SONY厂房布置(1).doc

Sonys Implementation ofProduction Innovation Equipment andManufacturing System SolutionsChapter 11Introduction1.1 Shift in production needs1.2 Importance of demand oriented production1.3 Production innovations 3 main types of loss1.4 Cell production methodShift in Production NeedsDiversification of NeedsSpecializationSevere EconomicalEnvironmentWorst post-war economic slumMulti-functionalDrastic MarketChangeFall of ProductPricesMass production Many types, small qty Various types, various quantitiesDecline of ConsumptionNetwork AgeTelecommunication RevolutElectronic CommerceWell-sold products change quicklySurplus of inventory due to the fall of product pricesProtection ofDemand OrientedProductionGlobalizationNo BordersGlobal Standardsthe EnvironmentDigitalizationLess EnergyLess Resources, RecyclingLSIMechanical SoftwareImportance of Demand Oriented ProductionSell what is producedProduce according to demandLarge module type production lineVarious demand-oriented cell production lines Line change-over, model changed e cfBatch-type production line Lead-time, Inventory, etc.baProducts which cannot be soldChange-over lossWIP lossLead timeHandling lossThe Ultimate Production SystemCost Investment Lead time Inventory SpaceChange-over loss Rejected products BreakdownZeroImplementation ofProduction InnovationOnly make the required products at the required timeProduction Innovations 3 main types of loss1. Handling loss2. Transportation loss3. Stagnation lossMinimization of non-value added resourcesProgress by Production Innovation (1)Production styleProductionLarge qtySmall Lot ProductionTarget:based on forecastproductionLarge inventory qtyInnovationZero InventoryCustomersReduced funds turnoverRequired products Reduced spaceRequired timeRequired qtyReduced control costsFlow-oriented production, informationMixed flowIndividual islandsInnovationFlow-orientedIn-lineReduction of WIP Reduction of handling Simplified quality trackingProgress by Production Innovation (2)Inventory Reduction by Logistic ImprovementsLarge Order/Delivery of PartsPush style provisionInputStockParts InventoryInnovationSmall qty order/deliveryDeliver only what is usedKanbanDirectReduction ofRaw materialsWIPOutputProvisionProduction lineRefrigeratorProduction lineManufacturing equipmentLarge-sizeHigh speedHigh performanceHigh priceSmall sizeLow-medium speedFunctionalLow priceWIP reduction by production levelingInnovationProgress by Production Innovation (3)From single operation to multi-operationDivided labor conveyor production style due to single operationMulti-operation and Cell production methodInnovationMulti-operation(Multi-skilled workers)WIP reduction by production levelingConveyor lineCellControl comprehensive for anyoneData management by computer10000 pcs.Select&OrderFixed placeFixed qtyFixed markingVisual managementstorage XXShould be in storage ? There should be pcs?InnovationMax(XXpcsMin(pcs)Part ABy seeing the abnormality, a quick response is possibleAbnormal !Example of Benefits of Production Innovation: Reduction of Manpower(Actual factory example)120010008006004002000（persons）94/3 9 95/3 9 96/3 997/3 9 98/3 9Example of Benefits of Production Innovation: Reduction of Space(Actual factory example)m21400012000100008000600040002000094/3 9 95/3 9 96/3 997/3 9 98/3 9Example of Benefits of Production Innovation: Reduction of Lead time(Actual factory example)(days)35302520151050In-house production94/3 9 95/3 9 96/3 997/3 9 98/3 9Example of Benefits of Production Innovation: Revenue&Profit(Actual factory example)10080（）RevenueProduction Innovation Activities6040200-20Profit est.Note) Ratio (%) with 1992 revenue as 100From conveyor line to various types of Cell ProductionConveyor line. 1 234nChange-over loss occursLayout modification is difficultLine balance loss occursHandling loss occursSmall module unit typeSpiral typeOne man cart typeOne man stall type1d ecf2banCartChapter 22. Benefits of Cell Production Method2.1 Cell Production Method2.2 Benefits of Cell Production Method2.3 Examples of Cell Production MethodCell Production MethodThe Cell Production Method is one of the best solutions of manufacturing styles for small lot production, in which assembly and work are done in one single process, by using small manufacturing instruments (tools), by operation of one or a few workers.Small scale lineProductsAssemblyInspectionMulti- functional workSmall lotFlow orientedPackagingproductionExample of Cell Production SystemBenefits of Cell Production MethodFlexibility UpVarious itemsQuantity fluctuationVarious layoutConveyor lineConveyor lineConveyor lineProducti onLoss in production line changeTimeLine multiplication is difficultLayout modification is difficultCell productionProducti onOperation in 3CellsTimeCell productionBy number of workersBu number of cellsCell productionImplementation of various cell types according to products attributes, level of operators, production quantity; layoutmodifications are possible flexiblyCells by production typeProduction by sales speedBenefits of Cell Production MethodManpowerSpace reductionProductivity up manpower reductionSpace reductionConveyor lineBelt conveyorHandling LossConveyor lineWork timeLoss timeWork tableProducti on qtyChange-over Loss ProcessTimeCell productionCell production Manpower reduction by elimination of conveyor line loss Space reduction by removal of conveyor Elimination of loss by reducing in-between spacesBenefits of Cell Production MethodShortening of production lead timeInventory reductionQuality improvementConveyor LineCell productionInspec- tionAssemblyAssyWork cellAs syAssyAs syPacka- gingInventoryPack.Insp.Pack.Insp.Stagnation of the products in processCarry Stagnation, transportation loss between or within processes Slow feedback of quality information Unclear responsibility concerning quality Reduction of stagnation in processes Lead time reduction Reduction of inventory Fast feedback of quality information Clear responsibility concerning quality Quality improvementHigher work morale by individual performanceChapter 33. Development of Production Innovation Equipment3.1 Role of Production Technology3.2 Codependence of Men and Machines3.3 Conditions of Production Equipment suitable forCell Production3.4 Development of Innovation EquipmentRole of Production Technology“Produce products which have not been produced before”Basic Technology Development which supports Products Excellence“Further strengthening of Product Creations QCD+F”Realization Engineering which supportsManufacturing ExcellenceCodependence of Men and MachinesRole of the operator:“efficiently operate production equipment”“make improvements to increase capacity”“make arrangements for next production models”“design systems”“make equipment, tools”“Creation”workConditions for Production equipment suitable for Cell Production SystemsCompact Ability to make the required qty atthe required pace (demand synchronized production) Small equipment, not taking much installation space Price suitable to achieve early profitFlexibilityQCD Easy reflection of improvement plans for higher efficiency (reflect the feelingStabilityon the work floor) Flexibility to adapt to product modifications Simple procedure for product change-over No production of rejected products Minimum required maintenance, easy to carry out Few breakdowns ROBOKIDS Makes Cell-Production Evolution RealizedDevelopment Concept:CompactMinimum CostTool to Realize“An Evolution ofCell Production System”Outstanding Features Compact :vs. conventional 1/4 （ A4 size ） Cost :vs. conventional1/3 Flexibility : Wide Variety of Applications（Soldering, Dispenser, Screw-Fastening, Circuit Board Splitting）ROBOKIDS Features Conventional TypeA4-SizeROBOKIDS Features ROBOKIDS can be utilized from the Day of InstallationRoboKidsDedicatedRobot Assy SystemSMART SYSTEMInstallationInstallation 1 month 2 months 3 months4 monthsROBOKIDS WORLD （Wide Variety）Screw FasteningROBOKIDSSoldering ROBOKIDSCircuit Board SplittingROBOKIDSDispenser ROBOKIDSActual condition at production factoriesFlexibility is a main issue in the assembly area , as a starting point of production innovation, however in the surface mounting area - Very expensive mechanical equipment is lined up- Large qty & high speed processing is a main objective, using identical models of high speed surface mounters- Large scale equipment investment is still needed“A mounting process, where production innovation is still difficult to introduce”Large lot productionMounting line(A)assy line(a)assy line(b)assy line(d)assy line(e)Mounting line(B)assy line(c)assy line(f)Large qty of WIP, InventoryObjectives of the “Cellular Mounter”1) Compatibility of both high precision and flexibility Building is possible depending on demand variation, variation of production types Realization of low investment (cost/shot）small space2)Realization of Investment in steps to obtain a high level of investment results Procure only the required function, at the required time, at the required levelFlexible StructureSI-E1000SI-E2000Connected machinesParentChildrenStandard type connectionOne machine is the parent unit and the other three machines are the children unitsParentChildrenPCB Mixed flow compatibleOne machine takes care of type-dependant parts, the other three machines are connected. (type change-over only for the first machine)Flexible Production Capacity= 12,857 in 1.2 m= 25,714 in 2.4 mVery= 38,571 in 3.6m= 51,428 in 4.8mFlexible!Comparison of Conventional Mounters and Celluar Mounter20 Investment saving and 55 space saving is possible （per line）Conventional2m2m16m6m6mSS-U2SS-U2SS-H2FSS-H2FInvestment -20% Space-55%7.2m1.2mCelluar MounterSI-E2000SI-E1000Chapter 44. Manufacturing System SolutionsTotal Plant EngineeringPoints of Production ImprovementEvolution of Cell ProductionBasic Design of Cell Production LineHorizontal Implementation of Production InnovationEquipment“SONY Cell” of Production InnovationEquipmentSummaryTotal Plant EngineeringConstruction of optimum operation systemAlternative scheme trade-off analysisClarification of system specificationsOptimum hardwareMachining, assembly, adjustment, inspectionMaterial handling systemsElimination of waste and lossesIE approachReduction of resources without added valueTotalPlantEngineeringOptimum softwareHigh-performance CIMMounting process control softwareEvaluation technologyEconomy analysisSystem simulationAssembly, disassembly capability evaluation methodPlant layoutSLP (Systematic Layout Planning)Construction specificationsPoints of Production ImprovementDesign for production: Design feedback using DACmethodDesign with high manufacturabilityReduction of number of partsStandardization of partsIE kaizen: Extensive elimination of muda (loss) by production innovationTransportOperationStagnationFactory automation: Low-cost, easy-to-maintain equipmentEvolutionary Cell Production SystemSymbiosis of Human & Machine： Evolution of Cell Production by ProductionInnovation EquipmentManual CellEvolutionary CellProduction InnovationEquipment Easy & SmoothOperationProduction Innovation EquipmentBenefits from Evolutionary Cell ProductionHeadcount SavingQuality ImprovementReduction of Lossesat Learning StageManual EvolutiontimeCellCellStarting UpEvolutionary Cell Production Example Evolutionary Cell Production Example Basic design of cell production line1. Production oriented design: feedback to design by using DACanalysis2. Summarized process organization3. Layout image drawing4. Application image using production innovation equipment5. Profitability investigationDesign for Assembly/Disassembly Cost-effectivenessFeatures of Parts evaluates the shape and other characteristics of a part that determines the ease with which it can be fed and acquired(picked).Features of Assembly evaluates the ease with which the part can be oriented, retained and assembled.Features of Processing evaluates the ease with which the base part can be retained or turned over for the next operation.Design with highassemblabilityDACSheetAssembly evaluation problems, summary of suggested improvementsNo.PartProblemImprovementPointsDesignBefore1Pinch drive arm2Gear cover CFeatures of Assembly：Difficult positioning during insertion (-10)When placing Gear cover C on the Pinch drive arm, the Pinch drive arm moves, so positioning is difficultFea