伟创力精益JIT项目精典案例复习课程

Date:2007.01.171、CURRENTSTATUS:PROJECT:LatteprinterLINE:Mainframe&sublineOperators(original):Leader:2EARepairer:1EAMobileOP：1EADirectOP:20EA(Mainline)DirectOP:17EA(FiveSub)TotalOperators:41EATakeTime:45SecTargetCapability:80pcs/h

ExpectationEffect:PlanningActionReducetheheadcount1.Balancetheline;2.Optimizeoperation;3.reducetransitReduceLeadtime1.reduceoverproduction;2.reduceWIPIncreasethevalueofspace1.changelayout;2.reduceoverproductionImprovequality1.reducetransit;2.usingfixturetofoolproofing第一页，共13页。LineStatus:LineArea:=12M*6.6M-8*1.5=67.2mm2、MAINLINE&SUBLAYOUT(original)12M6.6M8M1.5M第二页，共13页。3.WORKSAMPLINGSTATISTICS&H/CEVALUATION:第三页，共13页。4.MainLine&SubLayout(improved)LineStatus:LineArea:12M*4.5M=54mm12M4.5M第四页，共13页。5.PROCESSFLOWCHARTMainFrameBarrow,70m，40EA/time（16EA/BOX）AssemblyBarrow,5m，36EA/time（12EA/BOX）LeftFrameAssemblyRightFrameACMGearTrainDuplexAss’yBarrow,70m，160EA/time（80EA/BOX）Barrow,10m32EA/time（16EA/BOX）MainFrameAssemblyLeftFrameAssemblyRightFrameACMGearTrainDuplexAss’yChange第五页，共13页。6.6.BALANCEPRODUCTIONLINEEliminatewaiting,Neithermakeanybodytoobusy,Normakeanybodytoofree!OnlyaFairEnvironmentisabletofoundhighworkmorale.第六页，共13页。7.DIFFERENCE差异项目DifferenceItem当前实际Actual改善后Improved比率Ratio备注Remark人员HumanLeader210.50Nowwedon'tneedtotransitfivesubtomainline.Repairer111.00MobileOP111.00DirectOP37280.76Total41310.76设备/夹具FixtureFixture18110.61

Rack200.00

Screwdriver21200.95

ScrewSupplier661.0占用面积Area67mm54mm0.80

LeadTime(hour)1.420.660.46

每小时人均产能CapabilityPPH2.162.861.32

第七页，共13页。8-1.DETAILOFKAIZEN(1)

BeforeImprovingAfterImprovingTypeofWasteImprovingActionTransportation:Opsneedtransitprinterfromconveyerbelttoworkstation.

Userollerline,SoOpsdon’tneedtotransitprinterfromconveyerbelttoworkstation.AndeveryOpwillalmostreducealittletransportation.第八页，共13页。8-2.DETAILOFKAIZEN(2)

BeforeImprovingAfterImprovingTypeofWasteImproveActionMotion:Materialsisn’tappropriatelevelofreachPutscrewdriveronmaterialbracket,Sothedistancefromscrewdrivertoscrewholeismuchshorterthenbefore.Inlinetherearemanystationlikethis.第九页，共13页。8-3.DETAILOFKAIZEN(3)

BeforeImprovingAfterImprovingTypeofWasteImproveActionOver-processing,Transportation,Inventory,Overproduction,Defect:Poollayoutmakealmostthesefivetypeswasteinoldline.Redesignnew“JIT”layout,ReduceBatchSizeto“onepieceflow”.(pleaserefer4.MainLine&SubLayout(improved))第十页，共13页。8-4.DETAILOFKAIZEN(4)

BeforeImprovingAfterImprovingTypeofWasteImproveActionMotion:Switchusedwithfootpress,Opwouldkeeponelegstanding,thatmadethemtired.Putswitchoncollet，Opcanpresstheswitchinthesametimewhenmovetotherelevantposition.SwitchusedwithfootSwitchusedwithfinger第十一页，共13页。8-5.OTHERKAIZEN(1)

BeforeImprovingAfterImprovingTypeofWasteImproveActionMotion/Cost:Thepartputoneside(Aside)tooppositeside(Bside)fromAfixturetoBfixture.ImprovealittleAfixture,Thenthepartcanbeputononefixture,wheneverAsideorBside.TotalSevenfixtureeliminateinnewline.BsideSwitchusedwithfingerAsideAsideBside第十二页，共13页。8-6.OTHERKAIZEN(2)

BeforeImprovingAfterImprovingTypeofWasteImproveActionCost:Themetalclawisexpensive(142RMB/set),andtheyareeasytodamaged,Weneed