单元式生产布局CE

1、ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou议程 Agenda传统组装线设计Traditional Assembly Line Design工位设计 Work Station Design 物料展示 Material Presentation 物料补充 Materi

2、al Resupply 物料储存 Material Storage ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzho

3、u组装线布局的目的 Assembly Layout Goals 按照节拍时间, 生产优质产品Quality products produced at takt time 有效利用人力Productive utilization of people 装配工只做装配Assemble product only 按节拍分配任务达到高生产力High operator productivity through loading to takt time 工人能完成整个流程Operator to complete the full process 物料/工人流畅Flow of material and ope

4、rators 优化工位以方便摆放零件 物料 工具Work stations optimized for presentation of parts, materials, and tools 工位设计减少走动Work station design minimizes operator movements 信息即时反馈Immediate flow of information / feedback 问题立即暴露Immediately expose problems ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qi

5、ngdao Chongqing WenzhouU型线 U - Shaped Line 原料原料 RM 成品成品 FG按灯 Andon最少走动最少走动工人间的平衡工人间的平衡避免产生孤岛避免产生孤岛多工序作业多工序作业促进沟通促进沟通按灯识别异常按灯识别异常WS负责所有物料需负责所有物料需求求o从从“U” 型线外送料型线外送料o取走成品取走成品节拍变，你也变节拍变，你也变o人员安排可以应变人员安排可以应变Im water spider. Were operators. ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi

6、Qingdao Chongqing Wenzhou线体设计线体设计: 物流从右至左物流从右至左线体设计线体设计: 每条槽每条槽里放里放2个料箱个料箱 线体设计线体设计 :工具伸手可及工具伸手可及线体设计线体设计: 所有料箱都放所有料箱都放置于工位前方置于工位前方线体设计线体设计:模块化和模块化和可连接的工位设计可连接的工位设计线体设计线体设计:空料箱空料箱从料架下方回收从料架下方回收线体设计线体设计: 预留预留30% 的工位空间的工位空间线体设计线体设计: 工作工作区间距区间距 1.6米米线体设计线体设计: 工作台高度工作台高度0.81.2米米 (人机工程人机工程)线体管理线体管理 : 过道里

7、不过道里不许放料箱许放料箱为方便车间目视化为方便车间目视化和沟通和沟通: 建议料架高建议料架高度不超过度不超过1.5米米线体管理线体管理 : 禁止订单在缺少禁止订单在缺少零配件的情况下进行生产零配件的情况下进行生产线体管理：本独立工作线体管理：本独立工作单元中操作工的数量单元中操作工的数量（18人）人）目视化及目视化及5S管理管理:例：例：划线并确定相关货架划线并确定相关货架占地面积占地面积线体设计：最大偏差为线体设计：最大偏差为 20% 拉动信号拉动信号: 目视化和在制品控制目视化和在制品控制防错防错 : 一旦发现缺一旦发现缺陷立即停止生产陷立即停止生产B. 组装线设计组装线设计Contin

8、uedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouU型线 U - Shaped LineContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouB. 组装线设计组装线设计ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou直型线 Str

9、aight Line时间标记 Timing mark指挥棒交接区 Baton-pass Zone123412345当产品结构和物料展示能够保证时使用当产品结构和物料展示能够保证时使用Used when product configuration and material presentation warrant例如，汽车组装线例如，汽车组装线 e.g., automobile assembly生产线的速度由产品的移动速度决定生产线的速度由产品的移动速度决定 Line paced by product movement随时掌握装配进展随时掌握装配进展 Assembly progression o

10、n line已经设立了工人区已经设立了工人区 Worker zones are established已经定义了交接区已经定义了交接区(交接指挥棒交接指挥棒) Overlap (baton passing) is defined按使用次序安排物料按使用次序安排物料 Material is sequenced in order of use柔性生产时柔性生产时 For mixed-model production非整合分装非整合分装(预装预装)按配套供料按配套供料Non-integrated sub-assemblies are supplied as completed kits必须建立信息与

11、反馈系统必须建立信息与反馈系统Communication and feedback must be established例如喇叭例如喇叭 灯号灯号 e.g., speaker, lightsContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou有有喂料喂料”的直型线的直型线 Straight Line With FeedersMajorsubassemblyLine 主分装线一人单元 1-operator Cell两人单元2-operator Cell当进行柔性生产，分

12、装线周期时间会出现重大变化时，使用此类生产线。Used when a subassembly cycle time exhibits major variations in a mixed-model production environmento将会出现这种重大变化的分装线从总装线中分离出来Shifts the subassembly experiencing the wide variation off the main assembly line 总装线上设有“节拍器” “Pacemaker” established on final assembly lineo例如，生产线按节拍时间连

13、续移动i.e., continuous movement of the line at the takt time rate总装线 “拉动”分装线 Final assembly “pulls” from subassemblyo分装线的工作与总装线分开 Subassembly work separated from final assembly work o适应产品的变化 Facilitates product variationo在生产支线/生产单元完成分装工作 Subassemblies completed on “spur” line / cello例如，附属于总装线的生产支线/生产单元

14、 i.e., attached to main lineo分装线在需要使用零件的地方才介入总装线 Subassemblies enter at point of use从后面供应物料 Material supplied from backo多人的分装线单元要放在“背后”，因为分装线的输出是以其它零件和物料一样的方式，供应给总装线的。Multi-operator sub-assembly cell is on the “back”, since its output is presented to the main line operators just like other parts and

15、 materials.按使用次序安排物料 Materials sequenced in order of useContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou开放式平行线布局 Parallel (Open Room) Layout 需求大High demand 节拍时间短Shorter takt time 两个工人2 operators 单元单元1 Cell 1434352526161RMFGRMFG单元单元2 Cell 2434352526161RMFGRMFG

16、 需求小Low demand 节拍时间长Longer takt time 一个工人1 operator ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou开放式布局举例 Open Room Layout Example熔铅炉熔铅炉 Lead Pot盒子盒子 Boxes箱子箱子 Carton铸造铸造DieCastWIP on Shelves架上半成品架上半成品Pallets of Boxes卡板卡板Pallets of lead slugsCarts of lead w

17、heel Weights铅轮配重车铅轮配重车铅胚卡板铅胚卡板ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou123487651234876512348765新的工区布局新的工区布局New Work Area Layout铸造铸造Die Cast熔铅炉熔铅炉Lead Pot输送带输送带 Conveyors盒子盒子 Boxes箱子箱子Carton新的单元新的单元布局布局New Cell Layout开放式布局举例 Open Room Layout ExampleCont

18、inuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou典型工位 Typical Workstation2. 工位设计Work Station Design ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou工位设计目标 Work Station Design Objectives 减少各种浪费Minimize waste 缩短操作员周期时间Minimiz

19、e operator cycle time 保证产品质量Ensure good parts produced 能处理多工序Enable multi-process handling 建立目视工场Establish a visual workplace 支持及时生产原理支持及时生产原理 Support JIT PrinciplesContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou工位设计原理 Work Station Design Principles 标准化作业Sta

20、ndard operations 适当面积Appropriate size 零件排列Part arrangement 工具标准化Tool standardization 工具放置Tool placement 目视控制Visual controls 工人走动Operator motions 质量控制Quality controls 物料补充Replenishment ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou供料高度：供料高度：1500mm工作区域工作区域 :

21、900 to 1000 mm工作平台的高度工作平台的高度空料箱从工位下方返回空料箱从工位下方返回仅需部件：仅需部件：-照明灯具照明灯具-多孔插座多孔插座-文件架文件架-站脚站脚-电源电源按供料顺序，从前按供料顺序，从前方适量供料：方适量供料：1-2小时小时模块化和可连接的模块化和可连接的工位设计方便拆装工位设计方便拆装线体线体工作平台，使用工工作平台，使用工具简单、明确具简单、明确B. 组装线设计组装线设计 精益精益工位ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzho

22、u物料补充系统说明Material Replenishment System Comments 线上展示物料供给系统A line stock supply system for material presentation 线上送料员物料补充系统A water spider system for material resupply 物料储存超市系统A supermarket for material storage ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou物料

23、展示 Material Presentation 工人周期时间过长Excessive operator cycle time o 装配顺序错误 Assembly in wrong sequenceo 零件方向装错 Assembly with wrong part orientation 装配产品质量不良Defective assemblieso 零件丢失 Missing parto 用错零件 Wrong part installedo 零件用对了，但却装错了 Right part, but installed incorrectly 做错产品Wrong product built Contin

24、uedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou物料展示 Material Presentation 减少工人周期时间变动减少工人周期时间变动Minimize operator cycle time variationo 按使用顺序放零件Arrange parts in order of useo 按正确方向放零件Present parts in proper orientationo 按工人易拿取放零件Make parts easily accessible to the o

25、perator 减少工位物料存量减少工位物料存量Minimize material at the work station 有利于标准化作业有利于标准化作业，保证产品质量保证产品质量Enable standard operations ando 零件定位Consistent part locationo 零件定向Consistent part orientationo 零件定序Presentation sequence consistent with assembly sequence 容易补充物料容易补充物料, 不会影响工人不会影响工人Make replenishment easy &

26、; non-intrusiveo 供料不打扰、不影响工人操作Non-intrusive replenishment means that resupply doesnt interfere with or obstruct the operator.o 从生产单元外面或线后供料Resupply parts from outside the cell or behind the line 良好人机工程状态良好人机工程状态Establish good operator ergonomics o 不用弯腰 伸腰 扭腰或高举No bending, stretching, twisting, or li

27、fting.o 良好的人机工程消除了工人过多的动作、提高了生产力Good ergonomics also benefit productivity by eliminating the waste of excessive operator motions 设计原理设计原理 Design PrinciplesContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou线上双箱系统 Two - Bin System (Line Stock)空箱退回下面空箱退回下面Empty bi

28、nsReturned Below当一个箱子空了时，按灯会亮，表明需要补充第二个箱子了当一个箱子空了时，按灯会亮，表明需要补充第二个箱子了As one bin is emptied, an andon signal indicates the need for a second bin to be provided.每个箱子最多只能装两个小时的物料每个箱子最多只能装两个小时的物料Each bin contains at most one hours worth of parts.给空箱子补充物料，重新使用这些箱子给空箱子补充物料，重新使用这些箱子 Empty bins are refilled

29、and reused.最适合如下装配作业：最适合如下装配作业：Best used when the assembly operation has:o产品型号不多产品型号不多 A low number of modelso零件品种不多零件品种不多 Lesser part varietyo节拍时间较短节拍时间较短 A low takt timeo换模次数不多换模次数不多 A low number of setupsContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料

30、配送物料配送ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料配送物料配送工位送料设计工位送料设计(59”) - 1500 mm150 mm(6”)(31”) - 800 mm大件、重件、频大件、重件、频繁搬运区繁搬运区Zone recommended for frequent handling of heavy and bulky parts*可接受搬运区，可接受搬运区， 2 2次次/ /分钟分钟Zone acceptable for handling tw

31、ice / minute费力搬运区费力搬运区Arduous zone费力搬运区费力搬运区Arduous zoneContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料配送物料配送 取料取料/ /取箱空间取箱空间Space available for picking up containers or partsr E1 = E2 = 100 mm (4”)搬运料箱最小空间搬运料箱最小空间minimum for handling containers, r E1 =

32、150 mm (6”)从料箱内取料空间从料箱内取料空间if parts are to be picked up from inside containers. 最大取料深度最大取料深度“P” “P” Maximum pick-up depth P r 300 mm (12”) 需考虑料架厚度需考虑料架厚度with respect to shelf edge. 最小取料高度最小取料高度Minimum height r频繁搬运的物料频繁搬运的物料/ /料箱勿放地上料箱勿放地上dont place parts or containers to be frequently handled on the

33、 floor, r如必要，留出足够弯腰频繁搬运空间如必要，留出足够弯腰频繁搬运空间if necessary, leave enough space to crouch when lifting them. E2E1E2E2料架上的标准料箱料架上的标准料箱Standard containers on shelvesP工位送料设计工位送料设计ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou配套供料系统 Kitting System 何谓配套零件? Whats a par

34、ts kit? o“配套零件”就是生产一个产品所需的全部零件，它被准时化送达组装线A “kit” consists of all the parts needed to produce one unit, which is delivered to the assembly line “just in time”. 它的优点何在? What are the advantages? o有利于保证质量 Helps ensure qualityo建立生产线顺序 Establishes line sequencing 何时使用配套零件? Whens a kit used? o产品型号较多 A high

35、er number of modelso零件品种较多 (一套零件将全部展示给工人) Greater part variety (the kit displays all the parts needed to the operator)o节拍时间较长 A higher takt time (use “kit” above 7 as rule of thumb)o换模次数较多 A higher number of setupsContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenz

36、hou物料补充 Material Resupply 何谓线上送料员(水蜘蛛)? Whats a water spider?o线上送料员是专职的物料搬运人士，他根据标准化作业，及时地给生产单元补充物料A water spider is a dedicated material handler who replenishes a cell JIT, according to standard operations. 线上送料员如何工作? What does a water spiders work look like?o 线上送料员按特定的送料路径走动，从主供应点拿取物料，送到生产线上的存货供应点

37、A water spider follows a specific replenishment route, picking up materials from a main supply point and delivering them to the line stock supply points 为何要线上送料员? Why have a water spider? o好处好处 Benefits 快速地 稳定地给生产线提供物料Provides constant, rapid replenishment of material to the line 免除装配工人搬运物料之劳，提高装配工人

38、的效率，实现标准化作业Improves assembler efficiency by eliminating material handling from assembler tasks, enabling standard operations. 建立物料供应标准化作业，改善产品质量Improves quality by establishing standard work for material resupply线上送料员线上送料员(水蜘蛛) 系统系统 Water Spider SystemContinuedNagoya Shanghai Guangzhou Tianjin Hangz

39、hou Suzhou Wuxi Qingdao Chongqing Wenzhou线上送料员工具线上送料员工具 Water Spider Tools分料车分料车 Picking Cart分料单分料单 Pick List超市超市 Supermarket分料箱分料箱 Picking Container线上物料供应线上物料供应Line Stock Supply物料补充 Material ResupplyContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou线上送料员标准化作业线

40、上送料员标准化作业Water Spider Standard Operations物料补充 Material ResupplyContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou步骤1:确定工位标准化作业Step 1:Determine workstation standard operations步骤2:识别待送零件Step 2:Identify parts to be delivered步骤3:制定物料展示系统Step 3:Create material prese

41、ntation system步骤4:做好分料箱 / 配套箱Step 4:Create picking container(s) or kits步骤5:设计及制定线上送料员分料车和分料单Step 5:Design & create water spider picking cart & picking list步骤6:设计及建造超市Step 6:Design & build supermarket实施线上送料员系统实施线上送料员系统Implementing a Water Spider System 物料补充 Material ResupplyContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou物料补充 Material Resupply改善推动人 / 早期接受者Kaizen champion / early