伟创力精益JIT项目精典案例

1、DateDate : 2007.01.17 : 2007.01.17PROJECT:PROJECT:Latte printerLatte printerLINE:LINE:Main frame & sub lineMain frame & sub lineOperators (original):Operators (original):Leader : Leader : 2 EA2 EARepairer: Repairer: 1EA1EAMobile OPMobile OP： ： 1EA1EADirect OP: Direct OP: 20EA(Main line)20EA(

2、Main line)Direct OP: Direct OP: 17EA(Five Sub)17EA(Five Sub)Total Operators:Total Operators:41 EA41 EATake Time:Take Time:45 Sec45 SecTarget Capability:Target Capability:80pcs/h80pcs/h Expectation Effect:Expectation Effect:Planning ActionPlanning ActionReduce the headcount Reduce the headcount 1.Bal

3、ance the line; 2.Optimize operation; 3.reduce transit1.Balance the line; 2.Optimize operation; 3.reduce transitReduce Lead time1.reduce over production; 2.reduce WIP1.reduce over production; 2.reduce WIPIncrease the value of spaceIncrease the value of space1.change layout ; 2.reduce over production1

4、.change layout ; 2.reduce over productionImprove qualityImprove quality1.reduce transit ; 2.using fixture to fool proofing1.reduce transit ; 2.using fixture to fool proofingLine Status:Line Area:=12M*6.6M-8*1.5 =67.2mm12M6.6M8M1.5MLine Status:Line Area:12M*4.5M =54mm12M4.5MMainFrameBarrow,70m，40EA/t

5、ime（16EA/BOX）AssemblyBarrow,5m，36EA/time（12EA/BOX）Left FrameAssemblyRight FrameACMGear TrainDuplex AssyBarrow,70m，160EA/time（80EA/BOX）Barrow,10m32EA/time（16EA/BOX）MainFrameAssemblyLeft FrameAssemblyRight FrameACMGear TrainDuplex AssyChange Eliminate waiting, Neither make anybody too busy, Nor make a

6、nybody too free! Only a Fair Environment is able to found high work morale.差差异项目异项目 Difference Item当前当前实际实际 Actual改善后改善后 Improved比率比率 RatioRatio备备注注 Remark人人员员 Human Human LeaderLeader2 21 10.50 0.50 Now we dont need to Now we dont need to transit five sub to main transit five sub to main line.line.

7、RepairerRepairer1 11 11.00 1.00 Mobile OPMobile OP1 11 11.00 1.00 Direct OPDirect OP373728280.76 0.76 TotalTotal414131310.76 0.76 设备设备/ /夹具夹具 FixtureFixtureFixtureFixture181811110.61 0.61 RackRack2 20 00.00 0.00 Screw driverScrew driver212120200.95 0.95 Screw SupplierScrew Supplier6 66 61.0 1.0 占用面占

8、用面积积 AreaArea67mm67mm54mm54mm0.80 0.80 Lead Time ( hour )Lead Time ( hour )1.42 1.42 0.66 0.66 0.46 0.46 每小时每小时人均人均产能产能 Capability PPHCapability PPH2.16 2.16 2.86 2.86 1.32 1.32 Before ImprovingAfter ImprovingType of Waste Improving ActionTransportation: Ops need transit printer from conveyer belt t

9、o workstation. Use roller line, So Ops dont need to transit printer from conveyer belt to workstation. And every Op will almost reduce a little transportation.Before ImprovingAfter ImprovingType of Waste Improve ActionMotion: Materials isnt appropriate level of reachPut screw driver on material brac

10、ket ,So the distance from screw driver to screw hole is much shorter then before. In line there are many station like this.Before ImprovingAfter ImprovingType of Waste Improve ActionOver-processing, Transportation , Inventory, Over production, Defect: Pool layout make almost these five types waste i

11、n old line.Redesign new “JIT” layout ,Reduce Batch Size to “one piece flow”. (please refer Before ImprovingAfter ImprovingType of Waste Improve ActionMotion: Switch used with foot press, Op would keep one leg standing, that made them tired.Put switch on collet，Op can press the switch in the same tim

12、e when move to the relevant position.Switch used with footSwitch used with finger (1)Before ImprovingAfter ImprovingType of Waste Improve ActionMotion/Cost: The part put one side(A side)to opposite side(B side) from A fixture to B fixture.Improve a little A fixture ,Then the part can be put on one fixture, whenever A side or B side. Total Seven fixture eliminate in new line.B sideSwitch used with fingerA sideA sideB sideBefore ImprovingAfter ImprovingType of Waste Improve ActionCost :The metal claw is expensive (142RMB/set),and they are easy to damaged, We