IE线平衡改善（PPT46页).ppt

Whenareyougoingtofinishyourjob?Ihavebeenwaitingsolong!你到底要在什麼時間才能做完,我要等到什麼時候?,Mycycletimeistooquickforme!我來不及做了！,OperationTraining-線平衡改善,LineBalancing,CycleTime=6secondLineBalance=(4+5+3+3+4+6+5+4+4+3+3+6+2)/(6X13)=66.66%,LineBalanceConcept,CycleTime=6secondLineBalance=(4+5+6+4+6+5+4+4+3+3+6+2)/(6X12)=72.20%,LineBalanceConcept,CycleTime=6secondLineBalance=(4+5+6+4+6+5+4+4+6+6+2)/(6X11)=78.80%,LineBalanceConcept,CycleTime=5secondLineBalance=(5+5+5+5+5+5+4+5+5+5+3)/(5X11)=94.50%,LineBalanceConcept,CycleTime=4secondLineBalance=(4+4+4+4+4+4+4+4+4+4+4)/(4X13)=100%,LineBalanceConcept,Possible?,Conveyorspeedistoomuchfasterthanoperatorsability.如果傳送帶的速度遠遠快於作業員的作業能力1.ToomuchWIPatthebottleneckstation.在瓶頸站將堆積過多的WIP2.OperatorslackconcentrationWastetimetowaitforthecomingproductorpulltheproductfromthelineinsteadofcompletingtheproductinhand.作業員無法專心作業。等待材料及從正在作業的產品中分心以拿取線上流過的材料。,UnbalanceLinesProblems線上不平衡造成的主要問題,3.QualityProblem品質問題3.1IncompleteProcess制程不完善-Insufficientparts作業不全-Partsnotproperlyinserted材料未適當裝插-Wrongpartbeinginserted插件錯件-Wrongsideisbeinginserted插件反向-Notallrequiredpointsareinspected檢查不完備-DidnotcorrectlychoosetheSelectSwitch按錯測試鍵-DidnotputallLabelsorwronglyplaced.未全面貼放標籤或錯貼-etc.,UnbalanceLinesProblems線上不平衡造成的主要問題,3.2Defects不良-Damageanddirty破損及污漬-Scratches刮傷-Labelscratches標籤不良等etc.4.Inspectorsneedtorepairthedefects,thuscausingadditionaltime.作業員修復不良品將花費多餘工時,UnbalanceLinesProblems線上不平衡造成的主要問題,5.LineleadersandothersupportingpeoplehavetowastetheirtimeinassistingandsolvingtheWIPproblematthebottleneckstation.組長及其他線外支援人員不得不耗費時間以解決瓶頸站的WIP6.Thespaceavailableinthelinearealreadyverylimited,itwillbecomeevensmaller.線上空間本來有限，還需佔據空間7.Un-forecastableanduncontrollableoutput造成無法預計和控制的產出8.DecreasedProductivity生產力降低,UnbalanceLinesProblems線上不平衡造成的主要問題,Whentheconveyorspeedisslowerthantheoperatorsability.當傳送帶之速度遠慢於作業員的操作能力1.Losttimewithoutoutput無產出的異常工時2.Loweroutputthanexpected低於計劃的產能3.Operatorsarenotactiveenough,becomesdull作業員無法積極作業，變得懶散,UnbalanceLinesProblems線上不平衡造成的主要問題,4.Musttakemoretimetorecoverthelostoutput需要安排額外的工作時間以彌補未達成的產能5.Unitcostbecomeshigher單位產品的成本增加6.DecreasedProductivity生產力降低7.Cannotcontrolorforecasttheoutputsystematically無法系統的控制和預估產能,UnbalanceLinesProblems線上不平衡造成的主要問題,Stepoflinebalancing線平衡步驟,LINEBALANCEisthemethodusedtosetupworkingtimeofoperatorsinonelineasthesameaspossible.線平衡是盡可能把線上作業員的作業時間安排一致的方法。,LineBalancing,線上觀察,分析,討論,設定標準,標準工時及O/I檢討,起草作業指導書並檢討,執行,跟蹤情況,正式發行O/I,跟蹤及不斷的改善,動作制程布局治具,方便快捷安全價廉保障,合併去除改善(重排、調適)簡化,LineBalanceConcept,ProductionDesign(R&D),ProcessDesign,FlowChart,LayOut,OperationInstruction,Motion&TimeStudy,Seriouslycontinuousfollowup,產品設計(工程),制程規劃,流程圖,布局安排,作業指導書,功效研究,認真持續的跟蹤情況,LineBalanceConcept,Observation觀察,Analyze分析,SetNorm設定標準,Manload安排人力,Implement執行,Followup跟蹤,(Before&After),(Max,Min,Avg.最大值,最小值,平均數),(Observationsheet時間觀測表),-Combine合併-Eliminate去除-Improve改進-Simple簡化,(ProductivityPerformance生產力狀況),(Std.Time標準工時),Stepoflinebalance,Step1.Observation:Observeandtimingfromthestarttoendofeachprocessassample.第一步.觀察:如下所示,按制程從第一站到最後一站觀查並測量時間.,Stepoflinebalance,Step2.Analyze:Analyzetimefromobservationtodefineminimum,MaximumandAverage.第二步.分析:從觀察得出的數據中分析得到最小值，最大值及平均值.,Stepoflinebalance,Step3.Setnorm(standardtime):Selectthetimetobeusedasthestandardtimeateachstep.Normallywillbetheaveragetime.第三步.設定標準(標準時間):定訂每一站的標準時間.通常使用平均值.,Stepoflinebalance,Step4.Manload:Calculatemanpowertobeusedtoproduce.Thesenumberwillbethemosteffectiveandbalancetheproductionlineasmuchaspossible.(Comparebefore&After)第四步.人力安排:計算生產所需的人力.這個數據最有效並能最好的達到線平衡.(比較before&After),Stepoflinebalance,Stepoflinebalance,Step5.Implement:UsealldatatocompareastheBeforeandAfterReport.Setuplinebalancebyusingthefollowingconcept.第五步.執行:用所有的數據比較before&after,用以下的觀念平衡生產線.-Combine合併-Eliminate去除-Improve,Re-arrange改進,重排-Simplify簡化,Step6.FollowUp:Followupalltheimplementationcontinuinglyatleast2weeks.第六步.跟蹤:持續的跟蹤執行情況至少兩星期.,LineBalancingBenefits,LineBalancingBenefits線平衡的優點,1.Systematicproductionoutputcontrol系統的產能控制2.Constantflowanddistancebetweeneachproduct.持續的流水作業3.Reduceoperatorschancefordefectandcarelessness.降低作業員不良及忽略的錯誤4.Losstimereductionandcontrol.降低並控制異常工時.,LineBalancingBenefits線平衡的優點,5.PreventionofWIPintheproductionlines.防範線上WIP.6.Easeandclearidentificationoftheproblems.清楚的問題分析7.Whendefectsarefoundandseparatefromtheline,itcanbeveryclearlyidentified.不良品的明確標識，以便明確的區分.,LineBalancingBenefits線平衡的優點,8.Operatorsdonothavetobeworriedaboutthenextcomingmaterialwhenhis/herpresentoneisnotcompleteyet.在作業員進行當前作業時，無需擔心下一個材料.9.Operatorscanfullyconcentrateontheirjobs,theydonothavetocareaboutothersabilitytofinishtheirworkontimeornot.作業員全心投入工作,無需擔心其他組員的作業狀況.10.Theconstantdistancebetweenproductscanpreventdamagesfromdirecthits.產品之間的間隔可避免直接碰撞產生的損害,THEEND,LineBalanceExample線平衡範例,CycleTime(Bottleneck瓶頸)=9.85secondLineBalanceefficiency=Totaltime/(Bottleneckcycletime*O/PNo.)線平衡率=總工作時間/(瓶頸站cycletime*作業員人數.)=67.45%,-BeforeImprovement改善前,PROCESS,SEC,Improvement:ImproveprocessofproducingsuchasBottleneck改善:改善生產制程如瓶頸站,CycleTime(Bottleneck瓶頸)=7.47second(Avgofwinding)LineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=83.80%,PROCESS,SEC,BeforeImprovement改善前,AfterImprovement改善後,SolderpressedwirebeforeSoldertrimmingPress焊理線站後焊壓線,Separatepressingwireactivityforeachprocess壓線部份獨立出來,Eliminate:DecreaseLossorunnecessaryprocess去除:去除不必要及造成延誤的制程,Method:eliminatepressingMarginTapeprocessbyaskingoperatortouseTapeT26overMarginTape方法:去除壓膠布的制程,要求作業員在空白膠外使用T26膠,CycleTime(Bottleneck瓶頸)=7.35secondLineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=84.58%,SEC,PROCESS,Before&afterstationwindingwrapmargintape,Combine:combineprocessbyusingmotionandtimestudy合併:根據功效學合併制程,CycleTime(Bottleneck瓶頸)=7.35secondLineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=92.14%,Method:combineencasingCore(station4)andinputClip(station5)together.方法:合併包鐵芯(第4站)和上耳夾(第5站).,PROCESS,SEC,Simple:Usingfixturetohelpoperator.簡化:使用制具幫助作業員.,CycleTime(Bottleneck瓶頸)=7.10secondLineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=94.65%,SEC,PROCESS,BeforeImprovement改善前,AfterImprovement改善後,SolderinghavetopickupworkfromFixtureonebyoneafterprocess焊錫站需要從線上一個一個拿取,MakeNewfixturewhichcanreleaseallworkinthesametime作新制具以便同時作業,Before&Afteratstationsoldering,ComparingImprovement比較改善前後,InthecaseofimproveBottleneckanddecreaseoperator改善瓶頸站並減少作業員,IncaseofstableinputhourandimproveBottleneck如果投入不變而改善瓶頸站,RemarkStd.timeperpiecewilldecreaseandlinebalanceefficiencywillbehigher說明:單位產品所需的標準工時將減少，線平衡率將提升,ComparingImprovement比較改善前後,AdjustlinebalanceincaseofproducelowerthanPlan調整線平衡,DailyVarianceReport每日差異報表,AsfollowupfromvarianceReport,thefirsthourhasvarianceof100pieceslowerthanplan.Ifproductionlinewantstoproducecovervariance,Theconveyerisneedtobeadjustedasfollow:(Cycletime5sec)從每日差異報表的跟蹤情況可知,第一個小時較計劃有100個差異.如果生產線希望趕上計劃,傳送帶需做如下調整:(Cycletime5sec),Incaseofproducelessthanplan,Example范例(Cycletime5sec)8.25Hoursforoneday一天8.25小時=31500sectarget6300pcs.First1.20hour第1.20小時=4800secproduced860pcs.Workhavetobeproduce必須完成=6300-860=5440Pcs=31500-4800=26700/5440=4.94secThentheconveyerhavetobeadjustto4.94secinordertocoverVariance(Incaseofoperatorscoulddo)為了去除差距傳送帶速度需調整為4.94(假設作業員能做到),MethodofincreasingProductivity生產力提升之方法,OutputStable產量不變,InputDecrease投入減少Outputincrease產量增加,InputStable投入不變Outputincrease產量增加,InputDecrease投入減少OutputincreasedmuchmorethanInput產量的增加速度遠遠超出投入的增加速度OutputDecreasedmuchmorethanInput產量的減少速度遠遠超出投入的減少速度,BenefitofUsingConveyer,Reducetheexpenseoftransportationorproductmovement.降低運輸費用及產品的搬運.Reducetimetomoveorstoreworkinprocess(Wip).降低在制品移動及儲存的時間.ReduceexpenseoftoolorpallettokeepWorkinprocess.減少制具及盤子費用以便工作在線上作業.UseveryfewspaceforproductionlinebecausetherearenoneedspaceforstoreandWipmovement.生產線使用少量的空間因沒有必要為線上儲存材料而佔據空間.Ifhasagoodlinebalancing,workwillbeflownthroughfromstarttostop.工作從線頭流到線尾將會有較好的線平衡.LowerWorkinProcessinproductionline,Eachstationwillhaveonlypiecetoproduce.減少線上在制品,每一站只有一個產品生產.,Iftheprocesshasbeenbalancedeffectivelytheproductionlinewillbefastandeffective如果生產線得到有效的平衡，生產線會更快捷Ifplantoproduceonlyonemodel,thequalityofworkwillbebetterbecauseoftheprocessofchecking如果只生產一個機種,品質和產量會更好。Easytocontrolquantityandqualityiftheprocessofproducingarestable.如果生產制程穩定，產品品質和產量都會更易控制.EasytotracktheNGproduct,thelinecanbestopandcorrect.更