IE的工作職責(zé)及工作方法

1、Industrial Engineering Department,IE Training,Whats IE,IE organization chart,MSD,BOM setup,Preplanning,Flow-Chart / PFMEA,PFP / OBC,WSD,SMED,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 1,Industrial Engineering Department,Whats IE,IE, is,I,nclude,E,verything,I,nvolve,E,veryone,IE,is Industrial Enginee

2、ring,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 2,Industrial Engineering Department,工業(yè)工程簡介,什么是工業(yè)工程,美國質(zhì)量管理權(quán)威朱蘭博士說：美國值,得向全世,界夸耀的東西就是,IE,美國之,所以打勝第一次,世界大戰(zhàn)，又有打勝第,二次世界的力量，就是,美國有,IE,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 3,Industrial Engineering Department,IE-INDUSTRIAL ENGINEERING,工業(yè),工程，簡稱,IE,是世界上公認(rèn)的能

3、,杜絕各種,浪費，有效地提高生產(chǎn)率和經(jīng),濟(jì)效益的把技,術(shù)與管理有機(jī)地結(jié)合起來,的一門邊緣學(xué)科,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 4,Industrial Engineering Department,Industrial Engineering,Definition,Goal,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 5,Industrial Engineering Department,工業(yè)工程的特點,IE,的核心是降低成本，提高質(zhì)量和生產(chǎn),率,IE,是綜合性的應(yīng)用知識體系（技術(shù)和管理,注重人的因

4、素是,IE,區(qū)別于其他工程學(xué)科特點,之,一,IE,是系統(tǒng)優(yōu)化技術(shù),IE,的面向,由微觀向宏觀管理,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 6,Industrial Engineering Department,IE,的意識,成本和效率意識,問題和改革意識,工作簡化和標(biāo)準(zhǔn)化意識,全局和整體化意識,以人為中心的意識,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 7,Industrial Engineering Department,通常,IE,有哪些方法呢,方法研究：尋求完成任何工作的最經(jīng)濟(jì),合理的方法，達(dá)到減少

5、人員、機(jī)器、無,效動作和消耗，并使方法標(biāo)準(zhǔn)化,作業(yè)測定：制定用經(jīng)濟(jì)合理的方法完成,工作所需的時間標(biāo)準(zhǔn)，達(dá)到減少人員,機(jī)器設(shè)備的空閑時間,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 8,Industrial Engineering Department,方法研究內(nèi)容包括,1,程序分析,2,操作分析,3,動作分析,4,路線分析,作業(yè)測定內(nèi)容包括,1,秒表時間研究,2,工作抽樣,3,預(yù)定時間標(biāo)準(zhǔn)法,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 9,Industrial Engineering Department,IE

6、,分析過程的四大原則,1,取消,Eliminate,2,合并,Combine,3,重排,Rearrange,4,簡化,Simplify,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 10,Industrial Engineering Department,Whats IE,IE organization chart,MSD,BOM setup,Preplaning,Flow-Chart / PFMEA,WSD,PFP / OBC,SMED,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 11,Industrial E

7、ngineering Department,IE,的組織架構(gòu),是按項目分類的,Engineering,Manager,Lee Cheng,Industrial,Engineering,manager,Terry Wang,ME no missing;no mixed material,correct identification and quality,Raw material receiv,ing instructions,2)GZMMW4.15-1.3 Material,storage on racks working instruction,GZMMW4.15-1.10 Producti

8、on area,material distribution instruction,1)cutting plan,4,24,Mov,e material from warehouse to CuttingTube cutting Area; Final Assembly Area;lead,prepare area,correct /not damaged material, not mixed material,10,15,5,printing code on cable,cut lead and crimping,font clear and correct print location,

9、correct,CCH,CCW,pull force; correct cable square,length,color,correct terminal,2)GZENGW4.2-1.0014 PSA,wire coding instruction,3)GZENGW4.2-1.0007 Operation,instruction of Komax,Vs1,VPS#PSA02,6,inspect cut lead(including terminal) bundle,7,8,Wrap and mov,e cut lead to rack,wrapping in correct qty., co

10、rrect Kanban number,correct KanBan number, good appearance,CuttingPlan / VPS,Buggy plan,PREPA,RED BY: Xu Jun,VERIFIED BY: Kevin Liu,A,PPROVED BY:Sam Tian,DA,TE: 12/12/2002,DA,TE: 12/12/2002,DA,TE: 12/12/2002,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 23,Industrial Engineering Department,PFMEA,Potent

11、ial Failure Mode and Effects Analysis(Process FMEA,Identifies potential product related process failure modes,Assesses the potential customer effects of the failures,Identifies the potential manufacturing or assembly process,causes and identifies process variables on which to focus controls,for occu

12、rrence reduction or detection of the failure conditions,Develops a ranked list of potential failure modes, thus,establishing a priority system for corrective action considerations,Documents the results of the manufacturing or assembly process,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 24,Industrial

13、Engineering Department,POTENTIA,L,FA,ILURE MODE A,ND EFFECTS A,NA,LYSIS,PROCESS FMEA,RESTRICTED,Item,9641203280,9644025380,9640949380,Moddel Year/Vehicle 2003 Peugeot -T1MUX-IP,Core team,Process Responsibility Industry Engineering Dept/ MFG Dept,Key Date,05-25-02,FMEA Number FM-PSA-MY03IP-04,Prepare

14、d By Xu Jun(IE,FMEA Date(Orig) 05-9-02,REV)/ 3-10-03,Kevin Liu(IE).X,u jun(IE).Daniel Zong.(IE).ZhiyongCai(QA).Barbara Lin(QA).Guohua Ye(MFG).X,u Jing Li(MFG).Bruce Nie(Material).Harry Chen(PE).Qingping Wang(ME,Item,Potential,Potential,Failure,effect(s) Of,Failure,Circuit not operative,Loss of funct

15、ion,Loss of function,Loss of circuit function,6) Short circuit (8,S,e,v,function,Mode,Wrong material,C,l,a,s,s,Potential,Cause(s,Mechanism,s) of Failure,Material confusion,O,c,c,u,r,2,Current Process,Controls,Material label . Operater read,label . Self,control. QC,audit,Material label .self control,

16、Self control. Electric check,holder.Inspector check, QC,audit,D,e,t,e,c,2,R,P,N,24,Action Results,Recommend,Responsibility,Actions,S,O,D,e,c,e,Target,v,c,t,u,e,Completion,r,c,ed Action(S,Date,Taken,R,P,N,6,Damage material,26: Connectors,assembly,Damaged,connector,6,8,Wrong mounting,Wrong operation,s

17、upplier mistake,2,4,2,2,24,64,Feedback to,04/20/02,supplier; Training,operators,Reinforce quality,check to raw,material,Feedback,8,to supplier,Training,operators,Reinforce,quality,check to,raw material,2,2,32,Missing,connector,Use of wrong,connector,Loss of function (6,6,Wrong operation,1,26: Second

18、ary,Lock and cover,assembly,improper,dimmension of,connectors on,branches,Missing Sec,lock,Unseated terminals,cover,Loss of function,Loss of function (6,Assembly,impossibility(6,difficult to assemble on,car,6,Wrong operation,carelessness,holder loosed,improper board,layout,carelessness,2,6,1,Self co

19、ntrol. Electric check,control.Inspector check, QC,audit,Self control. Electric check,holder.Inspector check, QC,audit,Self control. .Inspector check,QC audit,1,6,2,24,2,12,6,4,Self control. Electric check,control.Inspector check, QC,audit,1,24,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 25,Industrial

20、 Engineering Department,Whats IE,IE organization chart,MSD,BOM setup,Preplaning,Flow-Chart / PFMEA,WSD,PFP / OBC,SMED,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 26,Industrial Engineering Department,Whats,WSD,W,ork,S,tandard,D,ata is a tool for calculating standard,work time of wiring harness,Whats,W

21、SD,used for,Quotation,Labor estimate,Line balance,What types of,WSD,do we use,European,WSD,AP,WSD,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 27,Industrial Engineering Department,Example: European WSD,SUB,OPERATION,GET & BUILD CONNECT,TO BOARD,1 - 6 WAY (to V-Pin,Incl.Terminal/Molded Parts,6 WAY 40 W

22、AY,To Conn Holder,/ = 40 WAY,To Conn Holder,GET & ROUTE WIRES,DOUBLE WIRES TO BE,CONSIDERED WIRES,INDIVIDUALLY,PER CONN,WIRE LENGHT,UP to 1000 mm,1001 - 2000 mm,2001 - 3000 mm,3001 - 4000 mm,4001 - 5000 mm,5001 - 6000 mm,6001 - 7000 mm,7001 - 8000 mm,8001 - 9000 mm,9001 - 11000 mm,11001 - 13000 mm,1

23、3001 - 15000 mm,PLUG TERMINAL TO,CONNECTOR,UN-SEALED,SEALED,JELLY SEALED,PER CONN,PER CONN,CODE,PARAMETERS,CODE,FINAL ASSEMBLY STANDARDS,STD,TIME,mins/100,QTY. PER,HARNESS,TOTAL,TIME,mins/100,PLANT,EQUIPMENT USED,PROCESS DESCRIPTION,2.59,6.05,9.08,0.00,0.00,0.00,EQUIP. PARAMETERS,CLOCK STARTING POIN

24、T,CLOCK FINISH POINT,SIGNIFICANT ISSUES,REMARKS,PLANT,5.28,8.06,10.55,21.64,27.93,32.91,47.54,57.01,69.91,87.24,107.93,129.01,0.00,0.00,0.00,0.00,0.00,0.00,0.00,0.00,0.00,0.00,0.00,0.00,EQUIPMENT USED,EQUIP. PARAMETERS,CLOCK STARTING POINT,CLOCK FINISH POINT,SIGNIFICANT ISSUES,REMARKS,PLANT,EQUIPMEN

25、T USED,4.27,6.77,9.36,0.00,0.00,0.00,EQUIP. PARAMETERS,CLOCK STARTING POINT,CLOCK FINISH POINT,SIGNIFICANT ISSUES,REMARKS,FI,NAL,ASSEM,BLY,STANDARDS,SU,B,O,PER,A,TI,O,N,C,O,D,E,PA,R,A,M,ETER,S,C,O,D,E,STD,TI,M,E,m,i,ns,100,Q,TY,PER,H,A,R,N,ESS,TO,TA,L,TI,M,E,m,i,ns,100,P,LA,N,T,E,Q,U,I,P,M,E,N,T,U,S

26、,E,D,PR,O,C,ESS,D,ESC,R,I,PTI,O,N,LO,C,K,C,O,N,N,EC,TO,R,S,SEC,LO,C,K,O,R,C,O,VER,A,TTA,C,H,E,D,LO,O,S,E,P,I,E,C,E,P,E,R,P,I,E,C,E,P,E,R,P,I,E,C,E,2,27,5,44,0,00,0,00,E,Q,U,I,P,P,A,R,A,M,E,TE,R,S,C,LO,C,K,S,TA,R,TI,N,G,P,O,I,N,T,C,LO,C,K,FI,N,I,S,H,P,O,I,N,T,Updated: 11/08/2004 Owner: Bob.Zheng,Page

27、: 28,Industrial Engineering Department,Example: AP WSD,ASIA PACIFIC BUDGET HOUR CALCULATION,PROJECT,PART NO,DATE,ESTIMATOR,BRD. SIZE.,VOLUME,Pcs. / Year,SET UP,Cuts/Day,REV. LEVEL,Description,Occur,FINAL ASSEMBLE,1,ASM 1- 6 Way Conn. To V-Pin (Get And Start,2,ASM 1- 6 Way To Conn. Holder (Get And St

28、art,3,ASM 7- 40 Way To Conn. Holder (Get And Start,BUILDING,Get & Build Connector To Board & Release,4,ASM 40+ Way To Big Conn. Holder (Get And Start,5,Build Washer Hose,6,Apply Gasket To Conn,7,ASM Small Screw To Conn,8,ASM Screw To Conn,9,Punch Holes In Cable Seal,10,ASM Cable Seal,Page: 29,Update

29、d: 11/08/2004 Owner: Bob.Zheng,Industrial Engineering Department,Whats IE,IE organization chart,MSD,BOM setup,Preplaning,Flow-Chart / PFMEA,WSD,PFP / OBC,SMED,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 30,Industrial Engineering Department,PFP,P,eople,F,ocused,P,ractice,PEOPLE FOCUSED PRACTICE CHART,

30、Analyst(s,Kevin Liu,Plant/Dept,Delphi Packard Guangzhou,Product,PSA-IP,Description,Customer,Peugeot,Note,To renumber rows after inserting a new row(s), copy the contents of the last,correct number down to the newly inserted row(s) and also the next row with,the now incorrect number,Work Element,DESC

31、RIPTION OF OPERATOR WORK,ID,1,2,12,BE11,XE24, 9004&9005,12,1,6, 8,10,12,8,296,295,8,4,6,8,8?296?295?8?4?6?8#,3#,9004B,9005B,3#?3,4,3,4,5,6,7,8,9,627586?636148,8,296,295,8,4,6,8,9,MC30E,9005A&9004A,9,8,4,17,9,628425,AE07,310?1#,2#?,(?),13,VE12,8101,8053,8110,13,1,2,3,5,12,Part Number,9,6,4,1,2,0,3,2,

32、8,0,9,6,4,4,0,2,5,3,8,0,9,6,4,0,9,4,9,3,8,0,Element Time,Operato,r,Machine,Wait for,Time,Time,Cycle,36.7,20.7,X,X,26.7,24.0,12.0,11.0,X,X,X,X,37.5,5.0,6.0,36.1,40.8,X,9.3,Page: 31,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,X,Updated: 11/08/2004 Owner: Bob.Zheng,Industrial Engineering Department,OBC,O,per

33、ator,B,alance,C,hart,Operator Balance Chart,Project,PSA-IP-9641203280,Planned Line Speed,82.2,Date,25-Dec-01,Improvement,opportunities,Op ,1,2,3,4,5,6,7,OPERATION NAME,Station 1A,Station 2A,Station 3A,Station 1,Station 2,Station 3,Station 4,Operator,Time,Wait For,Cycle,OPERATOR,TOTAL,Planned,Line Sp

34、eed,81.4,78.6,82.1,77.6,77.2,77.7,79.5,0.8,3.6,0.1,4.6,5.0,4.5,2.7,82.2,82.2,82.2,82.2,82.2,82.2,82.2,82.2,82.2,82.2,82.2,82.2,82.2,82.2,90.0,80.0,70.0,60.0,50.0,40.0,30.0,20.0,10.0,0.0,S,t,a,t,i,o,S,t,n,1,A,a,t,i,o,S,t,n,2,A,a,t,i,o,n,S,t,3,A,a,t,i,o,S,t,n,1,a,t,i,o,S,t,n,2,a,t,i,o,S,t,n,3,a,t,i,o,

35、n,4,TOTAL TIME,575.4,Page: 32,Updated: 11/08/2004 Owner: Bob.Zheng,Industrial Engineering Department,Whats IE,IE organization chart,MSD,BOM setup,Preplaning,Flow-Chart / PFMEA,WSD,PFP / OBC,SMED,Updated: 11/08/2004 Owner: Bob.Zheng,Page: 33,Industrial Engineering Department,SMED,S,ingle,M,inutes,C,hange,D,ie,Quick