单元式生产布局cell line

单元式生产布局CELL,议程Agenda,传统组装线设计TraditionalAssemblyLineDesign工位设计WorkStationDesign物料展示MaterialPresentation物料补充MaterialResupply物料储存MaterialStorage,1.传统组装线设计TraditionalAssemblyLineDesign,精益生产系统组装线模式特点,工人灵活Flexibleoperators(multiprocessingandcross-trained)走动方便Freedomofmovement(standing+movingoperations)标准化作业Standardoperations(assemblyonly,Waterspiders+standardoperations)目视化工场Visualworkplace(Aplaceforeverything,everythinginitsplace)最少线上存货Minimallinestock(nomini-w/h,max.2-hLinestock)柔性生产Flexibleproduction(variationsineithermixorvolume,Noislands!)节拍器Pacemakers(LinesincorporatepacemakerstosetpacetoTT,nottoself-pacing)保证质量Qualityensured(goornogo,3Nos),组装线布局的目的AssemblyLayoutGoals,按照节拍时间,生产优质产品Qualityproductsproducedattakttime有效利用人力Productiveutilizationofpeople装配工只做装配Assembleproductonly按节拍分配任务达到高生产力Highoperatorproductivitythroughloadingtotakttime工人能完成整个流程Operatortocompletethefullprocess物料/工人流畅Flowofmaterialandoperators优化工位以方便摆放零件物料工具Workstationsoptimizedforpresentationofparts,materials,andtools工位设计减少走动Workstationdesignminimizesoperatormovements信息即时反馈Immediateflowofinformation/feedback问题立即暴露Immediatelyexposeproblems,U型线U-ShapedLine,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负责所有物料需求从“U”型线外送料取走成品节拍变，你也变人员安排可以应变,Imwaterspider.,Wereoperators.,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0.81.2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（18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-ShapedLine,B.组装线设计,直型线StraightLine,当产品结构和物料展示能够保证时使用Usedwhenproductconfigurationandmaterialpresentationwarrant例如，汽车组装线e.g.,automobileassembly生产线的速度由产品的移动速度决定Linepacedbyproductmovement随时掌握装配进展Assemblyprogressiononline已经设立了工人区Workerzonesareestablished已经定义了交接区(交接指挥棒)Overlap(batonpassing)isdefined按使用次序安排物料Materialissequencedinorderofuse柔性生产时Formixed-modelproduction非整合分装(预装)按配套供料Non-integratedsub-assembliesaresuppliedascompletedkits必须建立信息与反馈系统Communicationandfeedbackmustbeestablished例如喇叭灯号e.g.,speaker,lights,有喂料”的直型线StraightLineWithFeeders,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。Usedwhenasubassemblycycletimeexhibitsmajorvariationsinamixed-modelproductionenvironment将会出现这种重大变化的分装线从总装线中分离出来Shiftsthesubassemblyexperiencingthewidevariationoffthemainassemblyline总装线上设有“节拍器”“Pacemaker”establishedonfinalassemblyline例如，生产线按节拍时间连续移动i.e.,continuousmovementofthelineatthetakttimerate总装线“拉动”分装线Finalassembly“pulls”fromsubassembly分装线的工作与总装线分开Subassemblyworkseparatedfromfinalassemblywork适应产品的变化Facilitatesproductvariation在生产支线/生产单元完成分装工作Subassembliescompletedon“spur”line/cell例如，附属于总装线的生产支线/生产单元i.e.,attachedtomainline分装线在需要使用零件的地方才介入总装线Subassembliesenteratpointofuse从后面供应物料Materialsuppliedfromback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-operatorsub-assemblycellisonthe“back”,sinceitsoutputispresentedtothemainlineoperatorsjustlikeotherpartsandmaterials.按使用次序安排物料Materialssequencedinorderofuse,开放式平行线布局Parallel(OpenRoom)Layout,需求大Highdemand节拍时间短Shortertakttime两个工人2operators,需求小Lowdemand节拍时间长Longertakttime一个工人1operator,开放式布局举例OpenRoomLayoutExample,改善前BeforeKaizen,铅胚卡板,改善后AfterKaizen,1,2,3,4,8,7,6,5,1,2,3,4,8,7,6,5,1,2,3,4,8,7,6,5,成品FG,原料RM,新的工区布局NewWorkAreaLayout,开放式布局举例OpenRoomLayoutExample,典型工位TypicalWorkstation,2.工位设计WorkStationDesign,成品,成品,原料,原料,工位设计目标WorkStationDesignObjectives,减少各种浪费Minimizewaste缩短操作员周期时间Minimizeoperatorcycletime保证产品质量Ensuregoodpartsproduced能处理多工序Enablemulti-processhandling建立目视工场Establishavisualworkplace,支持及时生产原理SupportJITPrinciples,工位设计原理WorkStationDesignPrinciples,标准化作业Standardoperations适当面积Appropriatesize零件排列Partarrangement工具标准化Toolstandardization工具放置Toolplacement目视控制Visualcontrols工人走动Operatormotions质量控制Qualitycontrols物料补充Replenishment,供料高度：1500mm,工作区域:900to1000mm,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,精益工位,物料补充系统说明MaterialReplenishmentSystemComments,线上展示物料供给系统Alinestocksupplysystemformaterialpresentation线上送料员物料补充系统Awaterspidersystemformaterialresupply物料储存超市系统Asupermarketformaterialstorage,物料展示MaterialPresentation,工人周期时间过长Excessiveoperatorcycletime装配顺序错误Assemblyinwrongsequence零件方向装错Assemblywithwrongpartorientation装配产品质量不良Defectiveassemblies零件丢失Missingpart用错零件Wrongpartinstalled零件用对了，但却装错了Rightpart,butinstalledincorrectly做错产品Wrongproductbuilt,物料展示不良之结果ResultsofPoorPartPresentation,物料展示MaterialPresentation,减少工人周期时间变动Minimizeoperatorcycletimevariation按使用顺序放零件Arrangepartsinorderofuse按正确方向放零件Presentpartsinproperorientation按工人易拿取放零件Makepartseasilyaccessibletotheoperator减少工位物料存量Minimizematerialattheworkstation有利于标准化作业，保证产品质量Enablestandardoperationsand零件定位Consistentpartlocation零件定向Consistentpartorientation零件定序Presentationsequenceconsistentwithassemblysequence容易补充物料,不会影响工人Makereplenishmenteasy&non-intrusive供料不打扰、不影响工人操作Non-intrusivereplenishmentmeansthatresupplydoesntinterferewithorobstructtheoperator.从生产单元外面或线后供料Resupplypartsfromoutsidethecellorbehindtheline良好人机工程状态Establishgoodoperatorergonomics不用弯腰伸腰扭腰或高举Nobending,stretching,twisting,orlifting.良好的人机工程消除了工人过多的动作、提高了生产力Goodergonomicsalsobenefitproductivitybyeliminatingthewasteofexcessiveoperatormotions,设计原理DesignPrinciples,线上双箱系统Two-BinSystem(LineStock),空箱退回下面EmptybinsReturnedBelow,当一个箱子空了时，按灯会亮，表明需要补充第二个箱子了Asonebinisemptied,anandonsignalindicatestheneedforasecondbintobeprovided.每个箱子最多只能装两个小时的物料Eachbincontainsatmostonehoursworthofparts.给空箱子补充物料，重新使用这些箱子Emptybinsarerefilledandreused.最适合如下装配作业：Bestusedwhentheassemblyoperationhas:产品型号不多Alownumberofmodels零件品种不多Lesserpartvariety节拍时间较短Alowtakttime换模次数不多Alownumberofsetups,C.物料配送,工位送料设计Workstationfeeding,C.物料配送,取料/取箱空间SpaceavailableforpickingupcontainersorpartsE1=E2=100mm(4”)搬运料箱最小空间minimumforhandlingcontainers,E1=150mm(6”)从料箱内取料空间ifpartsaretobepickedupfrominsidecontainers.最大取料深度“P”Maximumpick-updepthP300mm(12”)需考虑料架厚度withrespecttoshelfedge.最小取料高度Minimumheight频繁搬运的物料/料箱勿放地上dontplacepartsorcontainerstobefrequentlyhandledonthefloor,如必要，留出足够弯腰频繁搬运空间ifnecessary,leaveenoughspacetocrouchwhenliftingthem.,C.物料配送,工位送料设计Workstationfeeding,配套供料系统KittingSystem,何谓配套零件?Whatsapartskit?“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”consistsofallthepartsneededtoproduceoneunit,whichisdeliveredtotheassemblyline“justintime”.它的优点何在?Whataretheadvantages?有利于保证质量Helpsensurequality建立生产线顺序Establisheslinesequencing何时使用配套零件?Whensakitused?产品型号较多Ahighernumberofmodels零件品种较多(一套零件将全部展示给工人)Greaterpartvariety(thekitdisplaysallthepartsneededtotheoperator)节拍时间较长Ahighertakttime(use“kit”above7asruleofthumb)换模次数较多Ahighernumberofsetups,物料补充MaterialResupply,何谓线上送料员(水蜘蛛)?Whatsawaterspider?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AwaterspiderisadedicatedmaterialhandlerwhoreplenishesacellJIT,accordingtostandardoperations.线上送料员如何工作?Whatdoesawaterspidersworklooklike?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Awaterspiderfollowsaspecificreplenishmentroute,pickingupmaterialsfromamainsupplypointanddeliveringthemtothelinestocksupplypoints为何要线上送料员?Whyhaveawaterspider?好处Benefits快速地稳定地给生产线提供物料Providesconstant,rapidreplenishmentofmaterialtotheline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Improvesassemblerefficiencybyeliminatingmaterialhandlingfromassemblertasks,enablingstandardoperations.建立物料供应标准化作业，改善产品质量Improvesqualitybyestablishingstandardworkformaterialresupply,线上送料员(水蜘蛛)系统WaterSpiderSystem,线上送料员工具WaterSpiderTools,物料补充MaterialResupply,线上送料员标准化作业WaterSpiderStandardOperations,物料补充MaterialResupply,步骤1:确定工位标准化作业Step1:Determineworkstationstandardoperations步骤2:识别待送零件Step2:Identifypartstobedelivered步骤3:制定物料展示系统Step3:Creatematerialpresentationsystem步骤4:做好分料箱/配套箱Step4:Createpickingcontainer(s)orkits步骤5:设计及制定线上送料员分料车和分料单Step5:Design&createwaterspiderpickingcart&pickinglist步骤6:设计及建造超市Step6:Design&buildsupermarket,实施线上送料员系统ImplementingaWaterSpiderSystem,物料补充Material