ANDON-暗灯系统课件

1Principle:ContinuousImprovement

原则：不断改进

Element:29AndonConcept

要素：29暗灯概念

GM-GMSOperatingGuideline

全球制造系统操作指引

29.0AndonSystem

29.0暗灯系统23TableofContents

目录GM-GMSRelationship全球制造体系的内部联系Definition定义Purpose目的CoreRequirements核心要求Benefits益处AndonEnablers暗灯驱动因素ProcessOverview:过程概要

AndonComponents暗灯的组成

AndonPullcordandSwitches暗灯的拉绳和开关

Visual&AudioSignals目视和声音信息

AndonBoards暗灯板

ConveyorLineLayout传动链布局

SystemOperation系统运行

HowtoUsetheAndonSystem如何使用暗灯系统Roles&Responsibilities

角色和责任Summary总结Appendix:References

附录：参考资料Appendix:RevisionLog附录：审核日志4GM-GMSRelationship全球制造体系的内部联系TheGM-GMSOperatingGuideline#29.0AndonSystem,supportstheGM-GMSPrincipleofContinuousImprovementincontributingtotheBusinessGoals.GM-GMS#29.0操作指引“暗灯系统”支持GM-GMS“不断改进”原则，有助于制造系统五个目标的实现5Definition定义TheAndonSystemisanoperationalfloorprocesscontrolsystemthatcanbeactivatedmanuallyorautomaticallytocommunicatetheneedforassistancewhenabnormalconditionsoccur,aswellastocommunicateotherrelevantinformation.暗灯系统是流水线操作过程控制系统，当出现异常状况时，通过手动或自动激活系统来寻求帮助以及交流其他相关的信息。6Purpose目的ThepurposeoftheAndonSystemisto:暗灯系统的目的就是：Empoweroperationstopreventtheoccurrenceorpassingofdefectstothenextprocess.使操作过程能够防止缺陷产生或流入下一道工序。Callforassistancewhenbehindintheworksequenceoranoutofstandardconditionoccurs.当跟不上工作流程或有非标准的状况产生时，寻求帮助。Initiatetheproblemsolvingprocess.促使解决问题流程的实施Drivemanagementandsupportgroupsto“GoandSee”theproblemsonthefloorandtakeaction.推动管理层和支持工段“巡视发现”生产线上的问题并采取行动。Collectdata,identifyingwhereproblemsoccurmostfrequently.搜集数据，识别问题发生最多的地方Communicateoperationalstatusinformation.传递操作中的状态信息7AndonCoreRequirements暗灯核心要求1TheAndonSystem:暗灯系统a)visuallydisplaysrelevantinformationforanyonetoseeandquicklyrecognizetheproblem.

目视化显示相关信息使每个人都看见，并迅速确认问题b)Interlockstotooling,equipmentandmanualactivation和加工工具、设备和手动操作相互关联c)hasthecapabilitytostopthemovinglineprocessattheFPS,exceptinemergencycases

紧急情况下，在固定停止位阻止生产线的移动d)consistsofasinglepullcord/pushbuttonsystem,easilyaccessibletotheoperator

由简单的拉绳/按钮系统组成，方便操作者使用e)directsthesupportorganizationto“GoandSee”theproblems

指导支持团队“巡视发现”问题f)providesfeedbacktothesourcefromqualitychecks,inspectionandrepairstations

把质量检查、审核和返修工位的信息反馈回问题的源头g)providesinformationtothemaintenanceorganizationtorespond

向维修工段提供信息使其及时响应h)signalspeopletoperformstandard/routineactivities提醒员工进行标准/常规的活动i)providesdata(pullsandlinestoptime)byestablishedAndonzonetoproblemsolvebottlenecksandproblemareas

通过暗灯区域的数据(拉动和停线的时间)显示问题解决的瓶颈以及问题所在区域j)isflexibleenoughtoincorporateothervisualmanagementneedsastheyarise

有很大的弹性，可以融入其他的目视化管理需求82Apeoplesupport/teamconceptstructuremustexistthathasclearlydefinedrolesandresponsibilitiesasthejobrelatestotheproductionfloor(teamleader,groupleader,productionleadership,maintenance,personnel,engineering,quality,materials,other).

必须有一员工支持/团队概念体系，清楚地定义与生产线相关的所有工作的角色和责任(班组长，工段长，生产领导层，维修，人事，工程，质量，物料，及其他)3StandardizedWorkisclearlydocumentedandfollowed.

标准化操作明确地整理成文，并予以执行4QualityStandardsandProcessControlsaredefinedforeachjob.

每个工位的质量标准和过程控制都有定义5TheAndonSystemisusedtoachievetheconceptof“Donotaccept,build,orpassadefect”.

使用暗灯系统来达到“不接收，制造，或传递缺陷”的思想观念6TheProblemSolvingProcessisusedtoresolverecurringAndoncalls.

使用问题解决流程来消除重复的暗灯呼叫7Actualtakttime(conveyorspeed)isestablishedtoallowforproperuseoftheAndonSystem.

建立实际单件工时(传动链的速度)，合理利用暗灯系统8DecouplingexiststoallowfortheproperuseoftheAndonSystem.

退耦(装置)的存在使得要合理利用暗灯系统9Benefits益处TheAndonSystemsupportscontinuousimprovementinSafety,People,Quality,Responsiveness,andCost.暗灯系统支持在安全、人员、质量、响应和成本方面的不断改进Andonisusedasaformalcommunicationtooltoalerttheorganizationto“Callsforhelp”andabnormalprocessconditions.AnAndonresponseprocessshouldbeinplacetosupportandrectifysituationsasquicklyaspossible.暗灯作为一种正式的交流工具，警示相关部门寻求帮助以及有异常的流程状况发生。而设置暗灯响应流程为了尽快支持并纠正相关状况。Andonboardsforallareasareeasytounderstandandsupport”StatusataGlance”每个区域的暗灯板都容易理解并“一目了然”Andonareaconfigurationsareestablishedtodirectthesupportorganizationsto“GoandSee”theproblemsonthefloor.暗灯区的布局可以指导支持工段巡视并发现流水线上的问题Andonisflexibleinordertoincorporateimprovementsandrequiredchangesastheyarise.为了融入不断改进和所要求的变化，暗灯设计是柔性的。Andoncollectsdataforproblemsolvingandidentifyingwhereproblemsoccurmostfrequently.暗灯搜集解决问题的数据并识别问题发生最多的区域Andoncanremindemployeestoperformroutineactivitiesatregularintervals.暗灯可提醒员工定时进行常规活动EmpowersteammemberstoBuildQualityinStation使得员工在每个工位制造质量Andonisatooltokeepthelinerunning!暗灯是保持流水线运行的工具10AndonEnablers暗灯的驱动因素BelowaretheenablersthatshouldbeinplacepriortoactivatingtheAndonSystem.以下是在使用暗灯系统前需要合理设置的驱动因素ContinuousImprovementCulture不断改进的氛围ManagementCommitment管理层的义务Teamwork团队合作EmployeeTraining员工培训DefinedQualityStandards定义过的质量标准LevelScheduling同步的计划FixedPositionStop固定停止位Decoupling/Buffers退耦(装置)/缓冲StandardizedWork(KeyPoint:avoidoperationinterferenceanddowntimebyreducingoreliminatinglayerbuildsonadjoiningprocesses)标准化操作(关键点：在相邻的工艺流程减少或消除叠层制造，以避免操作的互相影响以及停线)StandardizedProblemSolving标准化问题解决流程AddressSystem定位系统CapableProcess&Equipment可行的工艺和设备MutualTrust&Respect互相信任和尊重11AndonComponents暗灯组成WorkstationAddresses工位的位置PullCords,Buttons,andSwitches拉绳，按钮和开关Lights亮灯AudioSignalsandSpeakers声音信号和扬声器AndonBoards暗灯板12Andonboards,workstationlightsandspeakersprovidealertstotheteamleader,groupleader,maintenanceteammember,andmanagementsotheycanrespondquicklyto“Callsforhelp”.暗灯板、工位灯和声音装置可以提醒班组长、工段长、维修员工和管理人员对于“寻求援助的需求”迅速响应。AndonSystemLayoutforaMovingLine流水线的暗灯系统布局13PullCords,ButtonsandSwitches拉绳、按钮和开关TheAndonsystemcanbeactivatedbyanumberofdifferentmethods.Thischartdescribestheproposeanduseofthedifferentpullcords,buttons,andswitchesoftheAndonsystem.有几种不同的方式激活暗灯系统。图表描述了暗灯系统不同拉绳、按钮和开关的目的及使用。14ActivationDevice激活设备Purpose目的WhereUsed使用的地方Description描述AndonPullCord暗灯拉绳AndonPushButton暗灯按钮RunStopSwitch运行停止开关ManipulatorOver-TravelLimitSwitch操作者超程限制开关TeamMemberHelpCall组员帮助响应TeamMemberHelpCall组员帮助响应Stoptheprocessorconveyorimmediatelyforsafetyreasons为了安全原因，立即停止流程或传动链Increaselevelofsafetyontheworkstationbystoppingtheconveyorwhenanover-travelconditionoccurs.当出现超程情况，停止传动链以提高工位的安全性Onaworkstationinamovingconveyorline移动的传动链上的工位WorkCells,suchasaBodyshoporPressLine,orinaPaintBooth工作间，如车身或冲压线，或在油漆房Installedalongtheconveyorandonallmajorequipment沿传动链在主要设备旁安装Thelimitswitchisinstalledalongthetravelofthemanipulator限制开关在操作者行进路程旁安装Connectedtoaswitchwithalightandloopedalongthelengthoftheconveyor亮灯和开关连接，沿传动链形成环路Switchboxwithapushbuttonislocatedinthemostconvenientlocationoftheworkcell有按钮的开关盒处于工作间最方便操作的地方PlacedatregularFixedPositionStopsonalternatingsidesoftheline.(Note:Mustbeinaccordancetoallsafetystandardsandregulations.)在线的两旁交替放置于固定停止位处(注：必须符合所有的安全标准和规定)Topreventmanipulators,articulatingarmsandassistdevicesfromdangerousover-travelconditionstoincreasesafetyontheworkstations.避免操作者、连接设备和辅助仪器发生危险的超程情况，提高工位的安全性。15PullCords,ButtonsandSwitches拉绳、按钮和开关16ActivationDevice激活设备Purpose目的WhereUsed使用的地方Description描述CriticalCheckCompleteButton&Light关键检验完成按钮和亮灯LocalQualityCallButtons区域质量响应按钮

DownstreamQualityCallButtons下道工序质量响应按钮

ToindicateCriticalCheckshavebeencompleted表示关键检查已完成TocallProductionTeamLeadertotheQualityVerificationStation呼叫班组长到质检工位TocalltheProductionGroupLeadertotheQualityVerification呼叫生产工段长到质检工位SwitchesinstalledinZoneareaorasneededtosupporttheprocess开关安装在需要的区域，支持工艺流程QualityVerificationStations质量检验工位QualityVerificationStations质量检验工位Thebuttonlightturnsonindicatingthatacheckmustbedone.Afterthebuttonispressed,thesystemturnsoffthelightbutton,acknowledgingthecheckhasbeencompleted.IftheTeamLeaderdoesnotpressthebuttonbythetimethechecktimeexpires,thebutton-lightflashes.灯亮表示必须检查。按下按钮后，系统关闭亮灯，表示检查完成。如果班组长在检查时间结束时，没有按下按钮，亮灯将闪烁。Pushbuttonswitchmountedonapedestal按下装在支架台上的开关按钮Pushbuttonswitchmountedonapedestal按下装在支架台上的开关按钮17VisualandAudioSignals目视和声音信号VisualSignals目视信号Standardcolorshelpdeterminethe“StatusAtAGlance”颜色标准帮助确定状态Greensignals“OK”orNormalStatus绿色表示OK或正常状态Yellowsignals“HelpRequired”PotentialRiskofLossofProductionorQuality.黄色表示需要帮助，生产或质量有潜在损失的风险Redsignals“Line,ProcessOrEquipmentIsDown”-ImmediateHelpIsRequired.红色表示生产线、流程或设备的停止-需要立即抢修(InsomeapplicationsofAndonitmaybenecessarytouseothercolorstofulfillalltherequirementsofthesystem.)在暗灯的有些使用中，需要应用其他颜色来满足系统的所有要求18AudioSignals声音信号AudiosignalsconveyauniquemelodyoraudiosignaltoalertthecorrectsupportpersonneltolookupattheAndonBoardortoseetheworkstationlightstodeterminethespecificlocationcallingforhelp.声音信号发出独特的音乐或声响来提醒纠正支持人员观察暗灯板或工位亮灯以确定需要帮助的特定工位。Typicallytwotypesofaudiosignalsareused:使用的两种典型的声音信号：

Melodies音乐

Tones音调UniquemelodiesareusedtodistinguishdifferentAndonevents,Groups,AndonZones,androutinereminders.独特的音乐用来区分不同的暗灯事件、工段、暗灯区域以及日常的提示TonesareusedforcommonAndonalerts,suchasequipmentfaultsandscheduledstartorstopoftheline.声调是用来常规的暗灯提醒，如设备故障，生产线的启动或停止。19AndonLights亮灯ActivationDevice激活设备Purpose目的WhereUsed使用的地方Description描述WorkstationLight工位灯Runstoplight运行停止灯EquipmentFaultlight设备故障灯

Supportshelpcallfunction寻求帮助功能SupportRunstopfunction运行停止功能Supportequipmentfaults显示设备故障OneYellowworkstationlightislocatedattheendofeachworkstation.每个工位的末端有一黄色的灯Oneredbeaconlightislocatedattherunstopswitch在运行停止开关处有一红色的信号灯Oneredbeaconlightislocatedatthecontrolpanelofeachpieceofmajorequipment在每个主要控制设备的面板上有一红色的信号灯Turnsonsolidyellowinaresponsetoacallforhelp.Flasheswhenthevehiclereachesthefixedpositionstop.寻求帮助时显示常黄。当车辆达到固定停止位就闪烁Whenrunstopswitchisactivated,thelightflashes.运行停止开关激活时，亮灯闪烁Whenanequipmentfaultoccurs,itflashes设备发生故障，灯就闪烁20AudioSignalsandSpeakers声音信号和扬声器TheAndonsystemwillplayuniqueaudiosignalssuchas,melodiesandtomesforspecifictypesofhelpcallsandfaults.Itshouldbeuserfriendlyandflexibletoallowforthefollowingfunctions:暗灯系统会发出独特的声音信号如，求助和发生故障的特定类型的音乐和声调。系统具有以下功能，对使用者友好并具有弹性：

LengthofTimeOn声音的长短

FastModeofPlay(25%to100%FasterthanOriginal)

播放的快速模式(比开始快25%到100%)Prioritylevelassignmentforeventmelodiesandtones

音乐和声调的优先级分配

SelectableLocationofMelodyPlay(Zone,Boardorboth)

可供选择的播放音乐(区域，显示板)CapableofsupportingallAndonCallsandFaultswithaspecificMelodyorTone

用一特定的音乐和声调支持所有的暗灯求助或故障情况

Adjustablespeakervolume可调节的声响21SpeakersareplacedtoensureTeamLeadersandGroupLeadersandallotherrespondershearthemelodies.Speakerplacementisespeciallycrucialforlouderfacilities.放置扬声器是确保班组长，工段长以及其他所有响应者听到音乐。扬声器的放置对于有噪声的设备十分重要。22AndonBoards暗灯板DifferentTypesofAndonBoards(allboardsmaynotberequiredtofulfillthecorerequirementsofAndon)不同类型的暗灯板(所有的暗灯板不一定都要满足暗灯的核心要求)GroupBoards工段板Supportsaspecificgroupofoperationsorproductionarea,usuallyonegroupleader’sarea支持一特定工段的操作或生产区域，通常是工段长区域ShopStatusBoard车间状态板Supportstheorganizationandprovidesreal-timestatusandperformanceinformationofthecurrentshift.提供当前班次的实时状态和绩效信息23PerformanceBoard绩效板SupportstheProductionteamleadersandgroupleadersbyprovidingreal-timepullcountanddowntimeinformationbyZoneforthecurrentshift.提供当前班次各个区域的拉灯次数及停线信息，支持生产班组长和工段长FinalProcessBoard最终工艺板SupportstheProductionandQualityOrganizationsbyprovidingqualityandthroughputinformationandinformsthemwherehelpisrequested支持生产部门和质量部门，提供质量和产量信息并告知需要帮助的地方MaintenanceBoard维修板SupportstheMaintenanceorganizationbyprovidinginformationrelatedtoabnormalitieswithequipmentandinformsthemwherehelpisrequested.提供设备异常的相关信息，支持维修部门并告知需要支援的地方24GroupBoard工段板TheGroupBoardsupportsaspecificgroupofoperations,conveyorlengthorproductionarea,usuallyonegroupleader’sarea.Theappropriatelightisturnedonandmelodyisplayedtoalertsupportpersonnelwhenhelpisrequestedorafaultoccurs.工段板是对一个特定工段的操作，传动链或生产区域，通常是工段长区域的支持。当需要帮助或发生故障时，相关的灯亮，音乐响起提醒支持人员。Becauseofdifferentprocessrequirements,groupsizes,andboardlocationsforeachdepartment,theboardsmayvaryslightlyfromdepartmenttodepartment.由于不同的工艺需要、工段大小和位置，每个工段的暗灯板略有区别Smallersizeboardscanbeusedwhereteammembersareworkinginisolatedworkcellsaslongastheyretainthecommonfunctionalityrequirements.员工在单独的工作间里操作时，可使用较小尺寸的暗灯板，只要符合通常的功能要求。ItshouldalsoberecognizedthatinotherworkcellapplicationsoftheAndonsystemsuchasastampingprocess,thegroupboardsmaylookdifferentfromwhatwewouldseeinatypicalmovinglineoperation.Theseboardswouldbemorefocusedoncellcallsandequipmentfaults,buttheintentofthesystemmuststaytruetothecorerequirementsofAndon.必须指出，在其他工作间使用的暗灯系统，如冲压流程，工段板和运行的流水线操作的工段板是不同的。这些板更注重于工作间的求助及设备故障，当然系统的内容必须符合暗灯的核心要求。2526ShopStatusBoard车间状态板Supportstheorganizationandprovidesreal-timestatusandperformanceinformationforthecurrentshift.提供当前班的实时状态和绩效信息Thelocationoftheboardistypicallyattheendofashop,orattheVisualManagementCenterwhereallteammemberscanobtainstatusinformationquickly.板的位置通常在车间的末端，或在目视化管理中心，所有的员工可以迅速得到状态信息。27Line生产线Condition情况ShopStatus车间状态AreaorLineStatus区域或生产线状态Starved/Blocked短缺/堵塞TotalDowntimeArea/Line总的停线时间KeyProductionInformation&Counts关键生产信息及数量Green-OK-Lineisrunning绿色-生产线运行正常Red-NotOK.Lineisnotrunning.红色-生产线没有运行FA：FloatAlarm:YellowSolidLevel2AlarmYellowFlashingLevel3Alarm缓冲警示：黄灯常亮2级警示，黄灯闪烁3级警示Green-OK-Lineisrunning绿色-生产线在运行Red-LineisdownforAndonCallorEquipment

红色-由于暗灯或设备的原因停线Green-OK绿色-OKStarved/Blocked-Red红色-短缺/堵塞TotalAreaorLinedowntime总的区域或生产线停线时间CurrentShiftProductionInformation-Goal,Actual,Trend,Quality,Float,Shipped当前班生产信息-目标，实际，趋势，质量，缓冲，装运PainttoGABufferCount油漆到总装的缓冲数28PerformanceBoard绩效板ThePerformanceboardsupportsaspecificgroupofoperationsorproductionarea,usuallyonegroupleader’sarea.绩效板支持一特定工段的操作或生产区域，通常是工段长区域。29Display显示Description描述AndonDowntimeClock暗灯停线时间计时钟EquipmentDowntimeClock设备停线时间计时钟VerificationStationDowntimeClock质检工位停线时间计时钟ZoneDowntimeClock区域停线时间计时钟ResetButtons重置按钮DisplaysthetotallinedowntimerelatedtoAndoncalls显示与暗灯相关的总停线时间DisplaythetotallinedowntimeduetoEquipmentfaults显示由于设备故障的总停线时间Displaysthetotallinedowntimeduetoqualitycallsandrepairsintheverificationstations显示由于质检工位的质量问题或返修而造成的停线时间Displaysthetotallinedowntimeforeachspecificzone显示每个特定区域的总的停线时间Resetbuttonsareusedtoreseteachdowntimeclockandpullcountdisplayafterinformationisrecorded.在记录数据后，用重置按钮重新设置每个停线计时钟和拉动次数30FinalProcessBoard终线流程板TheFinalProcessBoardsupportsthefinalprocessandproductionrepairorganizationsbyalertingthemwhenhelpisneeded.Italsoprovidesqualityandthroughputinformation.终线流程板支持最终工艺以及生产返修部门，提醒他们何时需要援助。同时提供了质量和产量信息。31QualityOKRates:质量通过率DisplayedistheActualOKratesfortheQualityVerificationstations显示质检工位的实际通过率ThroughputPerformance产量绩效DisplayedareActualnumberofvehiclesoffEOL显示离开终线的实际车辆数量OnholddisplaysthenumberofvehiclesOnholdHold表示滞留的车辆OK-Status:Normalfloatlevel,allrepairareasunderthepredeterminedfloatlevels.正常的浮动车辆标准，所有的返修区域在设定的浮动标准范围内Level1Alarm,forFinalProcessonly,Systemturnsonlevel1alarmconditionatapredeterminedpercentageoffloatlevelcapacity.只对终线工艺而言，系统在预置的流动容量百分比上显示一级警示状态Level2Alarm:SystemturnsonLevel2Alarmconditionatapredeterminedpercentageoffloatlevelcapacity,priortoreachingmaximumcapacity.Groupleadersinvolvedinproblemsolving.二级警示：在达到最大容量之前，系统在预置的流动容量百分比上显示二级警示状态。工段长参与问题解决。Level3Alarm:Systemturnsonatthemaximumallowablefloatlevelcapacity.Areamanagerandplantmanagementinvolvedinproblemsolving.三级警示：系统达到最大允许流动容量时的级别。区域经理和生产基地领导班组参与问题解决。

32MaintenanceBoard维修板TheMaintenanceBoardsupportstheMaintenanceorganizationbyprovidinginformationrelatedtoabnormalitieswithequipmentandtoolsandlocationwherehelpisrequested.提供设备异常的相关信息，支持维修部门并告知需要支援的地方TheMaintenanceBoarddisplayswillvarydependingonthemaintenancedeploymentstrategyimplemented.Insomecases,extramarqueesmaybeaddedasnecessarytosupporttheeffectivenessofthemaintenancefunction.Shownbelowareexamplesofdepartmentalmaintenanceboards.依据实施的维修分布策略，维修板的显示有所不同。有时，必须增加附加的车辆以支持维修的效率。以下是部门维修板的样例。33Line生产线Condition情况AreaorConveyorStatus区域或传动链状态EquipmentStatus设备状态EquipmentUptimeActual设备实际工作时间BufferCount缓冲数BufferCount缓冲数Green-OK;Equipmentandconveyorsrunning.绿色-设备和流水线运行正常Red-Linenotrunning.Conveyororequipmentnotrunning红色-流水线或设备停止运行Green-OK绿色-OKRed-Equipmentfault红色-设备故障DisplayedistheActualuptimeoftheequipmentineachrespectivearea.显示的是每个区域设备的实际工作时间PainttoGAbuffercount油漆到总装的缓冲数Trim4toChassis1buffercount内饰四到底盘一的缓冲数34AndonboardLayoutPlanning暗灯板规划布局WhenplanningAndonboardlayoutsandboardconfigurationsinadepartment,therearemanythingsthatneedtobeconsidered.Suchas:当在一部门进行暗灯板的规划和版面设置时，需要考虑很多事。如：WhataretheTeam/Groupsizesandlocations?班组/工段的大小和位置Canthegroup,includingtheverificationstation,betiedintooneboard?工段，包括质检工位，可否联成一块板？Isthereaclearlineofsightforteammembers?班组成员是否能清楚看见Whatistheclearanceheightneededunderneaththeboardstoallowforareaactivity?考虑区域活动的进行，板下的高度是多少？Whatisthemaintenancedeploymentstrategyforequipmentfaults?对于设备故障的维修分布策略是怎样的？Aretherecentralorsatellitemaintenanceworkshops?是否有维修中心车间？Aretherescheduledcontrolledstopsandstarts?是否有计划的控制停线和启动？Areproceduresinplaceforroutinereminderssuchascriticalchecksormaterialpullcardpick-up?是否有程序作为日常行动的提醒，如关键检查或物料拉动卡的搜集？Isthereflexibilityinthesystemforfutureneeds?对于系统将来的需求是否有可塑性？Isthereanervecenterorcentralmeetingarea?是否有控制中心或会议区域？35ConveyorLineLayout流水线的布局KeyPoints关键点GroupAndonboardssupportAndonzones.Typicallyazonerepresentsoneteam(4-6teammembers).Azonecanbeleftorrightoperationsand2-5workstations.Oneworkstationequalsthedistancebetweenthefixedpositionstopmarkings.Insomecasesduetoisolatedteamlocations,individuallinesegments,andautomation,Andonboardsmayneedtosupportthestationandteamlevel.工段的暗灯板支持暗灯区域。通常一个区域表式一个班组(4-6个组员)。一个区域包含左边或右边的操作，2-5个工位。每个工位在固定停止位标记间的距离是相同的。有些情况，由于独立的班组位置，单独的分装线，暗灯板需要支持这个工位和班组。Andoncordsareinstalledinaclotheslinefashiononmovinglinesorascallbuttonsinworkcellsandpaintbooths.Workstationlightsarelocatedattheendoftheworkstation.Runstopswitchesarelocatedasrequiredinthearea.Speakersareplacedineachzone.暗灯线在移动的生产线上的安装采用晒衣绳的样式，而在工作间和油漆房内采用按钮形式。工位的末端设置亮灯。运行停止开关在需要的区域放置。每个区域都有扬声器。36暗灯板位于生产线或区域的中央37SystemOperation系统运行InformationonthefollowingpagesdescribestheSystemhelpcallsandFaultconditionsoftheAndonsystem.Describedindetailarethecorrespondingvisualandaudioalertsforeachtypeofhelpcallandfaulteventlistedbelow:以下几页的信息描述了暗灯系统的系统求助信号和故障状态。对以下罗列的每一种求助信号和故障的目视和声音提示进行了详细的描述。

TeamMemberhelpcall组员帮助需求

ElectronicErrorProofinghelpcall电子防错帮助需求

FloatAlarm缓冲警报

LocalQualityverificationstationhelpcall

局部质量检验工位需求

Downstreamqualityverificationstationhelpcall

后道工序质检工位需求

Criticalcheckreminder关键检查提示

Runstop运行停止38Manipulatorout-of-positionandover-travel操作者越位和超程EquipmentandConveyorFaults设备和传动链故障EntranceandExitConveyorFaults传动链入口和出口故障StarvedandBlocked短缺和堵塞StatusofOtherLines其他线的状态ScheduledStartorStop计划启动或停线ProductionStatusInformation生产状态信息Goal目标Sub-Assembly分装线Actual实际ExitConveyorCount流出传动链车辆数Trend趋势BodiesfromPreviousProcess前道工艺的车身Quality质量FloatorBuffer悬浮或缓冲车辆Downtime停线时间39TeamMemberactivatesanAndoncall:组员激活暗灯需求：

Andonboardzone,station,orworkcellnumberturnsonflashingYellow.

暗灯板上相关区域，工位或工作间的数字闪烁黄色

Uniquezoneaudiosignalisplayed发出特定的区域声音信号

Yellowworkstationlightgoesonsolid工位黄色灯不动

FixedPositionStopisactivated,exceptinworkcellsandPaintbooths.

固定停止位发生作用，工作间和油漆房除外SystemOperation系统运行40IfFixedPositionStopisreachedbeforetheAndonisreset:在暗灯重置之前到达了固定停止位：

ConveyorstopsandDowntimeclockstarts.

传动链停止，停线计时钟启动

GreenLineStatusLight(Trim3)turnstoflashingRed

生产线状态灯绿色变成红色闪烁

FlashingYellowzonenumberremainsontheAndonBoard

暗灯板上依旧是闪动的黄色区域数字

UniqueAudioSignalforthezoneplaysfastmode.

独特的区域声音信号加快

YellowworkstationLightbeginstoflash工位的黄色灯开始闪烁SecondPullorreleasingthecallbutton,resetsthecalleventandthelineresumesnormaloperation.暗灯线第二次拉动或释放按钮，流水线恢复正常运行

Conveyorrestarts.传动链重新启动

Alllightsreturntonormaloperation.所有灯回复正常状态41SystemOperation系统运行WhentheerrorproofingOKsignalisnotreceivedandthepredefinedProgrammableWarningPointisreached,theerrorproofingsystemactivatesanAndonhelpcall.当防错的OK信号没有被接收，而达到预先审定的可编程警告点时，防错系统激活暗灯求助需求。

AndonboardzonenumberturnsonflashingYellow暗灯板上相关区域的数字闪烁黄色

Uniquezoneaudiosignalisplayed发出特定的区域声音信号

YellowworkstationlightturnsonSold工位黄色灯不动42IftheAndonsystemdoesn’treceiveanOK,Release,orBy-passsignal,theconveyorwillstopatthefixedpositionstopwhenreached.如果暗灯系统没有接收OK、释放或通过信号，当传动链到达固定停止位时就停线了。

ConveyorstopsandDowntimeclockstarts.

传动链停止，停线计时钟启动

GreenLineStatusLight(Trim3)turnstoflashingRed

生产线状态灯(内饰三)绿色变成红色闪烁

FlashingYellowzonenumberremainsontheAndonBoard

暗灯板上依旧是闪动的黄色区域数字

UniqueAudioSignalforthezoneplaysfastmode.独特的区域声音信号加快

YellowworkstationLightbeginstoflash工位的黄色灯开始闪烁WhentheerrorproofingreceivesanOK,Release,orBy-passsignal,thelineresumesnormaloperation.当防错系统接收了OK，释放或通过信号，生产线恢复正常运行

Conveyorrestarts.传动链重新启动

Alllightsreturntonormaloperation.所有灯回复正常状态43SystemOperation系统运行OKstatus:Normalfloatlevel,allrepairareaunderthepredeterminedfloatlevels.OK状态：正常的流通车辆水平，所有的返修区域在设定的流通水平范围内

FinalprocessAndonboardfloatalarmstacklightisGreen.终线工艺暗灯板流动警示灯是绿色的Level1Alarm,forFinalProcessonly,Systemturnsonlevel1alarmconditionatapredeterminedpercentageoffloatlevelcapacity.一级警示，只对终线工艺而言，系统在预置的流动容量百分比上显示一级警示状态。

Floatalarmmelodyisplayed(onFinalProcessBoardonly)发出流动警示音乐(只在终线板上)FinalProcessAndonBoardFloatAlarmStackLightturnsonsolidBlue

终线工艺暗灯板流动警示灯变为常蓝色44Level2Alarm:SystemturnsonLevel2Alarmconditionatapredeterminedpercentageoffloatlevelcapacity,priortoreachingmaximumcapacity.二级警示：在达到最大容量之前，系统在预置的流动标准容量百分比上显示二级警示状态。

FloatAlarm“FA”turnsonsolidYellow(allandonboards)

流动警示“FA”变为常黄色(所有的暗灯板)FloatAlarmmelodyisplayed(allareas)发出流动警示音乐(所有区域)FinalProcessBoardFloatAlarmStackLightturnsonsolidYellow.

终线工艺暗灯板流动警示灯变为常黄色Level3Alarm:Systemturnsonatthemaximumallowablefloatlevelcapacity.三级警示：系统达到最大允许流动容量时的级别

FloatAlarm“FA”turnsonflashingYellow流动警示“FA”变为闪烁的黄色

FloatAlarmmelodyisplayed(fastmodeallareas)

发出流动警示音乐(所有区域节奏变快)FinalProcessboardfloatalarmstacklightturnsonsolidRed.

终线工艺暗灯板流动警示灯变为常红色45SystemOperation系统运行Qualityteammembercallsforhelpbypressingtheappropriatequalityzonebutton.质检人员按下相应的区域质量按钮寻求帮助

QualityzonenumberbeginstoflashYellow.质量的区域数字变为闪烁的黄色

Uniquezonemelodyisplayed.播放独特的区域音乐TeamLeaderrespondstothequalityverificationstationandpressestheappropriatequalityzonebuttontoresettheevent.班组长响应质量检验工位，再次按下相应的区域质量按钮

Qualityzonenumberturnsgreen质量的区域数字变为绿色

Uniquezonemelodystopsplaying.独特的区域音乐停止46SystemOperation系统运行Qualityteammembercallsforhelpbypressingtheappropriateareaqualitybutton.质检人员按下相应的区域质量按钮寻求帮助

VerificationstationnumberisdisplayedflashingYellow表示质检工位的数字显示闪烁的黄色

Quality/FloatAlarmmelodyisplayedfor5seconds质量/流动警示音乐播放5秒种GroupLeaderrespondstothecallandtheappropriateareaqualitybuttonispressedtoresettheevent.工段长响应，重新设置相关的区域质量按钮

VerificationStationnumberisturnedoffandthedisplaychangesbacktonormaloperation.

质检工位的数字变为正常的操作状态47SystemOperation系统运行SystemautomaticallyturnsonCriticalchecklights系统自动亮起关键检查灯

Criticalcheck“C”turnsonsolidYellow“C”关键检查的C

变为常黄色的CCriticalcheckmelodyisplayedfor5seconds关键检查音乐播放5秒种

CriticalcheckcompletebuttonturnonsolidBluefortheappropriatezones

相关区域的关键检查完成按钮变为常蓝色48TeamLeaderspresstheirCriticalcheckcompletebuttonsoncetheyhavecompletedrecordingalltheirchecks.ThesystemwillturnofftheCriticalCheckCompleteButtonLightsastheyarepushed.只要班组长记录了检查的数据，就按下关键检查完成按钮。系统会关闭关键检查灯。OnceallteamleadershavepushedtheirCriticalCheckCompletebuttons,thesystemwill:一旦所有的班组长按下关键检查完成按钮，系统将

TurnthesolidY