制造管理诊断手法与实例.ppt

1、1,製造管理診斷手法與實例,報告人: 許棟樑 清華大學工業工程與工程管理系,2,Outline,Part I: A Plant diagnostic methodology 1) Crystallize key aspects of concern (認清 改善標的) 2) Diagnostics MTBFT = 12/1. ) as long as in up-time, there is a possibility for failure.,Ret,23,II.2 Improvement Drivers,24,II.3 Best practice comparisons,Process B

2、enching Marking - Excerpt C1 Company Benchmarking Table C2 Company Benchmarking Table C3 Company Benchmarking Table Best-in-class BM Other Detail Index Table,25,II.4) SMT Process reengineering cases,樣本定義 本次選擇了國內前三大筆記型電腦廠商，三家廠商1999年產量占全台灣產量的51%以上，基於保密原則，我們將三家公司定為C1 、C2 、C3，並保留相關機密資料。 在C1-C3中，各參與公司提供一

3、條最具代表性的PCBA生產線為樣本，實地由研究人員到廠 3-5 天，以收集所需的資料。,26,研究流程,27,C1 PCBA layout: IS vs TO-BE,改善後,改善前,Advantages: 1) Keep I/P O/P from same side. 2) Reduce manual cart transp. 3) Fast overhead movements. No traffic congestions.,28,Recommendation for C1 Case,Change layout to continuous U-shaped to connect whole

4、 PCBA area. Remove the board clipping stations. Adding placement machine to increase line balancing rate & reduce pulse rate. Reduce manual assembly and inspection to reduce cycle time. Automate repair data collection and analysis. Automate loading/unloading of ATE stations.,29,C1 AS-IS Simulation,3

5、0,Remove 2 split stations,31,Add Placement machine & adopt U-shape layout,32,C1 Improvement Effects 1/3,33,C1 Improvement Effects 2/3,34,C1 Improvement Effects 3/3,35,C1: IS vs TO-BE (1),Maximization,36,C1: IS vs TO-BE (2),Minimization,37,C3: PCBA layout IS vs To-be,Was,To-be,38,Recommendation for C

6、3 Case (1),Continuous U-shaped layout to connect whole PCBA line. Removing the X-RAY test process. Yield at the station is already very high & it is too slow. Remove the vibration test.Other plant can do without it. High test ratio. Review needs for tests. Introduce AOI.,39,C3 AS-IS Simulation,40,C3

7、 Remove X-ray.Vibration. Use AOI.,41,U-shape Layout,42,C3 Improvement effects (1/3),43,C3 Improvement effects (2/3),44,C3 Improvement effects (3/3),45,C3: IS vs TO-BE (1),Maximization,46,C3: IS vs TO-BE (2),Minimization,47,Conclusions,In-depth reviewed 3 major plants. Co. 51% Taiwan production in 19

8、99. For PCBA line: Established 58 PIs, 8 key PIs New indices: ORT ratios, Layout efficiency, Flow efficiency, Normalized Line Balance rate Located relative strength and weakness for plant improvement oppor. Major recom: reduce mfg segments, continuous U-shape line, reduce non-bottle buffer, Improve LBR, Use automation Used Simulation to verify and debug re-engineered processes. Some plants c