單元生產(chǎn)方式(cell)全面講解

Cell生產(chǎn)方式簡介IE：王紅日期：2009/12/102021/5/91目錄1.Cell的基本概念2.CellLine的優(yōu)點3.CellLine的基本布線規(guī)則4.單件流2021/5/921.每個細(xì)胞均具有獨立功能

2.可與其他單元任意組合

3.自主性/靈活性

4.細(xì)胞間活動協(xié)調(diào)一致1Cell的基本概念(1)～它代表著創(chuàng)造性與靈活性!!!～1.1Cell:“單元/細(xì)胞”的意思2021/5/931.如同蜜蜂群的組織分工

2.如同蜜蜂群的團(tuán)結(jié)合作

1Cell的基本概念(2)1.2Cell:“蜂窩”的意思～它代表著TeamWork的概念!!!～2021/5/94AAAABBCCCC1.增加產(chǎn)線靈活性(型號、產(chǎn)量、布局）2.庫存降低3.可依實際訂單決定開幾條線(彈性)4.后工序等待時間減少5.可快速換線(插入急單)AAAABBCCCC以機器設(shè)備為導(dǎo)向AAAABB’CCCCBB’以生產(chǎn)流程為導(dǎo)向優(yōu)點：2CellLine的優(yōu)點2.1同步化生產(chǎn)2021/5/951.換線容易(減少延誤工時)2.減少因線不平衡帶來的損失3.便于保養(yǎng)小型、低成本、低速、功能有限大型﹑高速﹑高效率2.2設(shè)備小型化優(yōu)點：2021/5/961.生產(chǎn)率提升2.工序的前置時間改善3.減少生產(chǎn)中的工作量4.減少因線不平衡帶來的損失5.品質(zhì)提升6.人員的減少多項作業(yè)操作ＩＪＫＬＡＢＣＤＥＦＧＨＡＢＣＤＥＦＧＨＡＢＣＤＥＦＧＨＩＪＫＬＩＪＫＬ單一作業(yè)操作ＡＢＣＤＥＦＬＫＪＩＨＧ2.3多能工的培養(yǎng)優(yōu)點：多能工2021/5/97Before1.按需生產(chǎn)2.生產(chǎn)排程的靈活性增強3.多機種混合生產(chǎn)4.換線容易5.小批量生產(chǎn)After2.4彈性（靈活）排程優(yōu)點：2021/5/981.節(jié)省取放材料的時間2.控制WIPABCD1.A工序做完后材料無須送往下一工序,由B工序同事來??；2.有用到工裝的站別，通常該工序員工只負(fù)責(zé)上工裝，做完后由下一站員工負(fù)責(zé)下工裝,(測試站別無人化操作)。2.5拉式生產(chǎn)方式優(yōu)點：～從上一工序拉(PULL)而非傳送下一工序(PUSH)～2021/5/99

1.生產(chǎn)排程的靈活性增強2.換線容易(減少延誤工時)3.作業(yè)員之間的溝通更容易、有效4.品質(zhì)提升5.制程的前置時間改善6.減少制程中的工作量7.減少因線不平衡帶來的延誤8.作業(yè)員責(zé)任明確直線觀念（流水線生產(chǎn)系統(tǒng)）細(xì)胞線觀念從左往右3CellLine的基本布線規(guī)則3.1站立、從左往右優(yōu)點：2021/5/9103.2人在內(nèi)轉(zhuǎn)時?；仡櫥?021/5/911CPCPCPCP600/天300/天300/天夠小夠精夠活3.3cell越小越好2021/5/9121.不落地生根傳統(tǒng)觀點認(rèn)為設(shè)備越大效率越高，通常將設(shè)備固定在地面而無法移動。設(shè)備不能移動，自然缺乏彈性，也就失去了改進(jìn)布置、應(yīng)對市場變化的能力。3.4架線的三不政策(1)改采設(shè)備小型化或設(shè)備可動化。管線不像常青藤2021/5/913設(shè)備“寄居”在固定的管、線及中央式裝置之下而無法移動。3.4架線的三不政策(2)2.不寄人籬下放棄中央式設(shè)施,改采用分離式設(shè)備如：快速接頭、彈性接口。~設(shè)備要像快餐車~2021/5/9141.品質(zhì)提升2.WIP減少3.前置時間減少4.消除搬運離線

隨線

工序2切勿離線作業(yè),只能以“主流,支流”的概念進(jìn)行站別布置!3.4架線的三不政策(3)3.不離群索居（INLINE）優(yōu)點：工序1工序2工序2工序1工序2工序2工序22021/5/915一筆畫布置3.5工廠一筆畫布置～工廠/生產(chǎn)流程在整體上呈一筆畫布置～2021/5/9161234IO一致原則1234空手走動浪費InputOutputInputOutput

生產(chǎn)投入點與完成品取出點盡可能靠近，以避免作業(yè)返程造成的時間和體力浪費。3.6生產(chǎn)線U形化(1)IO一致原則同樣適用于設(shè)備布置，亦可節(jié)省空間占用。2021/5/9171.以U字型布置方式按工藝流程排列生產(chǎn)。2.入口和出口盡量由同一作業(yè)者負(fù)責(zé)，能夠以產(chǎn)距時間按標(biāo)準(zhǔn)數(shù)量進(jìn)行生產(chǎn)及管理，也便于補充生產(chǎn)。3.便于作業(yè)者相互協(xié)作，異常時能停線，及時暴露問題并改善之。4.步行最短，可單件流動，人員可增可減。12345

81413121171096成品材料3.6生產(chǎn)線U形化(2)2021/5/918各站產(chǎn)出狀況數(shù)量111111111111111111111111111111111111站1站2站3站4站5站6平常堆貨的生產(chǎn)模式,每站看似都很忙,也能一直保障3pcs的產(chǎn)出,所以看不到線平衡的問題…單件流(站6只需要1pcs)的拉動式生產(chǎn)模式可輕易看到線平衡的問題…我只要1pcs4單件流2021/5/919單件流真的能節(jié)約時間嗎?時間會不會變長?單件流到底有什么好處? 我們可以通過下面動畫,看到傳統(tǒng)堆貨生產(chǎn)&單件流的不同(某個包含3站的產(chǎn)品)。面對單件流的疑問?2021/5/920傳統(tǒng)堆貨生產(chǎn)15811692171031811419125201362114700:00A站B站C站21pcs產(chǎn)品2021/5/92115811692171031811419125201362114700:01A站B站C站21pcs產(chǎn)品傳統(tǒng)堆貨生產(chǎn)2021/5/9221582169171031811419125201362114700:02A站B站C站21pcs產(chǎn)品1傳統(tǒng)堆貨生產(chǎn)2021/5/9231583169171011811419125201362114700:03A站B站C站21pcs產(chǎn)品2傳統(tǒng)堆貨生產(chǎn)2021/5/9241584169171021811119125201362114700:04A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9251585169171031811219121201362114700:05A站B站C站21pcs產(chǎn)品4傳統(tǒng)堆貨生產(chǎn)2021/5/9261586169171031811219121201352114700:06A站B站C站21pcs產(chǎn)品4傳統(tǒng)堆貨生產(chǎn)2021/5/9271587169171031811219121201352114600:07A站B站C站21pcs產(chǎn)品4傳統(tǒng)堆貨生產(chǎn)2021/5/9281587169171031811219121201352114600:08A站B站C站21pcs產(chǎn)品4傳統(tǒng)堆貨生產(chǎn)2021/5/9291597168171031811119122201352114600:09A站B站C站21pcs產(chǎn)品4傳統(tǒng)堆貨生產(chǎn)2021/5/9301510716917811811219123201352114600:10A站B站C站21pcs產(chǎn)品4傳統(tǒng)堆貨生產(chǎn)2021/5/9311511716917821810319124201352114600:11A站B站C站21pcs產(chǎn)品1傳統(tǒng)堆貨生產(chǎn)2021/5/9321512716917831810419115201312114600:12A站B站C站21pcs產(chǎn)品2傳統(tǒng)堆貨生產(chǎn)2021/5/9331512716917831810419115201312114600:13A站B站C站21pcs產(chǎn)品2傳統(tǒng)堆貨生產(chǎn)2021/5/9341513616917831810419117201212114500:14A站B站C站21pcs產(chǎn)品2傳統(tǒng)堆貨生產(chǎn)2021/5/9351513616917831810419117201212114500:15A站B站C站21pcs產(chǎn)品2傳統(tǒng)堆貨生產(chǎn)2021/5/9361613615917831810419117201212114500:16A站B站C站21pcs產(chǎn)品2傳統(tǒng)堆貨生產(chǎn)2021/5/9371613615101782189319117201212114500:17A站B站C站21pcs產(chǎn)品4傳統(tǒng)堆貨生產(chǎn)2021/5/9381613615111882179419107201212114500:18A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9391613615121982179518107201112114400:19A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9401612515132082179618107191112114400:20A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9411612515142182179718106191112013400:21A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9421612515142182179718106191112013400:22A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9431512516142182179718106191112013400:23A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9441512516142182179718106191112013400:24A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9451512516142182179718106191112013400:25A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9461512516142182179718106191112013400:26A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9471512516142182179718106191112013400:27A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9481512516142182179718106191112013400:28A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9491512516142182179718106191112013400:29A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9501512516142182179718106191112013400:30A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9511512516142182179718106191112013400:31A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9521512516142182179718106191112013400:32A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9531512516142182179718106191112013400:33A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9541512516142182179718106191112013400:34A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9551512516142182179718106191112013400:35A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/9561512516142182179718106191112013400:36A站B站C站21pcs產(chǎn)品3傳統(tǒng)堆貨生產(chǎn)2021/5/95715811692171031811419125201362114700:00A站B站C站21pcs產(chǎn)品單件流2021/5/95815811692171031811419125201362114700:01A站B站C站21pcs產(chǎn)品單件流2021/5/9591582169171031811419125201362114700:02A站B站C站21pcs產(chǎn)品1單件流2021/5/9601583169171011811419125201362114700:03A站B站C站21pcs產(chǎn)品2單件流2021/5/9611584169171021811119125201362114700:04A站B站C站21pcs產(chǎn)品3單件流2021/5/9621585169171031811219121201362114700:05A站B站C站21pcs產(chǎn)品4單件流2021/5/9631586169171041811319122201312114700:06A站B站C站21pcs產(chǎn)品5單件流2021/5/9641587169171051811419123201312114200:07A站B站C站21pcs產(chǎn)品6單件流2021/5/9651587169171051811419123201312114200:08A站B站C站21pcs產(chǎn)品6單件流2021/5/9661587169171051811419123201312114200:09A站B站C站21pcs產(chǎn)品6單件流2021/5/9671587169171051811419123201312114200:10A站B站C站21pcs產(chǎn)品6單件流2021/5/9681587169171051811419123201312114200:11A站B站C站21pcs產(chǎn)品6單件流2021/5/9691587169171051811419123201312114200:12A站B站C站21pcs產(chǎn)品6單件流2021/5/9701587169171051811419123201312114200:13A站B站C站21pcs產(chǎn)品6單件流2021/5/9711587169171051811419123201312114200:14A站B站C站21pcs產(chǎn)品6單件流2021/5/9721587169171051811419123201312114200:15A站B站C站21pcs產(chǎn)品6單件流2021/5/9731587169171051811419123201312114200:16A站B站C站21pcs產(chǎn)品6單件流2021/5/9741587169171051811419123201312114200:17A站B站C站21pcs產(chǎn)品6單件流2021/5/9751587169171051811419123201312114200:18A站B站C站21pcs產(chǎn)品6單件流2021/5/9761587169171051811419123201312114200:19A站B站C站21pcs產(chǎn)品6單件流2021/5/9771587169171051811419123201312114200:20A站B站C站21pcs產(chǎn)品6單件流2021/5/978158716917105181141912320