制造设备的精益设计

GeneralMotorsCorporation,DelphiAutomotiveConfidentialFirstEditionIssuedMay27,19982ndPrint,October22,1998LEANEQUIPMENTDESIGNGeneralMotorsCorporation,DelphiAutomotiveConfidentialCopyright,GeneralMotorsCorporation,DelphiAutomotive.ThisisunpublishedconfidentialandproprietarymaterialofDelphiAutomotivecreatedin1998,whichmayonlybeusedbysuppliersofDelphiinconnectionwiththeconductoftheirbusinessforDelphiAutomotive.ItmustnotbecopiedordistributedtoanythirdpartywithouttheexpresswrittenpermissionofDelphiAutomotive.GeneralMotorsCorporation,DelphiAutomotiveConfidentialiLEANEQUIPMENTDESIGNFirstEditionIssuedMay27,1998;2ndPrintOctober22,1998AdditionalcopiesareobtainablefromDelphiLeanEquipmentCOEMemberNorbGreenDelphiChassisSystemsJohnMcKeonDelphiEnergyandEngineManagementSystemsSamCicatelloDelphiHarrisonThermalSystemsGregShemitzDelphiPackardElectricSystemsMartySheridanDelphiSaginawSteeringSystemsTimDolanDelphiDelcoElectronicsSystemsPamelaBoydDelphiInteriorandLightingSystemsPreparedby:iiGeneralMotorsCorporation,DelphiAutomotiveConfidentialTABLEOFCONTENTS1.INTRODUCTION......................................................................................................11.1.Purpose...............................................................................................................................11.1.1.RelationshipofEquipmentDesignandPDP..............................................................11.2.ReviewofSystem/CellDesign..........................................................................................31.2.1.ProcessRequirements.................................................................................................41.2.2.System/CellDesignGoals...........................................................................................41.3.ReviewofManufacturingSystemDesign(MSD)Methodology...................................51.3.1.DetermineModuleSize...............................................................................................51.3.2.CalculateTAKTTime.................................................................................................51.3.3.ConstructaBlockDiagram.........................................................................................51.3.4.PrepareaMachineBalanceChart...............................................................................51.3.5.LayOuttheSystem.....................................................................................................61.3.6.PrepareanOperatorBalanceChart.............................................................................61.3.7.DetermineBufferSizes,LotSizesandLeadTime.....................................................61.3.8.DetermineContainerizationandPackagingRequirements.........................................61.3.9.Error-ProoftheSystem................................................................................................61.4.SystemSimulationandMockup......................................................................................72.EQUIPMENTDESIGNGUIDELINES......................................................................92.1.SupportstheOperator....................................................................................................102.1.1.SafetyandErgonomics..............................................................................................102.1.1.1.ProperLockoutPlacement.................................................................................102.1.1.2.SimpleButEffectiveGuarding..........................................................................102.1.1.3.EquipmentAddressesAllErgonomicIssues.....................................................112.1.2.SelectProperCycleInitiation...................................................................................122.1.3.ReduceMachineNoise..............................................................................................132.1.4.SimplePartPresentationDevices.............................................................................132.1.5.ProvideNecessaryVisualorAudioControls...........................................................142.1.6.WorkplaceOrganization...........................................................................................152.1.7.PacingMechanism....................................................................................................152.1.8.DistanceBetweenMachines.....................................................................................152.2.Simplified.........................................................................................................................172.2.1.ProperUseofAutomation.........................................................................................172.2.1.1.LevelsofAutomation.........................................................................................182.2.1.2.ManualLoading.................................................................................................192.2.1.3.ManualUnloadv