单元式生产布局CELL

单元式生产布局CELL 2017 4 13 微信分享 议程 Agenda 1 传统组装线设计Traditional Assembly Line Design 2 工位设计 Work Station Design 3 物料展示 Material Presentation 4 物料补充 Material Resupply 5 物料储存 Material Storage 1 传统组装线设计 Traditional Assembly Line Design 物料储存 Material Storage quality problems 悬挂式电动输送带Powered free conveyor 物料储存 Material Storage QP 物料储存 Material Storage QP 物料储存 Material Storage QP 物料储存 Material Storage quality problems 精益生产系统组装线模式特点 Lean Production System Assembly Line Model Characteristics 工人灵活Flexible operators multiprocessing and cross trained 走动方便Freedom of movement standing moving operations 标准化作业Standard operations assembly only Water spiders standard operations 目视化工场Visual workplace A place for everything everything in its place 最少线上存货Minimal line stock no mini w h max 2 h Line stock 柔性生产Flexible production variations in either mix or volume No islands 节拍器Pacemakers Lines incorporate pacemakers to set pace to TT not to self pacing 保证质量Quality ensured go or no go 3 Nos 组装线布局的目的 Assembly Layout Goals 按照节拍时间 生产优质产品Quality products produced at takt time 有效利用人力Productive utilization of people 装配工只做装配Assemble product only 按节拍分配任务达到高生产力High operator productivity through loading to takt time 工人能完成整个流程Operator to complete the full process 物料 工人流畅Flow of material and operators 优化工位以方便摆放零件 物料 工具Work stations optimized for presentation of parts materials and tools 工位设计减少走动Work station design minimizes operator movements 信息即时反馈Immediate flow of information feedback 问题立即暴露Immediately expose problems U型线 U Shaped Line 原料 RM 成品 FG 按灯 Andon 最少走动 工人间的平衡 避免产生孤岛 多工序作业 促进沟通 按灯识别异常 WS负责所有物料需求 o从 U 型线外送料 o取走成品 节拍变 你也变 o人员安排可以应变 I m water spider We re operators 线体设计 物流从右至左 线体设计 每条槽 里放2个料箱 线体设计 工具伸手可及 线体设计 所有料箱都放 置于工位前方 线体设计 模块化和 可连接的工位设计 线体设计 空料箱 从料架下方回收 线体设计 预留 30 的工位空间 线体设计 工作 区间距 1 6米 线体设计 工作台高度 0 8 1 2米 人机工程 线体管理 过道里不 许放料箱 为方便车间目视化 和沟通 建议料架高 度不超过1 5米 线体管理 禁止订单在缺少 零配件的情况下进行生产 线体管理 本独立工作 单元中操作工的数量 1 8人 目视化及5S管理 例 划线并确定相关货架 占地面积 线体设计 最大偏差为 20 拉动信号 目视化和在制品控制 防错 一旦发现缺 陷立即停止生产 B 组装线设计 U型线 U型线 U Shaped Line B 组装线设计 直型线 Straight Line 时间标记 Timing mark指挥棒交接区Baton pass Zone 123412345 当产品结构和物料展示能够保证时使用Used when product configuration and material presentation warrant 例如 汽车组装线e g automobile assembly 生产线的速度由产品的移动速度决定Line paced by product movement 随时掌握装配进展Assembly progression on line 已经设立了工人区Worker zones are established 已经定义了交接区 交接指挥棒 Overlap baton passing is defined 按使用次序安排物料Material is sequenced in order of use 柔性生产时For mixed model production 非整合分装 预装 按配套供料Non integrated sub assemblies are supplied as completed kits 必须建立信息与反馈系统Communication and feedback must be established 例如喇叭 灯号e g speaker lights 有 喂料 的直型线 Straight Line With Feeders Major subassembly Line 主分装线 一人单元 1 operator Cell 两人单元 2 operator Cell 当进行柔性生产 分装线周期时间会出现重大变化时 使用此类生产线 Used when a subassembly cycle time exhibits major variations in a mixed model production environment o将会出现这种重大变化的分装线从总装线中分离出来 Shifts the subassembly experiencing the wide variation off the main assembly line 总装线上设有 节拍器 Pacemaker established on final assembly line o例如 生产线按节拍时间连续移动i e continuous movement of the line at the takt time rate 总装线 拉动 分装线Final assembly pulls from subassembly o分装线的工作与总装线分开Subassembly work separated from final assembly work o适应产品的变化Facilitates product variation o在生产支线 生产单元完成分装工作Subassemblies completed on spur line cell o例如 附属于总装线的生产支线 生产单元i e attached to main line o分装线在需要使用零件的地方才介入总装线Subassemblies enter at point of use 从后面供应物料Material supplied from back o多人的分装线单元要放在 背后 因为分装线的输出是以其它零件和 物料一样的方式 供应给总装线的 Multi operator sub assembly cell is on the back since its output is presented to the main line operators just like other parts and materials 按使用次序安排物料Materials sequenced in order of use 典型工位 Typical Workstation 2 工位设计Work Station Design 工位设计目标Work Station Design Objectives 减少各种浪费Minimize waste 缩短操作员周期时间Minimize operator cycle time 保证产品质量Ensure good parts produced 能处理多工序Enable multi process handling 建立目视工场Establish a visual workplace 支持及时生产原理 Support JIT Principles Continued Nagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou 工位设计原理 Work Station Design Principles 标准化作业Standard operations 适当面积Appropriate size 零件排列Part arrangement 工具标准化Tool standardization 工具放置Tool placement 目视控制Visual controls 工人走动Operator motions 质量控制Quality controls 物料补充Replenishment 供料高度 1500mm 工作区域 900 to 1000 mm 工作平台的高度 空料箱从工位下方返回 仅需部件 照明灯具 多孔插座 文件架 站脚 电源 按供料顺序 从前 方适量供料 1 2小时 模块化和可连接的 工位设计方便拆装 线体 工作平台 使用工 具简单 明确 B 组装线设计 物料补充系统说明 Material Replenishment System Comments 线上展示物料供给系统A line stock supply system for material presentation 线上送料员物料补充系统A water spider system for material resupply 物料储存超市系统A supermarket for material storage 物料展示 Material Presentation 工人周期时间过长Excessive operator cycle time o 装配顺序错误 Assembly in wrong sequence o 零件方向装错 Assembly with wrong part orientation 装配产品质量不良Defective assemblies o 零件丢失 Missing part o 用错零件 Wrong part installed o 零件用对了 但却装错了 Right part but installed incorrectly 做错产品Wrong product built 物料展示不良之结果 Results of Poor Part Presentation 物料展示 Material Presentation 减少工人周期时间变动Minimize operator cycle time variation o 按使用顺序放零件Arrange parts in order of use o 按正确方向放零件Present parts in proper orientation o 按工人易拿取放零件Make parts easily accessible to the operator 减少工位物料存量Minimize material at the work station 有利于标准化作业 保证产品质量Enable standard operations and o 零件定位Consistent part location o 零件定向Consistent part orientation o 零件定序Presentation sequence consistent with assembly sequence 容易补充物料 不会影响工人Make replenishment easy non intrusive o 供料不打扰 不影响工人操作Non intrusive replenishment means that resupply doesn t interfere with or obstruct the operator o 从生产单元外面或线后供料Resupply parts from outside the cell or behind the line 良好人机工程状态Establish good operator ergonomics o 不用弯腰 伸腰 扭腰或高举No bending stretching twisting or lifting o 良好的人机工程消除了工人过多的动作 提高了生产力Good ergonomics also benefit productivity by eliminating the waste of excessive operator motions 设计原理Design Principles 线上双箱系统 Two Bin System Line Stock 空箱退回下面 Empty bins Returned Below 当一个箱子空了时 按灯会亮 表明 需要补充第二个箱子了 As one bin is emptied an andon signal indicates the need for a second bin to be provided 每个箱子最多只能装两个小时的物料 Each bin contains at most one hour s worth of parts 给空箱子补充物料 重新使用这些箱 子 Empty bins are refilled and reused 最适合如下装配作业 Best used when the assembly operation has o产品型号不多A low number of models o零件品种不多Lesser part variety o节拍时间较短A low takt time o换模次数不多A low number of setups C 物料配送 C 物料配送 工位送料设计Workstation feeding 150 mm 6 大件 重件 频 繁搬运区Zone recommended for frequent handling of heavy and bulky parts 可接受搬运区 2次 分钟Zone acceptable for handling twice minute 费力搬运区Arduous zone 费力搬运区Arduous zone C 物料配送 取料 取箱空间Space available for picking up containers or parts E1 E2 100 mm 4 搬运料箱最小空间minimum for handling containers E1 150 mm 6 从料箱内取料空间if parts are to be picked up from inside containers 最大取料深度 P Maximum pick up depth P 300 mm 12 需考虑料架厚度with respect to shelf edge 最小取料高度Minimum height 频繁搬运的物料 料箱勿放地上 don t place parts or containers to be frequently handled on the floor 如必要 留出足够弯腰频繁搬运空间 if necessary leave enough space to crouch when lifting them E2 E1 E2E2 料架上的标准料箱 Standard containers on shelves P 工位送料设计Workstation feeding 配套供料系统 Kitting System 何谓配套零件 What s a parts kit o 配套零件 就是生产一个产品所需的全部零件 它被准时化送达组装线A kit consists of all the parts needed to produce one unit which is delivered to the assembly line just in time 它的优点何在 What are the advantages o有利于保证质量Helps ensure quality o建立生产线顺序Establishes line sequencing 何时使用配套零件 When s a kit used o产品型号较多A higher number of models o零件品种较多 一套零件将全部展示给工人 Greater part variety the kit displays all the parts needed to the operator o节拍时间较长A higher takt time use kit above 7 as rule of thumb o换模次数较多A higher number of setups 物料补充 Material Resupply 何谓线上送料员 水蜘蛛 What s a water spider o 线上送料员是专职的物料搬运人士 他根据标准化作业 及时地给生 产单元补充物料A water spider is a dedicated material handler who replenishes a cell JIT according to standard operations 线上送料员如何工作 What does a water spider s work look like o 线上送料员按特定的送料路径走动 从主供应点拿取物料 送到生产线上 的存货供应点 o为何要线上送料员 Why have a water spider o好处 Benefits 快速地 稳定地给生产线提供物料Provides constant rapid replenishment of material to the line 免除装配工人搬运物料之劳 提高装配工人的效率 实现标准化作业Improves assembler efficiency by eliminating material handling from assembler tasks enabling standard operations 建立物料供应标准化作业 改善产品质量Improves quality by establishing standard work for material resupply 线上送料员 水蜘蛛 系统Water Spider System 线上送料员工具Water Spider Tools 分料车 Picking Cart 分料单 Pick List 超市 Supermarket 分料箱 Picking Container 线上物料供应 Line Stock Supply 物料补充 Material Resupply 线上送料员标准化作业 Water Spider Standard Operations 物料补充 Material Resupply 步骤1 确定工位标准化作业Step 1 Determine workstation standard operations 步骤2 识别待送零件Step 2 Identify parts to be delivered 步骤3 制定物料展示系统Step 3 Create material presentation system 步骤4 做好分料箱 配套箱Step 4 Create picking container s or kits 步骤5 设计及制定线上送料员分料车和分料单Step 5 Design create water spider picking cart picking list 步骤6 设计及建造超市Step 6 Design build supermarket 实施线上送料员系统 Implementing a Water Spider System 物料补充 Material Resupply 物料补充 Material Resupply 改善推动人 早期接受者Kaizen 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