精益生产推行之快速切换.ppt

1、,Quick Changeover Overview 快速切换概述,JCMS University Level 101 Core Concepts,QCO WSP - 6/25/03,2,Course Objectives 课程目标,Relate Quick Changeover (QCO) to level production. 将快速改革（QCO）与水平生产联系起来 Describe the differences between internal and external changeover time. 描述内部与外部制度改革时间的差异 Identify the eight stag

2、es of Quick Changeover (per process poster). 确认快速改革的八个步骤（每个步骤的海报）,QCO WSP - 6/25/03,3,Definition 定义,Quick Changeover is a structured process that: 快速改革是个结构过程用来 Reduces waste 减少浪费 Shortens lead times 减少时间 Improves manufacturing capacity, flexibility, and quality 提高生产能力,灵活性和质量. The goal is to reduce t

3、he time from “last good piece” to “first good piece,” down to customer takt time. 目标把从“最后一个好的零件”到“第一个好的零件”的时间减少至客户的takt时间,QCO WSP - 6/25/03,4,Terms 术语,Quick Changeover utilizes SMED (single minute exchange of dies) philosophy to achieve this. 快速改革利用SMED(硬模的单个分钟交换)理论来实现 Other terms associated with QC

4、O include: 与QCO有关的其他术语包括: Setup Reduction 结构缩减 Quick Die Change 快速硬模改变 Quick Mold Change 快速铸模改变 Cycle Time Reduction 降低循环时间,QCO WSP - 6/25/03,5,Scope 范围,Quick changeover applies to any machine in any part of the business that has more than one job. 快速改革可应用在任何适用于各种商业方面的机器 It is easiest to apply in ba

5、tch operations such as stamping, but welding, assembly, conveyors and office equipment can also benefit. 快速改革应用在成批运作如冲压中比较简单，然而焊接，组装，运输和办公设备也可从中获益。,QCO WSP - 6/25/03,6,JCMS Philosophy JCMS理念,Zero Tolerance for Waste 决不浪费,Stable Production Environment 稳定生产环境,Customer “Pull” Drives Production 客户需求拉动生产

6、,QCO WSP - 6/25/03,7,Quick Changeover Supports 快速改革支持,QCO reduces the following wastes associated with changeover: 快速改革降低以下与改革有关的浪费 Transportation 运输 Inventory 库存 Motion 移动 Waiting 等待 In concert with Total Productive Maintenance and 5S, QCO reduces setup time to the lowest level ( Customer takt time

7、). 与完全生产保养和5s一致,快速改革把起步时间减小到最低.(客户takt时间),Zero Tolerance for Waste决不浪费,QCO WSP - 6/25/03,8,Quick Changeover Supports,QCO improves the repeatability of changeover operations. 快速改革提高改革运作的可重复率 QCO generates confidence that a process will be producing quality parts within “X” minutes of changeover. 快速改革

8、引起相信在“X”分钟的改革内生产质量高的零件的信心 QCO makes it possible to go to “leveled production.” 快速改革使达到稳定的生产成为可能,Stable Production Environment决不浪费,QCO WSP - 6/25/03,9,Leveled Production 稳定的生产,Product,Demand /,Month,Production Timeline,One Month,A,100,B,200,C,300,One Month,Lot Production,Product,Demand /,Half Month,P

9、roduction Timeline,One Month,A,50,B,100,C,150,Half Month,Lot Production,(Smaller Lots),Produce the entire demand for the month in one lot,Produce more than once per month - smaller lots,QCO WSP - 6/25/03,10,Quick Changeover Supports快速改革支持,Quicker changeover means increased flexibility to handle sudd

10、en changes in customer demand. 快速改革意味着提高灵活性来应付客户要求的突然改变 Lot sizes and inventory levels can be reduced with no impact on utilization. 批量大小和库存大小可在对应用无影响的情况下减小. QCO supports “one piece flow” philosophy - the most flexible system available. 快速改革支持“一次流通”理念-现有的最灵活的系统,Customer “Pull” Drives Production客户需求拉

11、动生产,QCO WSP - 6/25/03,11,Waste In Changeover Operations在改革运作中的浪费,Internal Changeover Time Changeover Time = + External Changeover Time,QCO WSP - 6/25/03,12,Definitions 定义,Internal Changeover Time 内部改革时间 Begins when the last good part comes off the current run 开始当最后一个好的零件出现在本轮中 Ends when the first go

12、od (defect free) piece comes off the next run. 结束当第一个好的(没有毛病的)零件出现在下一轮中 Sometimes referred to as “last good to first good”. 从最后一个好的到下一个好的中的时间 During internal changeover time, the machine adds no value to the work piece. 在内部改革时间中,机器对工作部分没有增加值 External Changeover Time 外部改革时间 The time spent by an opera

13、tor carrying out setup procedures for the next run, independent of the machine, while the machine is operating. 操作者实行为下一轮的起步步骤的时间.与运作的机器无关.,QCO WSP - 6/25/03,13,QCO Goals 快速改革目标,Convert Internal to External changeover time. 从内部向外部改革时间转变 Reduce or eliminate External changeover time. 减少或消除外部改革时间,1,2,Q

14、CO WSP - 6/25/03,14,QCO Improvement Process快速改革改善过程,External Setup (Process is Running),Internal Setup (Process is Down),Change from Internal to External,Implement Jigs,Eliminate Adjustment,Improve Internal Setup,Mechanical Improvements,Parallel Operations,Standardization,2,3,4,5,7,6,Meet Goal,Separ

15、ate Internal and External,1,8,QCO WSP - 6/25/03,15,QCO Review QCO回顾,How does quick changeover relate to leveled production? 快速改革如何与稳定生产有关? What is the difference between internal and external changeover time? 内部改革和外部改革时间有何区别? What are the eight stages of quick changeover? 快速改革的八个阶段是什么?,QCO WSP - 6/2

16、5/03,16,QCO Application QCO附加材料,Understand/be able to explain the Quick Changeover process poster. 理解/解释快速改革过程海报 Pick a machine or process and挑选一个机器或流水线然后 Identify external changeover steps.确定外部改变步骤 Identify internal changeover steps.确定内部改变步骤 Identify any actions to convert internal to external.确定从内部向外部改变的任何行动 Identify any actions to reduce waster in the changeover process.确定在改变过程中减少浪费的任何行动,QCO WSP - 6/25/03,17,Additional Resources 附加材料来源,Quick Changeover Curriculum: 快速改革课程 Quick Changeover Overview: 30 minutes 快速改革概述:30分钟 Quick Changeo