精益生产之快速换线技巧.ppt

Change 4 tires 换4个轮子 Top off the fuel tank 加满油箱 Adjust the air wing 调整空气囊保护 Check the on-board computer 检查车上计算机 Give the driver a drink 给驾驶员一听饮料 Standardized method for a pit stop 标准化的停车方法 Elements of quick change are applied throughout 快速更换方法贯穿整个过程 A place for everything and everything in its place 所需要的工具随手可得 Things that can be done ahead of time 提前做好准备 Benefit for Setup Time Reduction减少换模时间的好处 We can produce more, because we have added capacity 我们可生产更多，因为我们增加了产能 We can lower inventory levels and save the money associated with inventory 我们可减少库存和与库存有关的资金 We can approach the goals of flow manufacturing: 我们可达到流动制造的目标 Make only what is required 只生产需要的产品 Make it when it is required 只是在需要的时候生产 Zero finished goods inventory 零成品库存 1 piece lot sizes 单件批量生产 6 Steps To Reduce Setup Time降低换模时间的6个步骤 Select cross-functional team 组成跨部门的团队 2. Observe complete set up 观察整个当前换模过程 3. Separate external from internal elements 将外部和内部换模的部分离开 4. Convert internal to external elements 尽可能的将内部换模的部分转移到外部换模 5. Streamline all aspects of the setup 优化所有的换模动作的顺序 6. Standardize set up procedure 标准化换模过程 Step 1: Select the team组建团队 Kaizen Team: Ideal Size - (6-8 People) 最好6~8人 Hourly operators from all three shifts 来自不同班次的操作工 Someone from “outside” the process 与此过程无关的人 Mfg Engineering representation 制造工程师的代表 Other Technical resource(s) as appropriate 其他相关的技术支持 Step 2: Observe the complete set up观察整个过程 Step 3: Separate internal from external elements 将内部和外部的动作区分开 Which are external and internal?哪些是外部和内部的动作 Putting the tires in the pit 将轮胎放到现场 Taking the old tires off the car 换下旧轮胎 Refueling the car 给赛车加油 Bringing the fuel line to the pit 将加油管拿到现场 Getting a beverage for the driver 给驾驶员一听饮料 Jacking up the car 将赛车顶起来 Step 4: Convert internal to external elements尽可能的将内部换模的部分转移到外部换模 This is the most