精益生產(chǎn)之快速換線技巧.ppt

1、Quick Changeover (SMED) 快速換型,2,An Indy 500 pit crew will do :F1 方程式賽車(chē)快速更換,Change 4 tires 換4個(gè)輪子 Top off the fuel tank 加滿油箱 Adjust the air wing 調(diào)整空氣囊保護(hù) Check the on-board computer 檢查車(chē)上計(jì)算機(jī) Give the driver a drink 給駕駛員一聽(tīng)飲料,All in 13 seconds!,3,We can learn from the pit crew我們從中學(xué)到了什么？,Standardized method

2、 for a pit stop 標(biāo)準(zhǔn)化的停車(chē)方法 Elements of quick change are applied throughout 快速更換方法貫穿整個(gè)過(guò)程 A place for everything and everything in its place 所需要的工具隨手可得 Things that can be done ahead of time 提前做好準(zhǔn)備,We can apply these ideas to our manufacturing environment,4,Benefit for Setup Time Reduction減少換模時(shí)間的好處,We ca

3、n produce more, because we have added capacity 我們可生產(chǎn)更多，因?yàn)槲覀冊(cè)黾恿水a(chǎn)能 We can lower inventory levels and save the money associated with inventory 我們可減少庫(kù)存和與庫(kù)存有關(guān)的資金 We can approach the goals of flow manufacturing: 我們可達(dá)到流動(dòng)制造的目標(biāo) Make only what is required 只生產(chǎn)需要的產(chǎn)品 Make it when it is required 只是在需要的時(shí)候生產(chǎn) Zero f

4、inished goods inventory 零成品庫(kù)存 1 piece lot sizes 單件批量生產(chǎn),5,6 Steps To Reduce Setup Time降低換模時(shí)間的6個(gè)步驟,Select cross-functional team 組成跨部門(mén)的團(tuán)隊(duì) 2. Observe complete set up 觀察整個(gè)當(dāng)前換模過(guò)程 3. Separate external from internal elements 將外部和內(nèi)部換模的部分離開(kāi) 4. Convert internal to external elements 盡可能的將內(nèi)部換模的部分轉(zhuǎn)移到外部換模 5. Strea

5、mline all aspects of the setup 優(yōu)化所有的換模動(dòng)作的順序 6. Standardize set up procedure 標(biāo)準(zhǔn)化換模過(guò)程,Repeat steps 2-6 until goal is met 重復(fù)以上步驟直到達(dá)到目標(biāo),6,Step 1: Select the team組建團(tuán)隊(duì),Kaizen Team: Ideal Size - (6-8 People) 最好68人 Hourly operators from all three shifts 來(lái)自不同班次的操作工 Someone from “outside” the process 與此過(guò)程無(wú)關(guān)的人

6、 Mfg Engineering representation 制造工程師的代表 Other Technical resource(s) as appropriate 其他相關(guān)的技術(shù)支持,7,Step 2: Observe the complete set up觀察整個(gè)過(guò)程,Definition: Set up time is the time from the last good piece with old tools to the first good piece with new tools 定義換模時(shí)間：是指從舊模的最后合格件到新模的第一個(gè)合 格件的時(shí)間 Watch and writ

7、e down every activity that happens 觀察并記錄所有的活動(dòng) Record a video of the process for the team to review 錄像換模的整個(gè)過(guò)程，用來(lái)回顧 Build a process map that defines the current state 建立反映當(dāng)前狀況的流程圖,8,Step 3: Separate internal from external elements 將內(nèi)部和外部的動(dòng)作區(qū)分開(kāi),External activities are those that can be accomplished whi

8、le the machine is running 外部動(dòng)作是指當(dāng)即機(jī)器在運(yùn)轉(zhuǎn)時(shí)就能完成的動(dòng)作 Move material for the next job to the machine 將下個(gè)工作需要的材料移到及其附近 Retrieve prints, control plans, and documentation for the next job 準(zhǔn)備好下一個(gè)工作需要的圖紙，控制計(jì)劃和文件 Move tooling next to the machine 將模具移到及其附近 Internal activities are those that can only be done while

9、 the machine is down 內(nèi)部動(dòng)作是指只有把機(jī)器停下來(lái)才可以做的動(dòng)作 The physical changing of tooling 實(shí)際更換模具的動(dòng)作,9,Which are external and internal?哪些是外部和內(nèi)部的動(dòng)作,Putting the tires in the pit 將輪胎放到現(xiàn)場(chǎng) Taking the old tires off the car 換下舊輪胎 Refueling the car 給賽車(chē)加油 Bringing the fuel line to the pit 將加油管拿到現(xiàn)場(chǎng) Getting a beverage for th

10、e driver 給駕駛員一聽(tīng)飲料 Jacking up the car 將賽車(chē)頂起來(lái),-External,-Internal,-Internal,-External,-External,-Internal,10,Step 4: Convert internal to external elements盡可能的將內(nèi)部換模的部分轉(zhuǎn)移到外部換模,This is the most critical step in the process 這是再換模過(guò)程中最關(guān)鍵的一步 This step can reduce total set up time by 60-65% 這一步能減少整個(gè)換模時(shí)間的60-65

11、% This step is based on operational improvement, not equipment improvement 這一步是依賴于操作的改進(jìn)，而不是設(shè)備的改進(jìn) Prepare all tools applicable 將需要的工具準(zhǔn)備好 Bring tools to convenient locations 將工具放在最方便的位置 Eliminate transportation of heavy items (dies and punches) 消除沉重物品的轉(zhuǎn)移（注塑模） Whenever possible, prestage tools, materia

12、ls, and dies for next job while the current job is running 在機(jī)器運(yùn)轉(zhuǎn)時(shí)，盡可能的提前為下一個(gè)工作將工具，材料和工裝準(zhǔn)備好,11,What does Step 4 do for us?第步作了什么,Machine Down,Machine Start,Time Line,Internal,External,Current,12,Step 5: Streamline all aspects of the set up process優(yōu)化所有的換模動(dòng)作的順序,For everything that remains internal, ide

13、ntify process improvements to make the internal elements quicker 對(duì)內(nèi)部換型的操作，識(shí)別出改進(jìn)的地方是內(nèi)部換模更快 Eliminate nuts and bolts 消除螺栓和螺母的緊固動(dòng)作 Introduce quick change tools 引進(jìn)快速更換的工具 Standardize 標(biāo)準(zhǔn)化 Eliminate adjustments 消除調(diào)整 For the external activities, focus on reducing the time that is lost searching for set up

14、hardware and set up information 對(duì)外不換型的操作，集中在由于尋找換型所需的硬件和信息所浪費(fèi)的時(shí)間上 Consolidate paperwork into one document 將紙面工作匯總在一個(gè)文件上 Mark dies with color codes and location numbers for where they are stored 在存放模具的地方對(duì)模具用顏色和位置編號(hào)進(jìn)行標(biāo)示,13,What does Step do for us?第步做了什么,Machine Down,Machine Start,Time Line,Internal,External,Current,After Step 4,External,Internal,14,Step 6: Standardize the set up procedure標(biāo)準(zhǔn)化快速換型的過(guò)程,Determine the one correct way to perform the activities 決定正確的方式進(jìn)行快速換模的活動(dòng) Document the standard way in the SOE / OMS 在SOM/OMS建立標(biāo)準(zhǔn)的規(guī)范 Train and Certify all operators