精益生产-快速换型_图文

1、Quick Changeover 快速换型Justin Tao 陶建刚2016Produce Large Lot Size? 大批量生产?It is a reality still used by many companies to produce, and the main objective is to smooth the setup time.事实上很多企业使用大批量生产方式进行生产,并且主要目标是使换型时间更加平稳This is the key of the “Mass Production”, it means:这点是“大规模生产”意思的关键所在:“Produce a large

2、amount of a only product”“生产大批量的单一产品”Heijunka Process 均衡化进程Too early 过早,inventory 库存Too late 过晚,out of stock 缺货Changeover Consequence of Long Setup Time长换型时间导致的结果All these factors increase the wastes in the workshop!所有这些因素都在车间中增加了浪费!Long Setup Time 长的换型时间 Long Production Cycle time 长的生产周期 Large amou

3、nt of WIP 大量的在制品 Equipment to transport and to storage需要设备搬运和存储Increase manpower need增加所需人员 Require space in the shop oor and area to storage需要空间存储 Definition of Setup Time and Its Structure换型时间的定义和构成:Setup time: The last qualified product in production run and the first qualified product in thenext

4、 production run换型时间:指介于一个生产作业的最后一件合格品和下一个生产作业的首件合格品之间的时间 Definition of setup in lean manufacturing: The last qualified product of one type to the firstqualified product of next type精益生产的换型定义:为从前一品种最后一个合格产品,到下一品种第一个合格产品之间的时间间隔。Preparing time 准备时间 Setup operationtime换型操作时间Adjusting time调整时间Sort 整理Prod

5、uct A 产品A Product B 产品BSetup time 换型时间 2 3 4 Right First Time (Elimination of Variables首次做好(消除变化 Streamline the Process简化过程 Separating Internal from E xternal Time 区分内部和外部时间 Continuous Improvement持续改进5 Understand theProcess了解过程 1 6 Teamworking团队合作 Set-up Reduction - The 6 Stages 换型时间降低-6步Step 1. Und

6、erstanding The Process第一步. 了解过程Record Current Process 记录当前流程Introduce Change-over Chart引进换型图Record Current Change-over Process记录当前换型流程Videotaping 视频拍摄Divide into steps 分解为步骤Time the steps 给步骤记时Gather facts 收集事实 TOOL STORES 刀具库 INSPECTION 检验Video the Complete Process 录下整个过程 Observation Sheet 观测表Obser

7、ve the Setup, describe and measure the time of all activities. See example below:观测换型,描述和测量所有活动的时间。举例如下:S 开始 F 结束 1 Get tools in the wardrobe 找到工具 0 4'02" 242" 2 Loose the dragring plate 松开环板 4'02" 4'58" 56" 3 Get measuring tool on the wardrobe 获得测量工具 4'58&qu

8、ot; 5'24" 26" 4 Adjust position of support device 调整支撑位置 5'24" 7'27" 123" 5 Fix supporting plate 固定支撑板 7'27" 7'42" 15" 6 Fix new supporting plate 固定新支撑板 7'42" 7'54" 12" 7 Get fixtures 获得工装 7'54" 8'17"

9、; 23" 8 Ajust position of fixtures 调整工装 8'17" 9'32" 75" Ajust with 3/4in screwdriver 调整3/4的螺丝起子 9 Fix fixture device 固定工装 9'32" 9'55" 23" 10 Get screwdriver 获取螺丝起子 9'55" 10'22" 27" 11 Ajust mechanincal range 调整机械范围 10'22&q

10、uot; 11'00" 38" 12 Adjust eletrical range 调整电位 11'00" 12'01" 61" TOTAL 总721" Coments 观测 Setup Time Observation Sheet 换型时间观测表 Step 步骤 Activity Description 活动描述Time 时间 Time 时间What We Should Observe During the Setup在换型过程中我们应该观测什么Transportation运输How is done the

11、transportation of devices, tools, components.部件,装置和工具的运输是如何发生的。Disassembly and withdraw of devices and tools.拆分收回工具和装置How many bolts, pins, porcas are withdrawn有多少螺钉螺销被收回How is the access to the tool (easy or difficult to the operator? Describe it.如何取得工具(对于工人来说是容易还是困难?进行描述Assembly operations 装配操作Mak

12、e the devices positioning and tools adjustments. 定位装置,调节工具。How many adjusts are necessary? How many times are spent to make the right positioning.多少调节使必须的?为了达到正确地位置,发生了多少次的调节。Operator Movements 工人行走How many handlings are done.多少次搬运发生Layout Organization 布局图What is the distance spent by each operator.

13、每一个工人的行走距离7 Wastes in Traditional Setup 传统换型活动的七大浪费Defect 缺陷Setup defects through observation 通过观察做出来的不良品进行调整Overproduction 过量生产Long setup time leads to overlarge batch 由于调整时间过长,产生的产品批量过大Transportation 运输Tools, toolings and materials are not prepared.工具、工装和材料没有事前准备好,停机后多次运输Waiting 等待In setup, equipm

14、ents/machines stop.在换型调整期间,设备/机器停止运转Inventory 库存Setup arrangement is based on large lot inventory or waiting.换型安排基于大批量的库存或排队等候Motion 动作Moving around to look for, fetch tools,toolings and materials.四处走动来寻找、拿取 工具、工装和材料等等Processing 过度加工Adjust data input and reply on measurement 调整数据输入依靠测量Check the fist

15、 piece首件检查Observe the Movements 观测走动 Trolleys extremely heavies (250 Kg很重的手推车(250公斤 Small wheels 小轮子 Excess of movements, heavy material 过多的走动和沉重的原材料Accident risk 意外危险Scraps 废品Hard to move 推动很费劲Observe Ergonomic and Safety Issues 观测人机工程学和安全事项 Points Hard to Reach 难以接触点 Hard access to x the device很难接

16、触到的安装设备Spaghetti Diagram Before 意大利面条图 -以前The aim is to demonstrate graphically the way (passage of the worker in the current situation of setup.目的是用图示的方法展示当前工人做换型工作的行动路径Distance travel: 805 meters 行走距离:805米 Tools table 工具台Tools cabinet工具柜 Machine设备Demonstrate graphically the way of the worker after

17、 improvements.用图形方法表示改善后工人的行走路程Distance travel: 30 meters 行走距离:30米Tools table工具台 Tools cabinet 工具柜Machine设备Spaghetti Diagram After 意大利面条图 - 之后 Step 2. Separating Internal From External Activities第二步.区分内部和外部动作Setup Activities Internal and External换型活动-内部和外部Internal Activities are those activities whi

18、ch only can be done when the “machine is stopped”.内部活动-是那些只能将“机器停止”后才能做的活动External Activities are those which can be done (in advance while the “machine is still working”.外部活动-是那些能够在“机器运转”的情况下完成(预先的活动。 Transferring Internal to External can reduce 把内部动作时间转换成外部动作 Set-up time by 30% to 50%可以降低30%到50%的换

19、型时间Changeover Time 换型时间 Internal内部动作 Set-Up Time 换型时间 Last piece of Previous Job 上一次活的最后一件 First Good piece of Next Job 下一次活的第一件良品 T ear Down 拆卸 W aiting Time 等待时间 C ollect Tools 收集工具 & Materials 物料 C lean Down 清洗干净 W aiting Time 等待时间 C hecking 检查 I nspection 检验 A djustments 调整 C lear Away 收拾干净E

20、xternal Time 外部动作时间Value add 增值 Value add 增值 Non value add 非增值 Process Time 加工时间Process Time 加工时间Internal 内部 External 外部 External外部 Identify Internal and External Tasks确定内部和外部活动The Current Situation?现有情况 TimeFornoAço Cortado comResistência com aBandeja com as Prensa Principal PrensaRolo Pr

21、ensa Auxiliar FB que ira entrarBitola do açoFerramenta do Rolo, que ira entrar Bandeja vazia,para ferramentasferramentas Ferramentaspara prensa auxiliar Itens que devem estar disponíveis antes do inicio do setupChecklist Preparation Before Do the Setup 检查单-换型的准备Oven 大炉 RM 原材料 Electrical re

22、sistance withsteel size 与钢铁尺寸相当的电阻Coming rolling tool 用到的辊压工具 Empty tray for tools为工具腾空盒子 Tray for Tools 工具小盒子Tools forsecondarypress 次冲压工具Items that should be placed BEFORE setup在换型之前需要准备的项目Rolling 辊压Main Press 主冲压Secondary Press次冲压Preparation for Operation 预先准备操作条件Before setup, prepare material, c

23、omponent, tools, and condition(temperature, pressure在换型开始前,准备好所需的材料、部件、工具和条件(温度、压力- Check meters 查仪表-Put objects in proper places 将物品放在合适的位置 -Preheat 预热-Make temporary lining 制作临时支架 Make two label frames to prepare a new roll of labelbefore machine stops 在机器上制作两个标签架,以便在停车前将能将新的一卷标签准备好 Preparation: P

24、reassembly mold 事前准备:模具预装配Preparation: Preheat the mold 事前准备:模具提前预热Prepare Mold 模具预先准备Step 3. Streamlining The Process第三步. 简化过程Ensure Tooling for the Set-up is Organised确保换型用的工装工具都准备良好Set-up a visual place for everything at point-of-use 建立一个可视化的地方,所有东西都放在使用点Hand tools 手动工具Change parts 更换零件Critical s

25、pares 重要备件Consumables 消耗品等 Mobile Trolley 移动小车Fixed Location 固定的位置Trolley for Setup 换型专用手推车 Tools for Setup 换型工具Before 改进前After 改进后 Before改进前After改进后 Before改进前After改进后 Place the tools near to the workplace将工具放置在工作区域附近 Define standardgroups of tools anddevices and placethem near to eachmachine.定义标准工具

26、、工装组并放置在使用的设备附近。Reduce turning in removing and assembling mold 减少卸下和安装模具过程中的”转身”动作; Simply the frequent motions “take and lay”into one 将多个拿放动作简化为一个动作; One single motion for once 单个动作一次放好; Use assembly lining, standard mold frame 使用装配架、标准模架等; Use standard tools, screws and bolts of the same type and

27、size 使用标准工具、同型号同大小的螺丝和螺栓等; Remove screws or reduce the use of it. 剔除、减少螺丝的使用。Special Fixture, Remove Screws, Simplifying 专用工装夹具、剔除螺丝、一切从简Avoid Use of Tools 最好不用工具改进之前 改进之后蝴蝶状螺栓六角螺栓蝴蝶状螺栓需要较少的力量就能松开Work in Parallel 并行工作To deduce setup time, in the changover, several persons can work in parallel.为了缩短停机

28、换型时间,可以在停机换型时间,多人同时进行换型工作Communicate before the parallel work; define specific responsibilities in case unnecessary motions occur and prevent defect in the process.并行协同工作要注意提前进行好沟通,明确分工,以免产生多余动作,更要避免出现操作遗漏 Two Operator reduce time 双人工作减少时间改进之前 改进之后单人换型 双人换型后方人员前方人员Use Setup Device 采用换型辅助设备改进之前 改进之后滚

29、筒式传送机固定模座 固定模座固定模座上改良装置Use Setup Device 采用换型辅助设备 Use Automatical Setup Equipment 采用自动化换型辅助设备 25T setup machine forModel 2两模各25T的换型台 35T setup machine for Model 1 一模35T的换型台Step 4. Right-First-Time The Elimination Of Variables 第四步. 首次做对 消除变化 Basic Activities of Setup (Usually 换型的基本活动(通常20%10% 45%25%Ge

30、t items 寻找资源Change parts (components 更换部件(组件Place the component in the machine 在机器上放置组件Adjustments 调试Standardise input conditions 标准化投入条件- Predictable 可预测的- Reliable 可信的- Repeatable 可重复的 Eliminate variables 消除变化 - Machine 机器- Tooling 工装- Materials 材料 Measure what is critical 测量关键尺寸 Treat inspection

31、as an EXTERNAL operation 检验作为外部动作进行 Team is accountable for its own Quality 团队对自己的质量负责Right First Time 首次做对 Fixed Go-No-Go Gauge 固定的过不过衡量标准 Visual Adjustments 可视化管理Elimination of Adjustment 调整的消除Trial run and adjustment take 50% of time; 试运行和调整占总换型时间的50%;Eliminate adjustment as possible, not just re

32、duce;尽量消除调整,而不仅仅是减少; Purpose: one- time success in adjustment 目标:一次性就调整成功;Use standard procedure in assembly and double check;在装配过程中使用标准程序,并进行双重检查;Improve setup technics 提高换型工装配技能;Technics for improving the reliability of assembly 提高装配可靠性的技巧:Use standard setting, like fixed scale使用标准设置,如:固定数字刻度/标尺;V

33、isual setting and reference line 可视化的设置值和参照线;Greatest common denominator theory 最小公倍数原理;Even a Fool Can Assembly (PokaYoke 傻瓜也能进行的装配(PokaYoke;Rely on data rather than intuition依赖于数值 而不是直觉 Mark specification of each product setting on machines在机器上的合适位置以数值显示每种产品规格对应的设置Scales makes setting more accurate 含刻度的标尺使得设置更加精确Die 模具Stop挡块Holders定位块Locking Pin锁钉Spring弹簧Use holders, location pin, location hole,guide pins,snap gages to reduce the use ofmeasuring tape, and capliper.采用定位块、定位销、定位孔、定位导轨、卡规等方式减少使用拉尺、卡尺等需要调整的量具