SONY厂房布置2

1、Sony' s Implementation ofProduction Innovation Equipment andManufacturing System SolutionsChapter 11. Introduction1.1 Shift in production needs1.2 Importance of demand oriented production1.3 Production innovation s 3 main types of loss1.4 Cell production methodSOZYShift in Production Needs? Spec

2、ializationEnvironent? Worst post-war economic slum? Multi-functional? Decline of ConsumptiononomicalAass production Many types,small qty Various types, variousquantitiesPricesastic MarketChangeWell-sold productsyNetwork Age? Telecommunication Revolut? Electronic Commercechange quickly? Surplus of in

3、ventory due to the fall of product pricesProtection ofDemand OrientedProductionNo Bordersthe EnvironmentLess Energy? LSI? Less Resources, Recycling? Mechanical - SoftwareSONYImportance of Demand Oriented ProductionAproduced_aige 1 module type production line | 1 x Line change-over,_mode|jhange(Batch

4、-type production linrm* l JVarious demand-oriented cellproduction lines.d eU1c fx Lead-time, Inventory, etc. WIP loss Lead time Products which cannot be sold Change-over lossLntnThe Ultimate Production SystemCost Investment Lead time Inventory SpaceChange-over loss Rejected products BreakdownSONYZer

5、oImplementn ofProduction InnovationOnly make the required products at the required timeProduction Innovation ' s 3 main types of loss1. Handling loss2. Transportation loss3. Stagnation lossMinimization of non-value added resourcesSONYProgress by Production Innovation (1)Small Lot ProductionTarge

6、t:Large inventory qtyInnovationZero InventoryCustomer' sReduced funds turnoverRequired qtyReduced control costsequired productsReduced spaceRequired timeFlow-oriented production, informationSOZYProgress by Production Innovation (3)Inventory Reduction by Logistic Improvementsi Large Order/Deliver

7、y of PartsPush style pStockoir-iInputParts InventoryOutputProvisionJ InnovationRaw materials ? WIP'KanbaHDirectRefrigera tor 'Production lineProduction line Manufacturing equipmentC1Large-size ? High speed ? High performance ? High price11ooooooooo o o ooooooooo111 JInnovationSmaJlsize ? Low

8、-medium speed? Functional ? Low priceWIP reduction _ byZproduction leveling00° 0°° 门门Qoo QooI J J JSOZYMultioperationWIP reduction by production leveling(Multi-skilled workers)Conveyor lineCell Control comprehensive for anyoneData management by computer10000 pcs.Select&Order ? Fix

9、ed place ? Fixed qty ? Fixed markingstorageXXInnovationMax')possible(XXpc sMin(Y Ypcs)Abnormal !SONYn Innovation: Reduction of Manpower(Actual factory example)200(persons)94/3995/3998/3996/3997/39SONV：1400012000100008000600040002000(Actual factory example)94/3 995/39996/3997/3998/3SOZYExample of

10、 Benefits of Production Innovation: Reduction of Lead time(Actual factory example)0(days)3530252015#59In-house production98/3996/3997/39ZYExample of Benefits of Production Innovation: Revenue&Profit(Actual factory example)100(%)80RevenueProduction Innovation Activities6040-20200Note) Ratio (%) w

11、ith 1992 revenue as 100SONYConveyor lineChange-over loss occursLine balance loss occurs? Layout modification is difficultHandling loss occursOne man 'stall ' typeLflI LflI LflISmall module unit typeSpiral typeCartSOZYCell Production MethodChapter 22. Benefits of Cell Production Method2.1 Cel

12、l Production Method2.2 Benefits of Cell Production Method2.3 Examples of Cell Production MethodSmall scalelineMulti-functionalworkSmall lotFlow orientedPackagingproductionSOZYExample of Cell Production SystemSONYBenefits of Cell Production Method Quantity fluctuation Various layoutConvbyor lineConve

13、yor lineConveyor line八Producti onLoss in productionline changeLine multiplication is difficultCell productionProduct i onOperation in 3CellsLayou t modif icati on is diffi cultTimeCell productionBy number of workersBu number of cells rTT1rIlJctypess,production quantity; layoutImplemeeaccordingleveln

14、tationltoofoflproductsoperatomodifications are possible flexiblyCell productionvariousattributers, Cells by production type Production by sales speedSOZMBenefits of Cell Production Method Space reductionConveyor lineWork timeWork tableLoss timeProducti-onqtyChange-overLossAProcessCell productionB CT

15、ime Manpower reduction by elimination of conveyor line loss Space reduction by removal of conveyorby reducing in-betweenElimination of lossspacesBenefits of Cell Production MethodAs syAs syPacka-gingInventoryInsp.Pack. Insp.Stagnation of the products in processryStagnation, transportation loss betwe

16、en or within processes Reduction of stagnation in processesSlow feedback of quality informationLead time reductionUnclear responsibility concerning quality Reduction of inventory Fast feedback of quality information Clear responsibility concerningquality一 Quality improvementHigher work morale by ind

17、ividual performanceSOZYChapter 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 EquipmentSOZYRole of Production TechnologyProduce prod

18、ucts which have not been produced beforeBasic Technology Development which supports Products ExcellenceFurther strengthening of Product Creation ' s QCD+FRealizationEngineering which supportsManufacturing ExcellenceSOTSTYCodependence of Men and MachinesRole of the operator:“efficiently operate p

19、roduction equipmentmake improvements to increase capacity make arrangements for next production models“Creation ”“design systems ”make equipment, toolsworkSOZYFlexibilityCompact? Ability to make the required qty atthe required pace (demand synchronizedprction)Small equipment, not taking muchinstalla

20、tiaceEasy reflection of improvement plans for efficiency (reflect the feeling? Price suitable to achieve eaon the work floor)Flexibility to adapt to productNo production of rejected productsmodificationsSimple procedure for productchange-over? Minimum required maintenance, easy to carry outFew break

21、downsSONYROBOKIDMakes Cell-Production Evolution RealizedDevelopment Concept:CompactOutstanding Features Compact :vs. conventional 1/4(A4 size ) Costvs. conventional1/3SONY Flexibility : WideVariety of Applications(Soldering, Dispenser, Screw-Fastening, Circuit Board Splitting)ROBOKIDS Features Conve

22、ntional TypeA4-Size4 0%SMART SYSTEM2 0%0%InstallationInstallation 1 month 2 months 3 months4 monthsSOZYROBOKIDS WORLDide Variety )Circuit BoardSplittingDispenser ROBOKIDSSOZYActual condition at production factoriesFlexibility is a main issue in the assembly area , as a starting point of production i

23、nnovation, 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 neededintroduceassy line(a)“A mounting proces

24、s, where production innovation is still difficult toLarge lot productionMounting line(A)assy line(d)Mounting line(B)assy line(b)assy line(e)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 possi

25、ble 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 levelSONYFlexible Structur

26、eSI-E1000SI-E2000Connectedmachines< Standard type connection >ParentChildrenOne machine is the parent unit and the other three machines are the children unitsP a r e n tre of type-dependant parts, the other three machines are connected. (type change-over only for the first machine)Children<

27、PCB Mixed flow compatib le >O1n em a c hi n et a k e scSOZYFlexible Production Capacityin 1.2 min 2.4 m=38,571 c p h=51,428 cphin 3.6min 4.8mSOZYComparison of Conventional Mounters and Celluar Mounter20% Investment saving and 55% space saving is possible(peMne )7.2mInvestment -20%Space-55%1.2mCel

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29、/| pSummarySONYTotal Plant Engineering Elimination of waste and losses? IE approach Construction of optimum operation system? Alternative scheme trade-off analysis 一? Reduction of resources without added value? Clarification of system specificationsTotalPlantEngineering Optimum software Optimum hard

30、ware? Machining, assembly,adjustment, inspectionMaterial handling systemsConstruction specificationsHigh-performance CIMMounting process control software Evaluation technologyEconomy analysisSystem simulationAssembly,disassembly capability evaluation method Plant layout? SLP (Systematic Layout Plann

31、ing)SOZYPoints of Production Improvement1 . Design for production: Design feedback using DAC method? Design with high ' manufacturability ? Reduction of number of parts? Standardization of parts2. IE 'kaizen' : Extensive elimination of'mudf (loss) by production innovation? Transport

32、? Operation ? Stagnation3 . Factory automation: Low-cost, easy-to-maintain equipmentSOZYSymbiosis of Human & Machine : Evolution of Cell Production by ProductionInnovation EquipmentProduction InnovationEquipmentEasy & SmoothProduction Innovation EquipmentBenefits from Evolutionary Cell Produ

33、ctionHeadcount SavingQuality ImprovementReduction of Lossesat Learning StageManualEvolutiontimeBasic design of cell production line1. Production oriented design: feedback to design by using DAC analysis2. Summarized process organization3. Layout image drawing4. Application image using production inn

34、ovation equipment5. Profitability investigationSOZYD ACDesign for Assembly/Disassembly Cost-effectivenessFeatures of Parts? evaluates the shape and other characteristics of a part that determines theease with which it can be fed and acquired(picked).Features of Assembly? evaluates the ease with whic

35、h 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 forthe next operation.Design with highassemblabilitySOZYDACSheetSOZYAssembly evaluation problems, summary of suggested improvementsNo.ParProblePoints

36、DesignImprovemen tBeforearm moves, so positioningpin (+10)is difficult1 Pinch drive armFeatures of Assembly : Difficult positioning during insertion (-10)2 Gear cover CWhen placing Gear cover C on the Pinch drive arm, the Pinch drive arm moves, so positioning is difficultWhen screw fastening (next o

37、peration), retaining is neededFeatures of Assembly : Difficult positioning duringFeatures of Assembly : Difficult positioning during insertion (-10), Retain (-10)When placing Gear cover C on the Pinch drive arm, the Pinch driveFac ili tat e pos iti oni ng by use of a pos iti oni ngFacilitate positio

38、ning by temporarily fixing with a Positioning pin (+10)Facilitate positionin g, and make retaining unnecessar y whenscrewfastening (+10)(After)90(100)80(100)insertion (-10)3 Gear cover AaciIitate positioning by use of a positioning5 Retaining cover4 Drum base6 Drum96Will be conside red(fe ed;Whenins

39、erting20Coaster S, T、in the Drumpic k;base,unstable-10)situationCommentWill be consideredWill be consideredWhen placing Gear cover A, the connection with the Mode gear is complicated, so positioning is difficultFeatures of Part ： During feeding, picking, situation is not completely stableFeatures of

40、 Assembly: Positioning difficult d.Assembly direction is diagonally down(-20), Difficult positioning (-10)pin (+10)(100)1 oiF P (-W RPi diW fa re nF0), slid ccursing (-10)_PQsilionjng pin is_ impossible assembly_ _J, difficult to remove by temporarily fixing (+30)(90)conside redof Drum is difficulte

41、ature rocesa 10)s of>ing : RetainFacilitate positioning byWill be considehen a etainittaching the ig board,making temporary fixing points (+10)70(90)redositior fficulthen s stenin :tainining iscrewg，g isracililale positioning, and make retaining unnecessary when screw fastening (+10)Facilitate po

42、sitioning by use20Improveme nt impossibl eeaturearys of Partof a positioning guide(+10)(30)cautionscratchneeded ioi es, dirt(-20)Features ofAssembly:SOZYProcess organizationP rocess or ganZation (45 sec cycl e cel)RO B O K ID S screw ing t ime: 1 place 4.5sec/screw ?Input/out put t im e4sec RO B O K I D S gear supply t ime: 1 place 8.0sec/1 ?nput/out put t im e 4sec RO B O K ID S grease appl ication ti me: 1 pl ace 4.5sec/1 ?Input/out put t ime4sec RO B O K I DS soldering ti me: 1 place 3sec/pl ace1solder?Fixture I nput/output 4secMech. assyF P C assyNoO perati onIDS C ycl eT ime K