通用匈牙利工廠精益生產(chǎn)實(shí)踐

1、Lean Activities & Overview GE Energy HungaryGE Proprietary and Confidential.Lean Implementation 2004-200720032004200520065S Implementation Point Kaizen Shingi AWO Kitting Employee suggestion system Flow Kaizen First “Model Line Kanban New employee suggestion system Lean training 25 pers. 3 “Model Li

2、ne Lean metrics Kaizen Commando Work with supplier Lean training 100 pers. Lean Core TeamLeanVision2007 Foundamentally reconsider operational procesessDeveloping long term lean vision/strategy for each cell Implement Lean assembly lines ITO-OTR process mapping Lean Committee.Suggestion evaluation an

3、d award systemBuilding of Lean CultureCurrent focus - Stator- Combustion- Repair- Facility&MaintenanceNew areas Jenbacher, LM6000 Logistic 14 suggestions/week Support functionsFinance, SourcingHR, IT, BD, EHSEmployee Suggestion System extension in 2007.5S monthly audit and competitionYTD 5S Scoring5

4、S Cap5S Cup handed over by GM.Combustion SMED on C&L cone press machineCombustion Fuel Nozzle Assembly lineCombustion TP 7E-9E mixed model lineStator Diaphragm teething machineStator Nozzle stg2&3 Single Piece FlowStator Shroud Lead time and WIP reduction JenbacherDesign container assembly lineLean

5、Activities .SMED on C&L cone press machine.ObservationResult:- The change over took 175 min- Operators took 245m walk- Second operator needed- Safety issuesOut of 175 min 47 was moved to external Separate internal and external time.Reduce external timeReduce internal time49 min reduction by implemen

6、t Hydraulic pump15 min reduction by locating the press tools next to the machine .Using 3P to design process to change the tool in 10 minutesFixture changer and storageClamp the press dies by screwMove the press dies like one unit .BeforeAfter594New ObservationChanges- Changeover time from 175 min t

7、o 594 sec Walking distance from 245m to 16 m No forklift or crane required Safety issues eliminated.SMED video.Locate shadow board to the console.Fuel Nozzle Assembly line.Job-shop workstationsOne operator assembles one endcoverNo flowOriginal Situation 2004Assembly carts storage takes up spaceBoxin

8、g storage area.Pulse line 2005The Fuel Nozzle operations have been divided into 4 Takt-s.The carts are moving in every 3 hours. Pulse line - Single piece flow 2006 Q2Build single carts to implement single piece flowThe Kits Prepared by warehouse.Flow testFIFO shelves for subassembliesLoad stationJib

9、 craneMoving Line Q3 2006.Chain drivenSafety equipmentsShingi AWO July 2006Material presentationStandard WorkTotal Investment NeedsChain91 USDChain-wheels55 USDBearings 182 USDInfra-red pointers54 USDTOTAL 382 USDKAIZEN means significant resultswith “no costBuilt by ourKaizen TeamCombustionModel Lin

10、e.Moving line video.Pulse LineMoving Line“Gipsy productionSingle Piece Flow LT 20 shiftsMan hours 380 minTurn 17.5LT 12 shiftsMan hours 360 minTurn 50.7LT 6 shiftsMan hours 344 minTurn 90LT 4 shiftsMan hours 300 minTurn TBD80% LT reduction within 2 yearsFuel Nozzle Assembly 2004-2006.TP 7E-9E mixed

11、model line.Process at a glanceComparing 9E and 7E processesOld TP7E and 9E routingsNew TP7 and 9 routingStandardize Oracle routings.Operator Need: 3 fitter 3 welder 1 NDT 1 FPI 1 Milling 1 QualityStandard combination sheet for all operationShared resourcesDefine standard work for each operators on t

12、he line.7E-9E mixed line 7E Fixture transferTP7E welding fixture will not be usedTP7E welding fixtureTP9E welding fixtureTP7E checking fixtureTP9 welding fixture will not be usedTP7E Pressing machine.Improve material flow- Simplify routing steps- Reduce the number of FPI and sizing operations- Using

13、 multi-skilled operators Using mobile fixturing FIFO+Single piece flowBeforeAfter.Kaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsNem tlthat a raktrbl kihozott anyagok mennyisge Az anyagokat kitekben hozza ki a raktrNem kell keresni az anyagokat 10 perc id megtakarits.Ka

14、izen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsAnyag trolsA tl sok anyag a terletenKANBAN rendszer bevezetse kis anyagokraKANBAN krtya a testreKevesebb bepl anyag a terleten.Kaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsKeretoldal kalibralas

15、A klnbz tipusok kszlkei ms helyen vannakA boxok kzs falnak elbontsa.A kszlkek elfrnek az sszenyitott boxban.7E fixture9 Long fixture9 Short fixture.Target:WIP: 35pcs - 8pcsLT: 10days - 4shiftsObservation sheetStd Work CombinationStd Work Sheet.TP 9E Production FlowParadigm change; from job-shop to m

16、ass production- BOM & routing change LPID Implemented Standard Work Sequence Visual Management Redesigned Layout Material presentation, Kitting, Kanban Production boardOperator training matrixBenefitLT Reduction by 65%WIP Reduction by 50% (1.2M USD)11% Labor efficiency improvementSmall Parts Kitting

17、 Main Parts Kitting Replenishment systemE-Production Board.Diaphragm teething machine.Old teething machineStep 1Lift in the 9 E Stg 2 fixture into the machine (10min)Step 2Positioning and Fastening the fixture on the machine (12min)Insert new driver curve (15min)Step 3Step 4Step 5Find the right size

18、 gauge for end switch setup (8 min)Setup the end switches on both side two places (15min)1,5 hours changeover time.Teeth Assy machineDS202m VTLDS20 2m VTLBulard2m VTLFAREL2m VTLThunderMillingThunderMillingCincinattiMillingThunderMillingOSP millingMILLNGTURNINGFixture loading for next turning jobDiap

19、hragm process- The diaphragm parts came from 5 different milling centers - The setup time is 1.5 hrs.Using 3P to design new machine9EStg 2 teething6B Stg 2 prepared on the fixture tableChanging the machine teething diameter to a predefined value : one minuteStep 1Step 2Step 3Predefined values.Before

20、 KaizenAfter Kaizen“U shapearrangement Teeth Kanban.Nozzle stg2&3 Single Piece Flow.Standard work combination sheet for manual operations Products on the Bay 3 production area: 9Est2, 9Est3, 9FAst2, 6Bst2, 6Bst3Calculated Takt Time: 0.8 hours/segment9E stg2 cyclesCycle time vs. T/TKaizen ideas to de

21、sign flow.Before KaizenAfter Kaizen OperationNozzle assemblyProblem DiscriptionNO special screwdriver for air-box screw Action TakenSpecial screwdriver made by operatorsResultShorter cycleSafety toolKaizen activity.Kaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsAssembly

22、No flowRearrange the layoutParallel flow assembly arial.LOCATORBefore KaizenAfter KaizenOperationProblem Actions TakenResultsAssemblyLess waiting timeThe nozzles wait for the last piece to start assembly Small tables implemented to make 3 piece assembly .SET BOOKBefore KaizenAfter KaizenOperationPro

23、blem Actions TakenResultsSet book for millingNozzle assemblySet book for assemblyProduction boardWeekly assembly plan.Diaphragm supermarketMaterial presentationAssembly Kitting Seal Kan-BanAccomplishments.Before KaizenAfter Kaizen OperationNozzle assemblyProblem DiscriptionThe welding KIT-s are far

24、from the welding boots, too many walking and searching Action TakenMove the locators of welding KIT-s closer Kaizen activityResultNo searching, no mess.Extend the flow to milling operationMilling 2Milling 4Milling 1Milling 3WasherAssy4Assy3Assy2Assy1CMMCMMWeld1Weld2Weld3Deb 1Deb 2Deb 3Meas1Meas2Meas

25、3Meas4Milling 2Milling 4Milling 1Milling 3WasherAssy2Assy1CMMCMMWeld1Weld2Deb 1Deb 2Meas1Meas2Meas3Meas4OP1OP1OP2OP2BeforeAfterNo dedicated milling centersLong milling cycle timeLot of WIPRed line 6B, 9E, 9FA second stagesOrange line 6B, 9E, 9FA third stagesLT reduction 30-40%WIP reduced by 50 %.6Bs

26、tg3 and 9Estg3HN02.08-HN02.0498% machine load6Bstg2 and 9Estg2HN02.02-HN02.0375% machine loadTakt time vs Cycle time ANALISYSMove to OP2.Kaizen activityBefore KaizenAfter KaizenOperationProblem Actions TakenResultsNew layoutbay3.Too many assembly tableNew layout implementedClear process.Nozzle stg2&

27、3 Single Piece Flow 2004-2006Single Piece Flow enablers Product lines Dedicated resources- Eliminate quality issues BOM, routing restructuring Process simplification- Redesigned Layout- Production board- Kan-Ban system- Inspection by operatorsBeforeDiaphragm supermarketMaterial presentationAssembly

28、Kitting Seal Kan-BanAfterBenefitIn house manufacturing lead time6B stg2&3 6 shifts9E stg2&3 9 shifts.Shroud Lead time and WIP reduction.SourcingOracle MRP(1 day)PSIOracle MDS(1 day)Prodn Cont.Oracle, MPS Level loading(2 days)Customer- 1 year forecast (rolling)- PO-s for Quarters- S1 Long term foreca

29、st (3 years)- PO 6 month in advanceWeeklyScheduleEvery 6 weeks2 times/ weekITurning 1DrillingMillingAssyOrdersOrdersOXOXCurrent State Map Shroud 7FA stg2 SupplierTurning 2SawPackingDeburr.EDMCleanaingHoneycomb brazing farm inBrazing SupplierSparepart Inventory14d5h1h8h30.5h7.5h39h9.5h49h12hlocator t

30、o stop overproduction0.5d3.5d3.6d0.5d2d0.5d0.5dBatch size reductionI162 hrs JOB in 28 days50% of the total LT is OSP1d3d1dAfter.Before KaizenAfter KaizenImplement production board and locators for each milling machine.SourcingOracle MRP(1 day)PSIOracle MDS(1 day)Prodn Cont.Oracle, MPS Level loading(

31、2 days)Customer- 1 year forecast (rolling)- PO-s for Quarters- S1 Long term forecast (3 years)- PO 6 month in advanceWeeklyScheduleEvery 2 weeks2 times/ weekITurning 1DrillingMillingAssyOrdersOrdersOXOXCurrent State Map Shroud 7FA stg2SupplierTurning 2SawPackingDeburr.EDMCleanaingSparepart Inventory

32、2d5h1h8h30.5h7.5h39h9.5h49h12h0.5d2d2d0.5d0.5d0.5dI162 hrs JOB in 15 days13 days reduction46% reduction1d3d1dBrazingwelding8h8h1dAfterBatch size reduction.Design container assembly line.Takt Time and assembly stations- Yearly demand 170-180- Available Working time 50w x 5d x 7hrs = 1750 hrsTakt time

33、 = 1750 hrs180= 10 hrs Total assembly time 320 hrs before test (without preparations) 3,5 operators can work at the same time on one unit420 JGC 3mAssembly stations = 320 hrs / 3.5T/T 10 hrs= 9 stations.= 320 / 9 =35.5 hrsAverage man hours by stationsAlign sequences to assy. stations 1,.Align sequen

34、ces to assy. stations 2,Checking of parallel activities- locations and compatibility- part handling and lifting requirements .Align sequences to assy. stations 3,189765432.Beam paintingPipe paintingPipe cleaningWater Pipe Welding,pressure check123456789Test benchDisassemblyCleaningPaint repairShippingWorkstations and WIPOutlet box and oil tank preparationControl panel preparationBeam preparationCable preparationEngine preparation.1234567