Celluar Production-Meteor单元生产方式

1CellDesign(TPM)AdministrativeLean(VSMi®)CellDesign/ProductionPreparationProcess(3P)KaizenKanbanProblemSolvingPokaYokeQualitySystemsProcessMappingSingleMinuteExchangeofDies(SMED)ValueStreamMapping(VSM)VisualManagementStrategicallyCreatingValueThroughtheEliminationofWasteOtherModulesInThisSeries:3ThisdocumentcontainstheconfidentialandproprietaryinformationofLeanHorizonsConsulting,LLC.Anydisclosure,use,copyingordistributionoftheinformationwithinthisdocumentisstrictlyprohibited.4GroundRulesforEventSafetyfirst(usepersonalprotectiveequipment)安全第一Activeparticipationbyall有效参与Startandendontime准时Allelectronicgadgets(phones,pagers,etc)turnedto“off”or“silent”ComputerstobeusedonlywheninstructedKeepanopenmindtochangeDon’tlet“perfect”getinthewayof“better”INTRODUCTION5CellDesignToapplytheprinciplesandcomponentsofproperCellDesigntoachieveatargetgoalforyourbusiness.GoalofCellDesignModule:Do’sandDon’tsofCellDesignBuildingQualityIntotheCellStepstoDesigningaCellKeyConceptsofCellDesignINTRODUCTION6Cellularization“GRAPHICGOESHERE”Anarrangementofequipment,people,machines,andmethodsthatfacilitatecontinuousflowproduction设备，人员，机器，和工作方式的合理整合以便于支持连续生产Allowsforone-pieceflowwheneverpossible一件流思路Oneoperatorcanprocesstheentirepartwhenneeded单人工完成流程Usuallygroupedbyeitherproductfamilyorprocess产品组Popularconfigurationis“U”ShapedU形工位INTRODUCTION7Cellularizationfundamentallyreducesallofthe8wastes消除8大浪费Lessinventory(improvedquality)库存Minimizeswalking走动Promotesbetterworkbalance(lowercost)工作平衡低成本Enablesmulti-processhandling多流程操作Promotesbettercommunication沟通Staffingflexibleasdemandchanges柔性Schedulingandmanningassignmentseasier方式简单Easiertomanage易于管理BenefitstoCellularization312546INTRODUCTION8Exercise:CellDesignCharterReviewMakeanymodificationstocharterasnecessary.30minutesAsateamreviewtheeventcharterandanswerthefollowingquestions:Whatisthebusinessneedforthisevent?Whoistheowner?Whatarethegoalsforthisevent?ReviewtheCellDesignCharterfortheeventagainstchartercriteriaObjectiveInstructionsTimetoCompleteDeliverableINTRODUCTION9Do’sandDon’tsofCellDesignKeyConceptsofCellDesignDifferentiatebetweenbatchproduction,flowproduction,and“fake”flowproductionReviewcharacteristicsofcellularflowCounterclockwiseflowMachinesincloseproximityOperatorFlowvs.PartFlowSeparateoperatorfrommachineDefinechaku-chakuandlevelsofautomation操作循环和自动化程度OBJECTIVESBuildingQualityintotheCellStepstoDesigningaCellKeyConceptsofCellDesign10WaveSolderPackingPCBoardAssemblyFinalAssemblyTestingCustomerRawMaterialOnePieceFlowProductioninaCellularLayoutProductFlowinaCellularPlantLayoutSignificantlyreduces:TransportationInventoryWaitingtimeWhileimproving:QualityDeliveryCostKEYCONCEPTSOFCELLDESIGN11INVENTORYBatchProductionKEYCONCEPTSOFCELLDESIGN12WasteFlowProductionKEYCONCEPTSOFCELLDESIGN13FakeFlowProductionKEYCONCEPTSOFCELLDESIGN14ExampleofCellularFlowKEYCONCEPTSOFCELLDESIGN15WhyCounterclockwise?CellularFlowisTypicallyCounterclockwiseDesignedtopullwiththerighthandandthenpasstothenextprocesswiththelefthandThismethodtakesintoaccountthattherighthandisthedominanthandformost…ReprintedwithpermissionfromBigPhotoStock.comKEYCONCEPTSOFCELLDESIGN1625’15’215PiecesOperatorruns3machinestoproduceapartDailyProduction____________Feetpershift____________FeetPer(240days)year____________Miles(5280ft.)peryear____________ShearPunchLathe17,2004,128,000782MachinesinCloseProximityKEYCONCEPTSOFCELLDESIGN1754321109876OperatorandpartfollowthesamesequenceOperatorFlowvs.PartFlowCellularFlowRFKEYCONCEPTSOFCELLDESIGN182134321456CellularFlow4321R5678FOperatorFlowvs.PartFlowOperatordoesnotflowthesameasthepartKEYCONCEPTSOFCELLDESIGN191OPERATOR,MULTIPLEMACHINES1OPERATOR,1MACHINECellularFlow:SeparateOperatorfromMachineKEYCONCEPTSOFCELLDESIGN20LevelCycleUnloadLoadTransfer1ManualManualManualManual2AutoManualManualManual3AutoAutoManualManual4AutoAutoAutoManual5AutoAutoAutoAutoLevel3=IdealState(Chaku-Chaku)ToAutomateorNottoAutomate?KEYCONCEPTSOFCELLDESIGN21Chaku-ChakuMeans“load-load”Operatorshouldflowcontinuouslyfromoperationtooperationspendinglessthan1-2secondsperoperationAoperatorsimplyloadsthepartandmovesontothenextoperationAutomaticunloadingoftheworkpiece(hanedashi)TheworkpieceisorientedatunloadAlloperatormovementinoneplane(noreaching)KEYCONCEPTSOFCELLDESIGN22Do’sandDon’tsofCellDesignStepstoDesigningaCellIdentifythestepstodesigningacellReviewexamplesofeachstepOBJECTIVESBuildingQualityintotheCellStepstoDesigningaCellKeyConceptsofCellDesign23StepstoDesigningaCellDeterminewhatthecellistoproduceCreatecardboardcut-outsofthecellIdentifytheworkstationdesignDeterminethetoolandmaterialpresentationDefinethematerialreplenishmentproceduresSTEPSTODESIGNINGACELL24StepstoDesigningaCellDeterminewhatthecellistoproduceCreatecardboardcut-outsofthecellIdentifytheworkstationdesignDeterminethetoolandmaterialpresentationDefinethematerialreplenishmentproceduresSTEPSTODESIGNINGACELL25DetermineWhattheCellistoProduceProductFamilyAna