Cell-Desig单元生产线设计

1、 2008 Gemba Research LLCCell Design单元生产线的设计 2008 Gemba Research LLCElements of Good Cell Design高效率生产线的设计要素1.Design allows for One Piece Flow设计遵循单一流程2.Equipment and work stations are close together设备及其配备装置共同停止运作3.Product flows from right to left 产品流自右向左4.There are no barriers to operator or material

2、flow对于操作者和操作流程无障碍5.Raw Materials fed from the outside of the cell by the material handler原材料由材料操作者从生产线外引进6.Equipment should be right sized设备应有准确的大小7.Operators are multi-skilled操作者具有多种能力8.One operator could run the cell 一个操作者能够管理生产线9.Equipment and work stations are easily movable 设备及工作站易于移动 2008 Gemb

3、a Research LLCElements of Good Cell Design高效率生产线的设计要素10. All work areas are safe and ergonomic所有工作站是安全的且符合人体工程学11. Tools and material are presented at point of use based on frequency of use and ergonomics工具和材料所呈现出的使用点以使用频率和人体工程学为基础12. Schedule is visual 计划是视觉化的13. Hour/Daily goals are posted and act

4、ual data is collected每时/每日的目标是清晰的，且收集实际数据14. Use visual management to manage materials and tools 使用目视化管理方法管理材料和工具15. Metrics and other key performance indicators tracked, clearly seen生产规律图和其他关键履行指标追踪跟进16. Root Cause Corrective Action process is in place根本原因纠正措施过程的适当实施17. Process steps are error proo

5、fed - Quality built into the process过程步骤是错误的证据-质量形成于过程中 2008 Gemba Research LLCTime to first piece is 21 minutes完成第一件需要21分钟Time to complete batch 30 minutes完成一批需要30分钟Batch & Queue批量批量LatheMillOne-Piece Flow单件流单件流LatheMillDrillDrillMake 10, Move 10Make 1, Move 11 min. cycle times per process每个过程1

6、分钟的周转时间Time to first piece is 3 minutes 完成第一件需要3分钟Time to complete batch 12 minutes完成一批需要12分钟Make 1, Move 1Make 1, Move 1Make 10, Move 10Make 10, Move 101. Design for Single Piece Flow单件流设计 2008 Gemba Research LLC2. Equipment & Stations are Close Together设备及其配备装置共同停止运作 2008 Gemba Research LLCMos

7、t people are more effective using their dominant hand. Most people are right-handed.大部分人更有效的使用他们受支配的手。大部分人使用右手The right brain processes spatial information with visual input from the left eye.右脑通过左眼输入空间性的视觉信息。Race tracks are counterclockwise for this reason.跑道由于这个原因自左向右。3. Product Should Flow From R

8、ight to Left产品流自右向左 2008 Gemba Research LLC Focused Cell 聚集的生产线 2008 Gemba Research LLCh Visual Control - Easy to see the whole process 目视化控制- 容易目视整个流程h Linked Processes 连接的流程hGood Information Flow 好的信息流h Shortest Part Travel Distance短距离的物品传送h Common Drop-off and Pick-up常见的下降和回升h Easier to implement

9、 Standard Work Sequence 较容易实现标准的工作次序h Easier to create multi-skilled workers 较容易培养多种技能的员工h Better Teamwork 较好的团队合作12345Advantages of U-shaped Cells U型生产线的优势14 2008 Gemba Research LLC4. No Barriers to Operators or Flow对于操作者和操作流程无障碍 2008 Gemba Research LLCEntry入口Exit出口Materials物料5. Material is Present

10、ed from Outside of the Cell物料是从线外呈现进来的 2008 Gemba Research LLC6. Equipment Should Be Right Sized设备应有准确的大小 2008 Gemba Research LLC7. Operators are Multi-Skilled操作者具有多种能力 2008 Gemba Research LLCOutput = X units/dayOutput = 3X units/day Operator does not need to follow product flow操作者不需要遵循产品流程 Staffing

11、 varies based on demand根据需求员工多样性8. Cell Could run with One Operator 单元产品能在一个操作者的情况生产ABCEDFProduct Flow产品的流动11Operator Flow操作者的流动1111ABCEDF122321 2008 Gemba Research LLCLean Cell精益单元LeanCycle Time = 60 Seconds / Cell4 Cells = 1 Mass Line4 Different Product Type at one time一次生产4种不同类型的产品110352345678910

12、1161514131211ABCDA= Walk Path 路径Product OutParts InParts InParts InParts InParts In 2008 Gemba Research LLC4567The Standard Work Orchestra标准生产曲线图1101132984576389121011 2008 Gemba Research LLCMachinesMachines9. Make Equipment Easy to Relocate使设备有利于再配置 2008 Gemba Research LLC10. Work Stations are Safe

13、 and Ergonomic工作站是安全且符合人体工程学的 2008 Gemba Research LLC11. Materials and tools are Managed Visually材料和工具目视化管理Tool Shadow Board工具阴影板 2008 Gemba Research LLC12. Schedule is Visual计划是视觉化的 2008 Gemba Research LLC13. Hour/Daily Goals Posted & Tracked每时/每日的目标追踪 2008 Gemba Research LLC14. Tools and Mater

14、ial at Point of Use工具和物料的使用要点Material 材料 2008 Gemba Research LLC15. Metrics & KPI Tracked, Clearly Seen清楚地目视被追踪的生产规律&KPI 2008 Gemba Research LLCDate 10/13 ShiftATakt Time 742 secTime+/- Issues7:00 - 8:0055558:00 - 9:0051049-1 Paintline Down 10min9:00 - 10:15515514-110:15 - 11:15520418-2 No c

15、hasis 15 min11:15 - 12:45525523-212:45 - 1:45530528-21:45 - 3:00535331-4 Test equipment down 25 min3:00 - 4:15136132-44:15 - 5:155:15 - 5:30Total36363232Pareto of IssuesCountermeasuresPRODUCTION BOARDPlanActualBalancerDown TimeIssuesMonthly KPIs for cell and business measurementsSelect top 1 or 2 it

16、emsWe can see a reduction in our daily issuesReview daily issues in a weekly paretoDeliveryMonthActual ProductionQualityMonthPPMCostMonthLabor ProductivityProcess results in measurable monthly improvementsCreate an action plan with names and dates16. Root Cause Corrective Action process根本原因纠正措施过程 2008 Gemba Resea