伟创力精益JIT项目精典案例

1、Date : 2007.01.171、CURRENT STATUS:PROJECT:Latte printerLINE:Main frame & sub lineOperators (original):Leader : 2 EARepairer: 1EAMobile OP： 1EADirect OP: 20EA(Main line)Direct OP: 17EA(Five Sub)Total Operators:41 EATake Time:45 SecTarget Capability:80pcs/hExpectation Effect:Planning ActionReduce the

2、headcount 1.Balance the line; 2.Optimize operation; 3.reduce transitReduce Lead time1.reduce over production; 2.reduce WIPIncrease the value of space1.change layout ; 2.reduce over productionImprove quality1.reduce transit ; 2.using fixture to fool proofingLine Status:Line Area:=12M*6.6M-8*1.5 =67.2

3、mm2、MAIN LINE & SUB LAYOUT (original)12M6.6M8M1.5M3. WORK SAMPLING STATISTICS & H/C EVALUATION:4.Main Line & Sub Layout (improved)Line Status:Line Area:12M*4.5M =54mm12M4.5M5. PROCESS FLOW CHART MainFrameBarrow,70m，40EA/time（16EA/BOX）AssemblyBarrow,5m，36EA/time（12EA/BOX）Left FrameAssemblyRight Frame

4、ACMGear TrainDuplex AssyBarrow,70m，160EA/time（80EA/BOX）Barrow,10m32EA/time（16EA/BOX）MainFrameAssemblyLeft FrameAssemblyRight FrameACMGear TrainDuplex AssyChange6.6.BALANCE PRODUCTION LINE Eliminate waiting, Neither make anybody too busy, Nor make anybody too free! Only a Fair Environment is able to

5、found high work morale.7. DIFFERENCE差异项目 Difference Item当前实际 Actual改善后 Improved比率 Ratio备注 Remark人员 Human Leader210.50 Now we dont need to transit five sub to main line.Repairer111.00 Mobile OP111.00 Direct OP37280.76 Total41310.76 设备/夹具 FixtureFixture18110.61 Rack200.00 Screw driver21200.95 Screw Su

6、pplier661.0 占用面积 Area67mm54mm0.80 Lead Time ( hour )1.42 0.66 0.46 每小时人均产能 Capability PPH2.16 2.86 1.32 8-1. DETAIL OF KAIZEN(1) Before ImprovingAfter ImprovingType of Waste Improving ActionTransportation: Ops need transit printer from conveyer belt to workstation. Use roller line, So Ops dont need

7、to transit printer from conveyer belt to workstation. And every Op will almost reduce a little transportation.8-2. DETAIL OF KAIZEN(2) Before ImprovingAfter ImprovingType of Waste Improve ActionMotion: Materials isnt appropriate level of reachPut screw driver on material bracket ,So the distance fro

8、m screw driver to screw hole is much shorter then before. In line there are many station like this.8-3. DETAIL OF KAIZEN(3) Before ImprovingAfter ImprovingType of Waste Improve ActionOver-processing, Transportation , Inventory, Over production, Defect: Pool layout make almost these five types waste

9、in old line.Redesign new “JIT” layout ,Reduce Batch Size to “one piece flow”. (please refer 4.Main Line & Sub Layout (improved)8-4. DETAIL OF KAIZEN(4) Before ImprovingAfter ImprovingType of Waste Improve ActionMotion: Switch used with foot press, Op would keep one leg standing, that made them tired

10、.Put switch on collet，Op can press the switch in the same time when move to the relevant position.Switch used with footSwitch used with finger8-5. OTHER KAIZEN (1)Before ImprovingAfter ImprovingType of Waste Improve ActionMotion/Cost: The part put one side(A side)to opposite side(B side) from A fixt

11、ure to B fixture.Improve a little A fixture ,Then the part can be put on one fixture, whenever A side or B side. Total Seven fixture eliminate in new line.B sideSwitch used with fingerA sideA sideB side8-6. OTHER KAIZEN (2)Before ImprovingAfter ImprovingType of Waste Improve ActionCost :The metal claw is expensive (142RMB/set),and they are easy to damaged, We need to replace them ter