SMED快速换模（培训课件）

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ASTRATEGYFORPERFORMANCEEXCELLENCESMED(OneStepSetup)Set-upandchangeoverreductionsforequipment,toolingandmachines.2ExecutiveOverviewParticipantmanualToolsWorkbookKnowledgeBreakthroughLecturenotesLecturenotesPerformanceExcellenceSeriesTrainingModuleElements3 Session1.0 Introduction…….……...…...4 Session2.0 WasteManagement……….12 Session3.0 SetupPractices……………..22 Session4.0 Traditional/StrategicSetupApproach……29 Session5.0 SMEDImplementationPlanning………….34 Element5.1 ImplementationTeam………36 Element5.2 ImplementationPlan……….37 Element5.3 CommunicationPlan……….38 Element5.4 TrainingPlan……………….40 Element5.5 OneStepSetup……………..42 Element5.5.1 SeparateInternalfromExternalSetup……44 Element5.5.2 IntegratingInternalintoExternalSetup….49 Element5.5.3 ReducingSetupProcessingTime………….63 Element5.5.4 OptimizingSetupProcesses………………..92 Element5.6 Verification&Standardization……………95 Session6.0 Summary……105TableofContentsKnowledgeBreakthroughSMED4SMEDisContinuousImprovementItisacustomerdrivenrequirement.Customersaredemanding: Productandservicediversity Lowercosts Higherreliabilityandquality.Inessenceorganizationsneedtobecomeleaner!Soorganizationsmust: Producesmallerlots,morefrequently. Expandthescopeanddiversityofproductsand services. Reducequalitydefects.5Ultimately,SMEDfocusesonreducingchangeoverandset-uptimes,thusenablingorganizationsto:Producesmallerlotsofproductsandservicesmorefrequently!Developabroaderscopeofproductsandservices!Reducequalitydefectstowardszero!MeetCustomer’sExpectations!6WhatDoesSet-up/changeoverreductionmeanformybusiness?

Increasedcustomerservicelevelsandprofits!ViaWasteEliminationresultingin:ReducedLeadTimes-FasterDeliveryZeroInventories-ReducedWorkingCapitalImprovedQualityImprovedSafetySmallerlotsofproducts-flexibilityDiversifiedProduct&ServiceOptions7Toeliminatethewastesthatresultfrom“uncontrolled”processesincreasinginventoriesandleadtimes..Togaincontrolonequipment,material&inventory.ApplyControlTechniquestoEliminateErosionofImprovements.StandardizeImprovementsforMaintenanceofCriticalSet-upParameters.LookFamiliar?WhySMED?8Major CPI Tools (6s) KaizenLean DescriptionCp/Cpk 4 ProcesscapabilityassessmentDOE 4 DesignofexperimentsSPC 4 ProcesscontrolbasedonstatisticsanddataanalysisFMEA 4 RiskassessmenttoolRegression 4 CorrelateeffectonevariablehasonanotherProcessMap 4

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4 Mapprocessstepstocommunicateandidentifyopportunities5whys/2hows444DeterminationmethodsforrootcausediscoveryPareto 4

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4 ColumnchartrankingitemshighesttolowestFishbone 4

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4 Cause/EffectDiagram5S 4

4 EliminationwasteVisualMgmt 4 4

4 EmphasisonvisualtechniquestomanageprocessPoka-Yoke 4

4 ErrorproofingtechniquesSpaghettiChart 4

4Kanban 4

4 MaterialstoragetechniqueusedtocontrolprocessTaktTime 4

4 DeterminepaceorbeatofaprocessStdWork 4

4 EvaluatetasksdoneduringaprocessSMED 4

4 Singleminuteexchangeofdies-QuickmachinesetupTPM 4 IntegratemaintenancestrategywithprocessCellularFlow 4 Reduceinventory&cycletimethroughprocesslayoutandpull productiontechniques ExpandProcessImprovementProgramtoUtilizeKaizenToolKitToolKitComparison9Identifywhattypesofinternalandexternalsetuptimesareinvolvedinthefollowingpictures.PictureA:WireCuttingMachinePictureB:MetalStampingMachine10Identifywhattypesofinternalandexternalsetup×areinvolvedinthefollowingpictures.PictureA:WireCuttingMachinePictureB:MetalStampingMachine________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________SetupTypeSetupTypeTime(Min)Time(Min)ThinkBreak11InternalExternalSetupClassifyThreeitemsundereachitemcategory.

ExternalInternal________________________________________________________________________WhichitemswouldyouconvertfrominternaltoexternalSetup?________________________________________________________________________________________________________Why?________________________________________________________________________________________________________ThinkBreak12TraditionalSetupPracticesMaterialmovementoccursafterthemachineisturnedoff.Detectionofdefectsormissingequipmentisnoticedwhichthemachineisrunning.Defectivetooling,fixtures,setupinstrumentsarenoticedafterthemachineisturnedon.Completedproductsaretransferredtonextoperation.Rawmaterialismovedafterthemachineisstopped.Setuptoolingdeliveredafterthechangeoverhasbegun.Defectiveproductidentifiedafterinternalsetuphasbegun.Theoperatornoticesthatequipmentismissingafterinternalsetuphasbegun.13Preparation-Ensuresthatallthetoolsareworkingproperlyandareintherightlocation.Mounting&Extraction-Involvestheremovalofthetoolingaftertheproductionlotiscompletedandtheplacementofthenewtoolingbeforethenextproductionlot.EstablishingControlSettings-Settingalltheprocesscontrolsettingspriortotheproductionrun.Inclusiveofcalibrationsandmeasurementsneededtomakethemachine,toolingoperateeffectively.FirstRunCapability-Thisincludesthenecessaryadjustments(re-calibrations,additionalmeasurements)requiredafterthefirsttrialpiecesareproduced.SetupImprovement-Thetimeafterprocessingduringwhichthetooling,machineryiscleaned,identified,andtestedforfunctionalitypriortostorage.5“Traditional”SetupStepsDefined14“Traditional”SetupResourceConsumptionAnalysis15Examplesofwastesinatraditionalsetup!Whatkindof“setupwastes”canyouidentifyinthispictures?________________________________________________________________________________________________________________________________________________________________________ThinkBreak16SeparateInternalfromExternalSetupOptimizingSetupProcessesIntegrateInternalintoExternalSetupReductionofSetupProcessesOneStepSetupImplementationPlanProgressiveEnhancementsStep2DevelopSpecificImplementationPlanStep3DevelopCommunicationPlanStep4DevelopOneStepSetupTrainingPlanStep5ImplementOneStepSet-upStep6Verification/StandardizationStep1DevelopOneStepSetupImplementationTeam17Phase2CombiningequipmentfunctionalityInvolvesstandardizingtheequipment(parts,tooling,processes)basedoncommonalitybetweensetupstoreducethenumberofsetupstepsandcycletimes.

Thecommonsetuppartswereidentifiedandrepl