單元式生產(chǎn)布局CELL

1、ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou單元式生產(chǎn)布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou議程 Agenda1.傳統(tǒng)組裝線設(shè)計Traditional Assembly Line Design2.工位設(shè)計 Work Station Design 3.物料展示 Material Presentation 4.物料補

2、充 Material Resupply 5.物料儲存 Material Storage ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou1.傳統(tǒng)組裝線設(shè)計 Traditional Assembly Line Design 物料儲存物料儲存MaterialStorage-quality problems 懸掛式電動輸送帶懸掛式電動輸送帶 Powered & free conveyor物料儲存物料儲存 MaterialStorage-QP物料儲存物料儲存Mate

3、rialStorage-QP物料儲存物料儲存MaterialStorage-QP物料儲存物料儲存 MaterialStorage-quality problems ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou精益生產(chǎn)系統(tǒng)組裝線模式特點Lean Production System Assembly Line Model Characteristics 工人靈活Flexible operators(multiprocessing and cross-trained)

4、 走動方便Freedom of movement (standing +moving operations) 標準化作業(yè)Standard operations(assembly only, Water spiders+standard operations) 目視化工場Visual workplace(A place for everything, everything in its place) 最少線上存貨Minimal line stock(no mini-w/h, max.2-h Line stock) 柔性生產(chǎn)Flexible production(variations in eit

5、her mix or volume , No islands!) 節(jié)拍器Pacemakers(Lines incorporate pacemakers to set pace to TT, not to self-pacing) 保證質(zhì)量Quality ensured(go or no go, 3 Nos) ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou組裝線布局的目的 Assembly Layout Goals 按照節(jié)拍時間, 生產(chǎn)優(yōu)質(zhì)產(chǎn)品Quality pro

6、ducts produced at takt time 有效利用人力Productive utilization of people 裝配工只做裝配Assemble product only 按節(jié)拍分配任務(wù)達到高生產(chǎn)力High operator productivity through loading to takt time 工人能完成整個流程Operator to complete the full process 物料/工人流暢Flow of material and operators 優(yōu)化工位以方便擺放零件 物料 工具Work stations optimized for prese

7、ntation of parts, materials, and tools 工位設(shè)計減少走動Work station design minimizes operator movements 信息即時反饋Immediate flow of information / feedback 問題立即暴露Immediately expose problems ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouU型線 U - Shaped Line 原料原料 RM 成品成品 F

8、G按燈 Andon最少走動最少走動工人間的平衡工人間的平衡避免產(chǎn)生孤島避免產(chǎn)生孤島多工序作業(yè)多工序作業(yè)促進溝通促進溝通按燈識別異常按燈識別異常WS負責所有物料需求負責所有物料需求o從從“U” 型線外送料型線外送料o取走成品取走成品節(jié)拍變，你也變節(jié)拍變，你也變o人員安排可以應(yīng)變?nèi)藛T安排可以應(yīng)變Im water spider. Were operators. ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou線體設(shè)計線體設(shè)計: 物流從右至左物流從右至左線體設(shè)計線體設(shè)計:

9、每條槽每條槽里放里放2個料箱個料箱 線體設(shè)計線體設(shè)計 :工具伸手可及工具伸手可及線體設(shè)計線體設(shè)計: 所有料箱都放所有料箱都放置于工位前方置于工位前方線體設(shè)計線體設(shè)計:模塊化和模塊化和可連接的工位設(shè)計可連接的工位設(shè)計線體設(shè)計線體設(shè)計:空料箱空料箱從料架下方回收從料架下方回收線體設(shè)計線體設(shè)計: 預(yù)留預(yù)留30% 的工位空間的工位空間線體設(shè)計線體設(shè)計: 工作工作區(qū)間距區(qū)間距 1.6米米線體設(shè)計線體設(shè)計: 工作臺高度工作臺高度0.81.2米米 (人機工程人機工程)線體管理線體管理 : 過道里不過道里不許放料箱許放料箱為方便車間目視化為方便車間目視化和溝通和溝通: 建議料架高建議料架高度不超過度不超過1.

10、5米米線體管理線體管理 : 禁止訂單在缺少禁止訂單在缺少零配件的情況下進行生產(chǎn)零配件的情況下進行生產(chǎn)線體管理：本獨立工作線體管理：本獨立工作單元中操作工的數(shù)量單元中操作工的數(shù)量（18人）人）目視化及目視化及5S管理管理:例：例：劃線并確定相關(guān)貨架劃線并確定相關(guān)貨架占地面積占地面積線體設(shè)計：最大偏差為線體設(shè)計：最大偏差為 20% 拉動信號拉動信號: 目視化和在制品控制目視化和在制品控制防錯防錯 : 一旦發(fā)現(xiàn)缺一旦發(fā)現(xiàn)缺陷立即停止生產(chǎn)陷立即停止生產(chǎn)B. 組裝線設(shè)計組裝線設(shè)計ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi

11、 Qingdao Chongqing WenzhouU型線 U - Shaped LineContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouB. 組裝線設(shè)計組裝線設(shè)計ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou直型線 Straight Line時間標記 Timing mark指揮棒交接區(qū) Baton-pass Zone123412345

12、當產(chǎn)品結(jié)構(gòu)和物料展示能夠保證時使用當產(chǎn)品結(jié)構(gòu)和物料展示能夠保證時使用Used when product configuration and material presentation warrant例如，汽車組裝線例如，汽車組裝線 e.g., automobile assembly生產(chǎn)線的速度由產(chǎn)品的移動速度決定生產(chǎn)線的速度由產(chǎn)品的移動速度決定 Line paced by product movement隨時掌握裝配進展隨時掌握裝配進展 Assembly progression on line已經(jīng)設(shè)立了工人區(qū)已經(jīng)設(shè)立了工人區(qū) Worker zones are established已經(jīng)定義了交

13、接區(qū)已經(jīng)定義了交接區(qū)(交接指揮棒交接指揮棒) 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柔性生產(chǎn)時柔性生產(chǎn)時 For mixed-model production非整合分裝非整合分裝(預(yù)裝預(yù)裝)按配套供料按配套供料Non-integrated sub-assemblies are supplied as completed kits必須建立信息與反饋系統(tǒng)必須建立信息與反饋系統(tǒng)Communication and feedback must be establi

14、shed例如喇叭例如喇叭 燈號燈號 e.g., speaker, lightsContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou有有喂料喂料”的直型線的直型線 Straight Line With FeedersMajorsubassemblyLine 主分裝線一人單元 1-operator Cell兩人單元2-operator Cell當進行柔性生產(chǎn)，分裝線周期時間會出現(xiàn)重大變化時，使用此類生產(chǎn)線。Used when a subassembly cycle time

15、 exhibits major variations in a mixed-model production environmento將會出現(xiàn)這種重大變化的分裝線從總裝線中分離出來Shifts the subassembly experiencing the wide variation off the main assembly line 總裝線上設(shè)有“節(jié)拍器” “Pacemaker” established on final assembly lineo例如，生產(chǎn)線按節(jié)拍時間連續(xù)移動i.e., continuous movement of the line at the takt time

16、 rate總裝線 “拉動”分裝線 Final assembly “pulls” from subassemblyo分裝線的工作與總裝線分開 Subassembly work separated from final assembly work o適應(yīng)產(chǎn)品的變化 Facilitates product variationo在生產(chǎn)支線/生產(chǎn)單元完成分裝工作 Subassemblies completed on “spur” line / cello例如，附屬于總裝線的生產(chǎn)支線/生產(chǎn)單元 i.e., attached to main lineo分裝線在需要使用零件的地方才介入總裝線 Subassem

17、blies enter at point of use從后面供應(yīng)物料 Material supplied from backo多人的分裝線單元要放在“背后”，因為分裝線的輸出是以其它零件和物料一樣的方式，供應(yīng)給總裝線的。Multi-operator sub-assembly cell is on the “back”, since its output is presented to the main line operators just like other parts and materials.按使用次序安排物料 Materials sequenced in order of useC

18、ontinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou開放式平行線布局 Parallel (Open Room) Layout 需求大High demand 節(jié)拍時間短Shorter takt time 兩個工人2 operators 單元單元1 Cell 1434352526161RMFGRMFG單元單元2 Cell 2434352526161RMFGRMFG 需求小Low demand 節(jié)拍時間長Longer takt time 一個工人1 operator Conti

19、nuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou開放式布局舉例 Open Room Layout Example熔鉛爐熔鉛爐 Lead Pot盒子盒子 Boxes箱子箱子 Carton鑄造鑄造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 wheel Weights鉛輪配重車鉛輪配重車鉛胚卡板鉛胚卡板ContinuedNagoya Shanghai Gu

20、angzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou123487651234876512348765新的工區(qū)布局新的工區(qū)布局New Work Area Layout鑄造鑄造Die Cast熔鉛爐熔鉛爐Lead Pot輸送帶輸送帶 Conveyors盒子盒子 Boxes箱子箱子Carton新的單元新的單元布局布局New Cell Layout開放式布局舉例 Open Room Layout ExampleContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wu

21、xi Qingdao Chongqing Wenzhou典型工位 Typical Workstation2. 工位設(shè)計Work Station Design ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou工位設(shè)計目標 Work Station Design Objectives 減少各種浪費Minimize waste 縮短操作員周期時間Minimize operator cycle time 保證產(chǎn)品質(zhì)量Ensure good parts produced 能處

22、理多工序Enable multi-process handling 建立目視工場Establish a visual workplace 支持及時生產(chǎn)原理支持及時生產(chǎn)原理 Support JIT PrinciplesContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou工位設(shè)計原理 Work St

23、ation Design Principles 標準化作業(yè)Standard operations 適當面積Appropriate size 零件排列Part arrangement 工具標準化Tool standardization 工具放置Tool placement 目視控制Visual controls 工人走動Operator motions 質(zhì)量控制Quality controls 物料補充Replenishment ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing We

24、nzhou供料高度：供料高度：1500mm工作區(qū)域工作區(qū)域 : 900 to 1000 mm工作平臺的高度工作平臺的高度空料箱從工位下方返回空料箱從工位下方返回僅需部件：僅需部件：-照明燈具照明燈具-多孔插座多孔插座-文件架文件架-站腳站腳-電源電源按供料順序，從前按供料順序，從前方適量供料：方適量供料：1-2小時小時模塊化和可連接的模塊化和可連接的工位設(shè)計方便拆裝工位設(shè)計方便拆裝線體線體工作平臺，使用工工作平臺，使用工具簡單、明確具簡單、明確B. 組裝線設(shè)計組裝線設(shè)計 精益精益工位ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzh

25、ou Wuxi Qingdao Chongqing Wenzhou物料補充系統(tǒng)說明Material Replenishment System Comments 線上展示物料供給系統(tǒng)A line stock supply system for material presentation 線上送料員物料補充系統(tǒng)A water spider system for material resupply 物料儲存超市系統(tǒng)A supermarket for material storage ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou

26、Wuxi Qingdao Chongqing Wenzhou物料展示 Material Presentation 工人周期時間過長Excessive operator cycle time o 裝配順序錯誤 Assembly in wrong sequenceo 零件方向裝錯 Assembly with wrong part orientation 裝配產(chǎn)品質(zhì)量不良Defective assemblieso 零件丟失 Missing parto 用錯零件 Wrong part installedo 零件用對了，但卻裝錯了 Right part, but installed incorrectl

27、y 做錯產(chǎn)品Wrong product built ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou物料展示 Material Presentation 減少工人周期時間變動減少工人周期時間變動Minimize operator cycle time variationo 按使用順序放零件Arrange parts in order of useo 按正確方向放零件Present parts in proper orientationo 按工人易拿取放零件Make

28、parts easily accessible to the operator 減少工位物料存量減少工位物料存量Minimize material at the work station 有利于標準化作業(yè)有利于標準化作業(yè)，保證產(chǎn)品質(zhì)量保證產(chǎn)品質(zhì)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 容易補充物料容易補充物料, 不會影響工人不會

29、影響工人Make replenishment easy & non-intrusiveo 供料不打擾、不影響工人操作Non-intrusive replenishment means that resupply doesnt interfere with or obstruct the operator.o 從生產(chǎn)單元外面或線后供料Resupply parts from outside the cell or behind the line 良好人機工程狀態(tài)良好人機工程狀態(tài)Establish good operator ergonomics o 不用彎腰 伸腰 扭腰或高舉No bend

30、ing, stretching, twisting, or lifting.o 良好的人機工程消除了工人過多的動作、提高了生產(chǎn)力Good ergonomics also benefit productivity by eliminating the waste of excessive operator motions 設(shè)計原理設(shè)計原理 Design PrinciplesContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou線上雙箱系統(tǒng) Two - Bin System

31、(Line Stock)空箱退回下面空箱退回下面Empty binsReturned Below當一個箱子空了時，按燈會亮，表明需要補充第二個箱子了當一個箱子空了時，按燈會亮，表明需要補充第二個箱子了As one bin is emptied, an andon signal indicates the need for a second bin to be provided.每個箱子最多只能裝兩個小時的物料每個箱子最多只能裝兩個小時的物料Each bin contains at most one hours worth of parts.給空箱子補充物料，重新使用這些箱子給空箱子補充物料，重

32、新使用這些箱子 Empty bins are refilled and reused.最適合如下裝配作業(yè)：最適合如下裝配作業(yè)：Best used when the assembly operation has:o產(chǎn)品型號不多產(chǎn)品型號不多 A low number of modelso零件品種不多零件品種不多 Lesser part varietyo節(jié)拍時間較短節(jié)拍時間較短 A low takt timeo換模次數(shù)不多換模次數(shù)不多 A low number of setupsContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wu

33、xi Qingdao Chongqing WenzhouC.物料配送物料配送ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料配送物料配送工位送料設(shè)計工位送料設(shè)計(59”) - 1500 mm150 mm(6”)(31”) - 800 mm大件、重件、頻大件、重件、頻繁搬運區(qū)繁搬運區(qū)Zone recommended for frequent handling of heavy and bulky parts*可接受搬運區(qū)，可接受搬運區(qū)， 2 2次次/ /分鐘分

34、鐘Zone acceptable for handling twice / minute費力搬運區(qū)費力搬運區(qū)Arduous zone費力搬運區(qū)費力搬運區(qū)Arduous zoneContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料配送物料配送 取料取料/ /取箱空間取箱空間Space available for picking up containers or partsr E1 = E2 = 100 mm (4”)搬運料箱最小空間搬運料箱最小空間minimum

35、for handling containers, r E1 = 150 mm (6”)從料箱內(nèi)取料空間從料箱內(nèi)取料空間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”) 需考慮料架厚度需考慮料架厚度with respect to shelf edge. 最小取料高度最小取料高度Minimum height r頻繁搬運的物料頻繁搬運的物料/ /料箱勿放地上料箱勿放地上dont place parts or containers

36、 to be frequently handled on the floor, r如必要，留出足夠彎腰頻繁搬運空間如必要，留出足夠彎腰頻繁搬運空間if necessary, leave enough space to crouch when lifting them. E2E1E2E2料架上的標準料箱料架上的標準料箱Standard containers on shelvesP工位送料設(shè)計工位送料設(shè)計ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou配套供料系統(tǒng) Ki

37、tting System 何謂配套零件? Whats a parts kit? o“配套零件”就是生產(chǎn)一個產(chǎn)品所需的全部零件，它被準時化送達組裝線A “kit” consists of all the parts needed to produce one unit, which is delivered to the assembly line “just in time”. 它的優(yōu)點何在? What are the advantages? o有利于保證質(zhì)量 Helps ensure qualityo建立生產(chǎn)線順序 Establishes line sequencing 何時使用配套零件?

38、Whens a kit used? o產(chǎn)品型號較多 A higher number of modelso零件品種較多 (一套零件將全部展示給工人) Greater part variety (the kit displays all the parts needed to the operator)o節(jié)拍時間較長 A higher takt time (use “kit” above 7 as rule of thumb)o換模次數(shù)較多 A higher number of setupsContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Su

39、zhou Wuxi Qingdao Chongqing Wenzhou物料補充 Material Resupply 何謂線上送料員(水蜘蛛)? Whats a water spider?o線上送料員是專職的物料搬運人士，他根據(jù)標準化作業(yè)，及時地給生產(chǎn)單元補充物料A water spider is a dedicated material handler who replenishes a cell JIT, according to standard operations. 線上送料員如何工作? What does a water spiders work look like?o 線上送料員按

40、特定的送料路徑走動，從主供應(yīng)點拿取物料，送到生產(chǎn)線上的存貨供應(yīng)點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 為何要線上送料員? Why have a water spider? o好處好處 Benefits 快速地 穩(wěn)定地給生產(chǎn)線提供物料Provides constant, rapid replenishment of material

41、 to the line 免除裝配工人搬運物料之勞，提高裝配工人的效率，實現(xiàn)標準化作業(yè)Improves assembler efficiency by eliminating material handling from assembler tasks, enabling standard operations. 建立物料供應(yīng)標準化作業(yè)，改善產(chǎn)品質(zhì)量Improves quality by establishing standard work for material resupply線上送料員線上送料員(水蜘蛛) 系統(tǒng)系統(tǒng) Water Spider SystemContinuedNagoya

42、Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou線上送料員工具線上送料員工具 Water Spider Tools分料車分料車 Picking Cart分料單分料單 Pick List超市超市 Supermarket分料箱分料箱 Picking Container線上物料供應(yīng)線上物料供應(yīng)Line Stock Supply物料補充 Material ResupplyContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qing

43、dao Chongqing Wenzhou線上送料員標準化作業(yè)線上送料員標準化作業(yè)Water Spider Standard Operations物料補充 Material ResupplyContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou步驟1:確定工位標準化作業(yè)Step 1:Determine workstation standard operations步驟2:識別待送零件Step 2:Identify parts to be delivered步驟3:制定物料

44、展示系統(tǒng)Step 3:Create material presentation system步驟4:做好分料箱 / 配套箱Step 4:Create picking container(s) or kits步驟5:設(shè)計及制定線上送料員分料車和分料單Step 5:Design & create water spider picking cart & picking list步驟6:設(shè)計及建造超市Step 6:Design & build supermarket實施線上送料員系統(tǒng)實施線上送料員系統(tǒng)Implementing a Water Spider System 物料補充 Material ResupplyContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Su