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LineBalancingfor018017Series(DCDriver)TeamMembersandProductDetailsImprovementSummaryMainToolsComparisonChartBeforeImprovementAfterImprovementBatteryLineComparisonChartBeforeImprovementAfterImprovementLayoutBeforeImprovementLayoutAfterImprovementLayoutImprovementBeforeImprovement1).OneairpressmachineassemblybearingtoshaftthentheotherpressesassemblycompleteshaftwithbearingtoDieCasting.2).Using2pressesand2tableslowmachineutilization.3).Overallusing24sectofinish2process.Process:BearingandshaftpressingondiecastingImprovementActionKaizenItem1).Bycombiningbothfixtureintoonetimepressfixture.2).Afterimplementedsaveaairpressmachineandoneproductiontable.3).Overallusing20sec,machineutilizationincreaseandsaveRMB6700(airpress).AfterImprovementImprovementActionKaizenItemBeforeImprovementAfterImprovementProcess:Motorandgearboxlockpinassembly1).Assemblygearboxlockpinintomotorbyusingverticalhandpressingmethod.2).Difficulttocentralizedbothlockpinintomotor.3).Assemblytime14sec.1).Changetheassemblyfixturetohorizontalassemblysothattheoperatorcaneasilycentralizedthepin.2).Assemblytime8sec.Process:BatterybalancetesterBeforeimprovementneededtocoverbothtopandbottomcellbeforerunningthetestModifiedthebottomcellcoversothatdonotneedtousetopsellcover.ImprovementActionKaizenExampleBeforeImprovementAfterImprovementPCBcoverblockthesolderingoperatorvisualcauseddifficulttosolderandslow.AfterstudyandchangethesolderingmethodwhichcaneliminatethePCBcover.Process:PCBsolderingImprovementActionKaizenExampleBeforeImprovementAfterImprovementMainTools1.Improvementcost:FixturemodificationcostRMB5002.CostSaving:Productivityup18.40%afterimprovementAnnualmanhourrequired57401h×WorkerhourlysalaryRMB9.77×Productivityup%=RMB103188(USD14868)CostCountLaborCost:125981-500=RMB125481TotalSaving＄18080(USD)BatteryLine1.CostSaving:Productivityup12.27%afterimprovementAnnualmanhourrequired19014h×WorkerhourlysalaryRMB9.77×Productivityup%=RMB22793(USD3284)LineSetup&ModelChangeover接著式轉拉生產轉拉前型號轉拉後型號水蜘蛛式轉拉上料接著式转拉BeforeImprovement:1)2007年生產97個model,共生產線(主機+牙箱)21條.2).生產轉拉型號無歸律,無統一類型.3)轉拉人員為三人.BeforeImprovementAfterImprovement:1).2008年生產260個model,共生產線(主機+牙箱)27條.2).改善後生產轉拉型號按規律統一類型,同一系列型號於同一條生產線轉拉生產,減少變異,縮短了原來轉拉時間的一半.3).轉拉人員不變.AfterImprovementBeforeImprovement:1).改善前調校風批扭力在生產線內,調校時間為15分鐘.2).線內調機並佔用線內的作業場地,佔用了員工開始作業的時間.BeforeImprovementAfterImprovement:1).改善後線外調校風批扭力,節省了線上轉拉的時間,將調好的風批掛於拉上只用10秒,打螺絲時再微調2分鐘就可正式使用投入生產.2).將調好的風批貼上標識,參照指導書可明確的將風批掛在所用工位.AfterImprovementBeforeImprovement:1).改善用油壓機啤壓加工零件,夾具用螺絲來定位,調校時需用扳手扭動,上模也需安裝調校,夾具沒有定位導向桿.2).轉拉換模時間較長,需要15分鐘.BeforeImprovementAfterImprovement:1).組件啤壓力較大的需油壓機啤壓,底模夾具增加定位導向桿,固定夾具的螺絲上加小手柄,方便快速的調校油壓機只需2分鐘.2).啤壓力較小的組件由油壓機改用汽啤機一體化機模夾具啤壓組件,有定位導向桿,固定夾具鎖塊為扣位式,方便快速的換模,調機時間只用10秒.AfterImprovement油壓機啤壓組件螺絲固定夾具固定夾具螺絲上增加小手柄扣位式鎖塊及定位銷BeforeImprovement:1)改善前調校加油機於生產線內,從加油到調校好需花費時間20分鐘.2).線內調機並佔用線內的作業場地,佔用了員工開始作業的時間.BeforeImprovementAfterImprovement:1).改善後於生產線外將加油機準備好,加好潤滑油,並調校好在轉拉時只需20秒.2).線外的轉拉活動節省了時間,轉拉快速.AfterImprovementHanedashi&Poka-YokeStartDateBeforeImprovement:1).改善前用兩台氣啤機,,分別把大小齒輪和大小軸承啤壓於一體,等待啤壓,然後用手取出,放到下一工位,效率低.2).佔用兩張工作台,面積較大,員工操作需多次走動.3).此工位操作時間為24秒,效率低.BeforeImprovementImprovementTitlePlantNameTTiGembaKaizenReport2008/11/19ConfirmationDateCompletiondateofimprovement2008/10/811CurrentPlanning900一台機一張台CostSavingRMBManpower/MachineDownKeep工序時間節省了10秒,為下一步線平衡作基礎UpKeepDownUpproductivityCostReductionImplementationstatus2008/11/18AfterImprovement:1).改良合並夾具,由原來的兩台氣啤機兩套模合為一台機一套模,啤壓完後自動送出,此操作員不用等待.2).改良夾具後可減少一台氣啤機,也節省了一張工作台,減少員工的走動,減輕員工的勞動強度.3).改良後此工位操作時間為14秒.提高了生產效率.ExplanationTPF-PIE侯曉強PreparedbyIssueNo:Date:2008Year11Mth19DayT08GK47f076QualityPhotographConfirmationoftheeffectiveness6000ImprovementCostRMBAfterImprovement夾具合並及自動送料018021001Model/Process生產成本降低組蘇得強/侯曉強ImprovementPIC蘇得強鐘志強陳聯強CheckedbyCheckedbyApprovedby兩台啤機和台24s一台啤機和台14sStartDateBeforeImprovement:1).2個model的機殼外形很相似.2).曾經有機殼用錯的情況.機殼內側要裝軸承,打螺絲,改善前作業員有時候不使用夾具直接放在桌面打螺絲,所以會用錯.BeforeImprovementImprovementTitlePlantNameTTiGembaKaizenReport2009.4.1ConfirmationDateCompletiondateofimprovement2009.3.611CurrentPlanning無無CostSavingRMBManpower/MachineDownKeepUpKeepDownUpproductivityCostReductionImplementationstatus2009.3.20AfterImprovement:1).對打螺絲夾具進行改良,增加一個電磁閥,只有在機殼完全放如夾具的時候,風批才會工作,反之風批不能工作.2).如果沒有完全放入,沒有按下處動開關,電磁閥不能工作.ExplanationTPP-PIE王耀輝PreparedbyIssueNo:Date:2009Year4Mth2DayT09GK10F042QualityPhotographConfirmationoftheeffectiveness386ImprovementCostRMBAfterImprovement0380234Model/Process降低生產成本組OoiImprovementPIC黃耀建鄧強龍陳聯強CheckedbyCheckedbyApprovedby防錯改善180230觸動開關&電磁閥StartDateBeforeImprovement:1).改善前3.AP/P用3台機踫焊(2條拉),1.5AP/P用2台機踫焊(1條拉).2).效率低,資源浪費.3).員工作業的勞動強度大.BeforeImprovementImprovementTitlePlantNameTTiGembaKaizenReport2009.5.6ConfirmationDateCompletiondateofimprovement2009.1.333CurrentPlanning663,103三台機CostSavingRMBManpower/MachineDownKeep生產效率力提升7.2%Up經QA抽檢30PCS無品質不良.KeepDownUpproductivityCostReductionImplementationstatus2009.5.5AfterImprovement:1).改良踫焊夾具,設定自動踫焊程序,增加編程控製箱.2).改良後可減少一台踫焊機,減少一名作業員.3).提高了效率,減輕了員工的勞動強度,品質有保證.可防漏踫,減少踫焊壞機的比率.4).節省費用:A)三台踫焊機:602505RMBB)人工費:3.0A23582RMB1.5A:70135RMBExplana