单元式生产布局CELL（PPT35页)

ContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou单元式生产布局CELLContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou议程Agenda1.传统组装线设计TraditionalAssemblyLineDesign2.工位设计WorkStationDesign3.物料展示MaterialPresentation4.物料补充MaterialResupply5.物料储存MaterialStorageContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou1.传统组装线设计TraditionalAssemblyLineDesign物料储存MaterialStorage-qualityproblems悬挂式电动输送带Powered&freeconveyor物料储存MaterialStorage-QP物料储存MaterialStorage-QP物料储存MaterialStorage-QP物料储存MaterialStorage-qualityproblemsContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou精益生产系统组装线模式特点LeanProductionSystemAssemblyLineModelCharacteristics工人灵活Flexibleoperators(multiprocessingandcross-trained)走动方便Freedomofmovement(standing+movingoperations)标准化作业Standardoperations(assemblyonly,Waterspiders+standardoperations)目视化工场Visualworkplace(Aplaceforeverything,everythinginitsplace)最少线上存货Minimallinestock(nomini-w/h,max.2-hLinestock)柔性生产Flexibleproduction(variationsineithermixorvolume,Noislands!)节拍器Pacemakers(LinesincorporatepacemakerstosetpacetoTT,nottoself-pacing)保证质量Qualityensured(goornogo,3Nos)ContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou组装线布局的目的AssemblyLayoutGoals按照节拍时间,生产优质产品Qualityproductsproducedattakttime有效利用人力Productiveutilizationofpeople•装配工只做装配Assembleproductonly•按节拍分配任务达到高生产力Highoperatorproductivitythroughloadingtotakttime•工人能完成整个流程Operatortocompletethefullprocess物料/工人流畅Flowofmaterialandoperators•优化工位以方便摆放零件､物料､工具Workstationsoptimizedforpresentationofparts,materials,andtools•工位设计减少走动Workstationdesignminimizesoperatormovements信息即时反馈Immediateflowofinformation/feedback问题立即暴露ImmediatelyexposeproblemsContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·WenzhouU型线U-ShapedLine原料RM成品FG按灯Andon最少走动工人间的平衡避免产生孤岛多工序作业促进沟通按灯识别异常WS负责所有物料需求o从“U”型线外送料o取走成品节拍变，你也变o人员安排可以应变I’mwaterspider.We’reoperators.ContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou线体设计:物流从右至左线体设计:每条槽里放2个料箱线体设计:工具伸手可及线体设计:所有料箱都放置于工位前方线体设计:模块化和可连接的工位设计线体设计:空料箱从料架下方回收线体设计:预留30%的工位空间线体设计:工作区间距1.6米线体设计:工作台高度0.8~1.2米(人机工程)线体管理:过道里不许放料箱为方便车间目视化和沟通:建议料架高度不超过1.5米线体管理:禁止订单在缺少零配件的情况下进行生产线体管理：本独立工作单元中操作工的数量（1~8人）目视化及5S管理:例：划线并确定相关货架占地面积线体设计：最大偏差为20%拉动信号:目视化和在制品控制防错:一旦发现缺陷立即停止生产B.组装线设计U型线ContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·WenzhouU型线U-ShapedLineContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·WenzhouB.组装线设计ContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou直型线StraightLine时间标记Timingmark指挥棒交接区Baton-passZone123412345当产品结构和物料展示能够保证时使用Usedwhenproductconfigurationandmaterialpresentationwarrant例如，汽车组装线e.g.,automobileassembly生产线的速度由产品的移动速度决定Linepacedbyproductmovement随时掌握装配进展Assemblyprogressiononline已经设立了工人区Workerzonesareestablished已经定义了交接区(交接指挥棒)Overlap(batonpassing)isdefined按使用次序安排物料Materialissequencedinorderofuse柔性生产时Formixed-modelproduction非整合分装(预装)按配套供料Non-integratedsub-assembliesaresuppliedascompletedkits必须建立信息与反馈系统Communicationandfeedbackmustbeestablished例如喇叭､灯号e.g.,speaker,lightsContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou有喂料”的直型线StraightLineWithFeedersMajorsubassemblyLine主分装线一人单元1-operatorCell两人单元2-operatorCell当进行柔性生产，分装线周期时间会出现重大变化时，使用此类生产线。Usedwhenasubassemblycycletimeexhibitsmajorvariationsinamixed-modelproductionenvironmento将会出现这种重大变化的分装线从总装线中分离出来Shiftsthesubassemblyexperiencingthewidevariationoffthemainassemblyline总装线上设有“节拍器”“Pacemaker”establishedonfinalassemblylineo例如，生产线按节拍时间连续移动i.e.,continuousmovementofthelineatthetakttimerate总装线“拉动”分装线Finalassembly“pulls”fromsubassemblyo分装线的工作与总装线分开Subassemblyworkseparatedfromfinalassemblyworko适应产品的变化Facilitatesproductvariationo在生产支线/生产单元完成分装工作Subassembliescompletedon“spur”line/cello例如，附属于总装线的生产支线/生产单元i.e.,attachedtomainlineo分装线在需要使用零件的地方才介入总装线Subassembliesenteratpointofuse从后面供应物料Materialsuppliedfrombacko多人的分装线单元要放在“背后”，因为分装线的输出是以其它零件和物料一样的方式，供应给总装线的。Multi-operatorsub-assemblycellisonthe“back”,sinceitsoutputispresentedtothemainlineoperatorsjustlikeotherpartsandmaterials.按使用次序安排物料MaterialssequencedinorderofuseContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou典型工位TypicalWorkstation2.工位设计WorkStationDesignContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou工位设计目标WorkStationDesignObjectives减少各种浪费Minimizewaste缩短操作员周期时间Minimizeoperatorcycletime保证产品质量Ensuregoodpartsproduced能处理多工序Enablemulti-processhandling建立目视工场Establishavisualworkplace支持及时生产原理SupportJITPrinciplesContinuedNagoya·Shanghai·Guangzhou·Tianjin·Hangzhou·Suzhou·Wuxi·Qingdao·Chongqing·Wenzhou工位设计原理WorkStationDesignPrinciples标准化作业Standardoperations适当面积Appropriatesize零件排列Partarrangement工具标准化Toolstandardization工具放置Toolplacement目视控制Visualcontrols工人走动Operatormotions质