基于tps电子产品系统维修线效率提升研究

上海交通大学硕士学位论文基于TPS电子产品系统维修线效率提升研究姓名：姚琪申请学位级别：硕士专业：工业工程指导教师：刘品宽;陈信政20090301学硕学论ITPS“”()TOYOTAProductionSystemTPS“”OnePieceFlowOPF“”“”U学硕学论II“”学硕学论ABSTRACTIIITHESTUDYONEFFICIENCYIMPROVEMENTOFSYSTEMREWORKLINEOFELECTRONICPRODUCTBASEDONTPSABSTRACTAstheprogressanddevelopmentofelectronictechnology,aswellastheend-users’continuouslydemandfortheproductfunctionandquality,electronicmanufacturestrytoshortentheresearchanddesigncycleofnewproduct,inordertomakethecycleofpushingnewproductsintomarketasshortaspossible,therebytheycangetmorenewchancesinthefiercemarketcompetition.Thecyclethatnewproductsfromdesigntobeputintomarkethasbeensignificantlycompressed,andtheproficiencyoftheoperatorscannotupgradeinashortterm,sofortraditionalmanufacturingindustries,therewillinevitablybringalargenumberofqualityproblemsandwillbealargenumberofdefectiveproductsintheproductionprocess(includingfinishedproductsandsemi-finishedproducts).Thedefectiveproductscanre-entertheproductionlineandbenormallyoutputafterrepairedandrecognizedOKbymaintenancedepartment.However,thereisgreatrandomicityoftheemergenceofdefectiveproducts,andtheNGphenomenaareoftendiverse,whichisaseveretrialforthemanagementofthemaintenancedepartment.TheymustcontinuouslyenhancetheirefficiencyandmaketheNGproducts学硕学论ABSTRACTIVrapidlytransformedintoqualifiedones,asaresult,theproductscanre-enterproductionlinesassoonaspossible.Butmaintenancehasbeenalwaysneglectedforenterprisemanagers.Maintenanceefficiencyispoor,andsuchinventoryaccumulationproblemsaffecttheefficiencyofenterprises.Thispaperanalyzesthatthereareoverstockinventory,slackprocess,unreasonablelayoutandsuchphenomenonintheelectronicenterprisesystem,andwestudyfurtherthefeatureofsystemreworkofelectronicproducts.IntroducingthetheoryofTOYOTAProductionSystem(referredtoas:TPS),andaccordingtothecoreprinciplesofToyotamanagement“Onepieceflow”(referredtoas:OPF),webringforwardageneralflowthathowsystemreworklinerealizestheOPF.Andwedesigntherunningmodethateliminatesthewaste,sowecanreachtheultimateobjectiveofreducingtheinventory,enhancingefficiencyandlow-costasaresult.Finally,weprogramagainthesystemreworklineofUcompanybyusingthegeneralprocesswhichrealizestheOPF,andactuallychangingtheoldworkmodebybringingthesystemreworkline’sworkmode.Consequentlythemodereducestheinventory,acceleratestheprocessandeliminatesthewaste.Asabove,wevalidatetheeffectofthegeneralflowandtherunningmode.KEYWORDSSystemrework,DefectiveProduct,OnePieceFlow,Inventor学论签::□权书学论属□“√”::刘宽:学硕学论11.11.2100FWTaylor学硕学论21910Frank.&.L.Gilbreth17Threbligs[1]805S5S5S806σSixSigma62104325.5σ2080学硕学论3198871300200000Camry1991Camry19924000020Camryl31850017[2]20801.3“Apennysavedisapennyearned”“”“”CostDown学硕学论4LeadTimeLeadTimeLeadTimeLeadTimeTOYOTA“”LeadTime1.4TPS学硕学论5U11Fig.1Therelationofeachchapters学硕学论62.1TPS“”90%[2]JustintimeJITTPSJIT“”“”“”“”“”“”“”“”JIT学硕学论7[3][4]TPS“”TPS2.1.1TPS“”1930学硕学论8“”“”“”学硕学论9100%“”“”“”“”[2][5]学硕学论10,,,,,,,,,------(),“”“”学硕学论112.1.2TPS1234567[6][7]QualityCostDeliveryServiceQCDS2.2学硕学论121学硕学论132342学硕学论1412Fig.2Theworkflowchartoftypicalsystemreworkline学硕学论1523452.3学硕学论163,,5SSFIS3Fig.3TheoverallflowchartofimplementationOPFinsystemreworkline学硕学论175S5S[8]LeadTimeE学硕学论184Fig.4ThebaseflowchartofOPFinsystemmaintenanceline4学硕学论192.4TPSTPS“”“”学硕学论203.13.255Fig.5Thelayoutofsystemreworklineforon-linemodel1234学硕学论2166Fig.6Thelayoutofintegrativesystemreworkline1234学硕学论221学硕学论231[9]学硕学论24SEIRISEITONSEISOSEIKETSUSHITSUKE5S“”“”[10]5S“”“”“”“”“”学硕学论25“”77447Fig.7Thesampleofdedicatedreworkengineeringstation观键盘维驱维测试1234学硕学论26TPS“”828Fig.8Thesampleofgenericreworkengineeringstation维1维11学硕学论2723.3学硕学论2899Fig.9TheMaterialflowdiagramforSystemMaintenanceLine学硕学论291~210RL3.12200()()(1,2,3...)iiiSxxyyin=−+−=3.1学硕学论303.2220011()()nniiiiiiSxxyySnn==−+−==∑∑3.2iS3.3:1010niiniixxnyyn====∑∑3.33.300(,)Rxy222(,)Lxy333(,)Lxy(,)nnnLxy444(,)Lxy111(,)Lxy(0,0)xy...10Fig.10Themodeloflocationlayoutforsystemreworkline学硕学论313.4学硕学论324.14.2ITIT学硕学论334.3InformationTechnologyIT,ShopFloorInformationSystem,SFIS4.3.1SFISSFISShopFloorInformationSystemSFISERP()SFIS:()()学硕学论34()()SFISSFISSFISIDSFISSFISSFISSFISSFISIDSFISScaner4.3.2学硕学论35“”“”“”“”“”“”[4]SFIS34学硕学论36IDSFISSFISSFISSFIS3123424231922412340001OKOK1PCSOKOK001PCS04.4SFIS11IDSFISID学硕学论37IDSFIS11Fig.11TheflowchartofinformationflowforsystemreworklineSFIS1212学硕学论384.5SFIS学硕学论395.15SUUUTPSTPSTPSU5.212学硕学论40SFISIDErrorCodeScanerSFISSFIS学硕学论41SFISIDErrorCodeSFISSFISNNYYEND12Fig.12TheOPFflowchartforsystemreworkline学硕学论42“”“”“”“”“”働设计设备员够动发时进产处这维业颈业时进働调处况实际维业会现产线发维员应统计数现过标时产线线决5.3UU500UUForecastForecastU100130学硕学论43211%13021.54N13010/21.51%/2300=××≈U1IDIDIDSFISScaner2ID3学硕学论444ID5ID6ID13TPS学硕学论45LeadTime2U13Fig.13Theexistinglayoutofsystemreworkline学硕学论461010niiniixxnyyn====∑∑3.3143731414Fig.14Theexistingworkshoplayoutofsystemreworkline学硕学论47UTPS5.4U5S5SU170810学硕学论48UU24V24VU2U90mm×40mm×12mm100mm×50mm×50mm学硕学论4915SFISUSFIS16SFISScaner15Fig.15Thelayoutofsystemreworkline学硕学论50ScanerUScanerLCDLCDSFIS16SFISFig.16TheexampleofSFISInterfaceforsystemreworkline学硕学论51U5.5U55min