单元生产方式cell全面解PPT课件

.,1,Cell生产方式简介,IE：王红日期：2009/12/10,.,2,目录,1.Cell的基本概念,2.CellLine的优点,3.CellLine的基本布线规则,4.单件流,.,3,1.每个细胞均具有独立功能2.可与其他单元任意组合3.自主性/灵活性4.细胞间活动协调一致,1Cell的基本概念(1),它代表着创造性与灵活性!,1.1Cell:“单元/细胞”的意思,.,4,1.如同蜜蜂群的组织分工2.如同蜜蜂群的团结合作,1Cell的基本概念(2),1.2Cell:“蜂窝”的意思,它代表着TeamWork的概念!,.,5,1.增加产线灵活性(型号、产量、布局）2.库存降低3.可依实际订单决定开几条线(弹性)4.后工序等待时间减少5.可快速换线(插入急单),优点：,2CellLine的优点,2.1同步化生产,.,6,1.换线容易(减少延误工时)2.减少因线不平衡带来的损失3.便于保养,2.2设备小型化,优点：,.,7,1.生产率提升2.工序的前置时间改善3.减少生产中的工作量4.减少因线不平衡带来的损失5.品质提升6.人员的减少,2.3多能工的培养,优点：,多能工,.,8,Before,1.按需生产2.生产排程的灵活性增强3.多机种混合生产4.换线容易5.小批量生产,After,2.4弹性（灵活）排程,优点：,.,9,1.节省取放材料的时间2.控制WIP,1.A工序做完后材料无须送往下一工序,由B工序同事来取；2.有用到工装的站别，通常该工序员工只负责上工装，做完后由下一站员工负责下工装,(测试站别无人化操作)。,2.5拉式生产方式,优点：,从上一工序拉(PULL)而非传送下一工序(PUSH),.,10,1.生产排程的灵活性增强2.换线容易(减少延误工时)3.作业员之间的沟通更容易、有效4.品质提升5.制程的前置时间改善6.减少制程中的工作量7.减少因线不平衡带来的延误8.作业员责任明确,从左往右,3CellLine的基本布线规则,3.1站立、从左往右,优点：,.,11,3.2人在内转,.,12,600/天,300/天,300/天,够小,够精,够活,3.3cell越小越好,.,13,1.不落地生根,传统观点认为设备越大效率越高，通常将设备固定在地面而无法移动。设备不能移动，自然缺乏弹性，也就失去了改进布置、应对市场变化的能力。,3.4架线的三不政策(1),改采设备小型化或设备可动化。,管线不像常青藤,.,14,设备“寄居”在固定的管、线及中央式装置之下而无法移动。,3.4架线的三不政策(2),2.不寄人篱下,放弃中央式设施,改采用分离式设备如：快速接头、弹性接口。,.,15,1.品质提升2.WIP减少3.前置时间减少4.消除搬运,离线,随线,工序2,切勿离线作业,只能以“主流,支流”的概念进行站别布置!,3.4架线的三不政策(3),3.不离群索居（INLINE）,优点：,工序1,工序2,工序2,工序1,工序2,工序2,工序2,.,16,一笔画布置,3.5工厂一笔画布置,工厂/生产流程在整体上呈一笔画布置,.,17,1,2,3,4,IO一致原则,1,2,3,4,空手走动浪费,Input,Output,Input,Output,生产投入点与完成品取出点尽可能靠近，以避免作业返程造成的时间和体力浪费。,3.6生产线U形化(1),IO一致原则同样适用于设备布置，亦可节省空间占用。,.,18,1.以U字型布置方式按工艺流程排列生产。2.入口和出口尽量由同一作业者负责，能够以产距时间按标准数量进行生产及管理，也便于补充生产。3.便于作业者相互协作，异常时能停线，及时暴露问题并改善之。4.步行最短，可单件流动，人员可增可减。,1,2,3,4,5,8,14,13,12,11,7,10,9,6,成品,材料,3.6生产线U形化(2),.,19,各站产出状况,数量,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,站1,站2,站3,站4,站5,站6,平常堆货的生产模式,每站看似都很忙,也能一直保障3pcs的产出,所以看不到线平衡的问题,单件流(站6只需要1pcs)的拉动式生产模式可轻易看到线平衡的问题,我只要1pcs,4单件流,.,20,单件流真的能节约时间吗?时间会不会变长?单件流到底有什么好处?我们可以通过下面动画,看到传统堆货生产&单件流的不同(某个包含3站的产品)。,面对单件流的疑问?,.,21,传统堆货生产,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:00,A站,B站,C站,21pcs产品,.,22,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A站,B站,C站,21pcs产品,传统堆货生产,.,23,15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A站,B站,C站,21pcs产品,1,传统堆货生产,.,24,15,8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A站,B站,C站,21pcs产品,2,传统堆货生产,.,25,15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A站,B站,C站,21pcs产品,3,传统堆货生产,.,26,15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,6,21,14,7,00:05,A站,B站,C站,21pcs产品,4,传统堆货生产,.,27,15,8,6,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,7,00:06,A站,B站,C站,21pcs产品,4,传统堆货生产,.,28,15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:07,A站,B站,C站,21pcs产品,4,传统堆货生产,.,29,15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:08,A站,B站,C站,21pcs产品,4,传统堆货生产,.,30,15,9,7,16,8,17,10,3,18,11,1,19,12,2,20,13,5,21,14,6,00:09,A站,B站,C站,21pcs产品,4,传统堆货生产,.,31,15,10,7,16,9,17,8,1,18,11,2,19,12,3,20,13,5,21,14,6,00:10,A站,B站,C站,21pcs产品,4,传统堆货生产,.,32,15,11,7,16,9,17,8,2,18,10,3,19,12,4,20,13,5,21,14,6,00:11,A站,B站,C站,21pcs产品,1,传统堆货生产,.,33,15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:12,A站,B站,C站,21pcs产品,2,传统堆货生产,.,34,15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:13,A站,B站,C站,21pcs产品,2,传统堆货生产,.,35,15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:14,A站,B站,C站,21pcs产品,2,传统堆货生产,.,36,15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:15,A站,B站,C站,21pcs产品,2,传统堆货生产,.,37,16,13,6,15,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:16,A站,B站,C站,21pcs产品,2,传统堆货生产,.,38,16,13,6,15,10,17,8,2,18,9,3,19,11,7,20,12,1,21,14,5,00:17,A站,B站,C站,21pcs产品,4,传统堆货生产,.,39,16,13,6,15,11,18,8,2,17,9,4,19,10,7,20,12,1,21,14,5,00:18,A站,B站,C站,21pcs产品,3,传统堆货生产,.,40,16,13,6,15,12,19,8,2,17,9,5,18,10,7,20,11,1,21,14,4,00:19,A站,B站,C站,21pcs产品,3,传统堆货生产,.,41,16,12,5,15,13,20,8,2,17,9,6,18,10,7,19,11,1,21,14,4,00:20,A站,B站,C站,21pcs产品,3,传统堆货生产,.,42,16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:21,A站,B站,C站,21pcs产品,3,传统堆货生产,.,43,16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:22,A站,B站,C站,21pcs产品,3,传统堆货生产,.,44,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:23,A站,B站,C站,21pcs产品,3,传统堆货生产,.,45,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:24,A站,B站,C站,21pcs产品,3,传统堆货生产,.,46,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:25,A站,B站,C站,21pcs产品,3,传统堆货生产,.,47,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:26,A站,B站,C站,21pcs产品,3,传统堆货生产,.,48,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:27,A站,B站,C站,21pcs产品,3,传统堆货生产,.,49,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:28,A站,B站,C站,21pcs产品,3,传统堆货生产,.,50,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:29,A站,B站,C站,21pcs产品,3,传统堆货生产,.,51,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:30,A站,B站,C站,21pcs产品,3,传统堆货生产,.,52,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:31,A站,B站,C站,21pcs产品,3,传统堆货生产,.,53,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:32,A站,B站,C站,21pcs产品,3,传统堆货生产,.,54,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:33,A站,B站,C站,21pcs产品,3,传统堆货生产,.,55,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:34,A站,B站,C站,21pcs产品,3,传统堆货生产,.,56,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:35,A站,B站,C站,21pcs产品,3,传统堆货生产,.,57,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:36,A站,B站,C站,21pcs产品,3,传统堆货生产,.,58,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:00,A站,B站,C站,21pcs产品,单件流,.,59,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A站,B站,C站,21pcs产品,单件流,.,60,15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A站,B站,C站,21pcs产品,1,单件流,.,61,15,8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A站,B站,C站,21pcs产品,2,单件流,.,62,15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A站,B站,C站,21pcs产品,3,单件流,.,63,15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,6,21,14,7,00:05,A站,B站,C站,21pcs产品,4,单件流,.,64,15,8,6,16,9,17,10,4,18,11,3,19,12,2,20,13,1,21,14,7,00:06,A站,B站,C站,21pcs产品,5,单件流,.,65,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:07,A站,B站,C站,21pcs产品,6,单件流,.,66,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:08,A站,B站,C站,21pcs产品,6,单件流,.,67,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:09,A站,B站,C站,21pcs产品,6,单件流,.,68,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:10,A站,B站,C站,21pcs产品,6,单件流,.,69,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:11,A站,B站,C站,21pcs产品,6,单件流,.,70,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:12,A站,B站,C站,21pcs产品,6,单件流,.,71,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:13,A站,B站,C站,21pcs产品,6,单件流,.,72,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:14,A站,B站,C站,21pcs产品,6,单件流,.,73,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:15,A站,B站,C站,21pcs产品,6,单件流,.,74,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:16,A站,B站,C站,21pcs产品,6,单件流,.,75,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:17,A站,B站,C站,21pcs产品,6,单件流,.,76,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:18,A站,B站,C站,21pcs产品,6,单件流,.,77,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:19,A站,B站,C站,21pcs产品,6,单件流,.,78,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:20,A站,B站,C站,21pcs产品,6,单件流,.,79,15,8,7,16,9,17,10,5,18,11,4,19,12,