling putty B/S/H B O S C H A N D S I E M E N S H O M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 25 （2）总装线，焊漏返修线与总装主线转换处的流水线光电传感器装配的不太合理， 每次焊工在切换焊漏返修线的冰箱到总装主线时都需要用手套挡住光电传感 器感光头（

58、如图3），不但繁琐而且不安全。建议设计一个带有挡板的摇杆装 置，并且把手柄伸出流水线之外。 （2）Final assembly line: photoelectric sensor in changeover place of welding leakage repairing line and final assembly line is not assembled reasonably, solders have to use gloves to cover the photosensitive head of photoelectric sensor when they want to

59、switch the refrigerator from welding leakage repairing line to the final assembly line, it is red tape and also not safe, It is recommended that we should design a rocker device with screen and put the hand shank outside of the final assembly line. （1） （3） （2） B/S/H B O S C H A N D S I E M E N S H O

60、 M E A P P L I A N C E S G R O U P COMPANYNAME, Year 6/11/2021 I Slide: 26 （3）门封条挤出线，磁条托盘中间的圆柱半径过大（如图1），工 人多采取扯断的方式来使磁条套进去，造成物料浪费(如图2)。建议改小 半径。 (3)Door-Gasket Extruding line: radius of column in the middle of magnetic stripe salver is too large(Picture 1),workers usually pull magnetic stripe to make