GK129-1000T快速换型

ConfidentialManzoni—SMEDStampingWorkshopApr,12th—16th2010现场改善GK1291000T快速换型Confidential2Presentation'sTitleGK129team改善团队–奔驰Teammembers团队成员冲压主任—龚小范维修主任—张建强模修领班—王佑春传播者—王伟操作工—张传有模修—王树林维修计划—刘景鹏电子工程师—刘伟东860项目组—胡智平860项目组—高洋巴西专家—Silviu巴西专家—EvandroSpeckhahn巴西模修—Renato精益–张春杰Confidential3Presentation'sTitleThesourceoftheGK项目来源Kaizen改善SMED1.VSM价值流程图2.860项目组CapacityExpansionproject8.6M/yConfidential4Presentation'sTitleObjectiveandGoal目的与目标•降低1000T换型时间==》从35分钟至20分钟Decreasethesetupmodeltime(1000T)==》From35minsto20mins•人因工程改善==》1项ErgonomicImprovement==》1Item•安全改善==》1项SafetyImprovement==》1Item•可视化管理==》1项VisualManagement==》1Item•5S改善==》1项5SImprovement==》1ItemObjectivesandGoal目的与目标35200510152025303540AntesMetaHistoryGoalConfidential5Presentation'sTitleBenefitsofSMED快速换型的好处Reducesunproductivetime减少非生产时间Allowstoimprovetheclientservice(leadtime,quantity)有利改善客户服务(交货周期、数量等)Enlargesrealcapacityofmachines扩大机器实际产能Reducetheinvestmentandproductioncost减少投资，降低成本SMED快速换型Allowstoreducethestocks有利降低库存Shorterseriesbecomescheaper(reducebatchsize)产品系列更换时间更短、成本更低(缩小批量)Confidential6Presentation'sTitleStep1步骤一Step2步骤二Step3步骤三Step4步骤四Step6Changeovermethodnotrationalised没有理顺换模方法Studyoftheactualsituation研究实际情况SeparateinternalworkFromexternalwork将内部工作与外部工作分开Convertinternalworkinexternalwork将内部工作转化为外部工作Step5步骤五Reduceofinternalwork减少内部工作•Absenceofmethod没有方法•Preparationtimewithbigvariations准备时间变化太大•Thereisnodistinctionbetweenexternalworkandinternalwork内部和外部工作没有什么区别•Improvementoflogisticsupport改善物流运输•Improvementserviceability改善可用性•Pre-assembly预先装配•Pre-adjustments预先调整•Pre-heating预热•Previousworkbeforethemachinestop停机前的准备工作•Worktobedonewiththemachinestopped停机时要做的工作•Worktobedoneafterstopping停机后要做的工作Registerandclassifiedallthenecessaryworkingelements将所有必要的工作进行登记和分类•Video视频•Chronograph计时器The5StepsofSMED快速换型的五个步骤Startingpoint始点SMED快速换型•Eliminateadjustmentsandsettings消除调整和设定•Simplifyfixationandtightening简化固定和上紧程序•Parallelwork平行作业InternalWork:Operationswhichhavetohappenwhenthemachineisnotrunning外部工作：机器没有运作时要进行的工作Externalwork:Theoperationswhichcantakeplacewhenthemachineisrunning内部工作：机器运作时要进行的工作Reduceofexternalwork减少外部工作Confidential7Presentation'sTitleStep1:Studyoftheactualsituation步骤一：研究实际情况Makethelistofsetupstepthroughfilm观看录像列出换型步骤(共59步）Confidential8Presentation'sTitleStep2SeparateinternalworkFromexternalwork步骤二：区分内部工作和外部工作对59步换型步骤进行内部外部工作的区分Confidential9Presentation'sTitleAfterKaizen改善后BeforeKaizen改善前Step3Convertinternalworktoexternalwork将内部工作转换成外部工作工具准备PrepareandOrganizetoolsPhoto将换型工具按照模型摆放在车上，便于取放。同时增加1个套筒和1个六角扳手Putthetoolsinthecaraccordingtheformerinordertotakeeasilyandatthesametimeadd1steeltubeand1wrench工具在车上摆放无序,只有1个套筒和1个六角扳手Thetoolswereputwithoutorderinthecarandtherewas1steeltubeand1wrenchConfidential10Presentation'sTitleNúmeroAtividades/Tarefas/ElementosPessoaPassosHoraTempo(Segundos)0000:00:451OperardesbobinadorparanovabobinaOpA100:00:572CortarfitaOpA200:01:173IntroduzirchapaatéoroloOpA300:02:0200:00:4500:00:4549AbrirportãoelimparrespingosdeóleoOpB400:01:1100:00:2300:00:2319Regulagemdos4rolosOpA2200:09:0000:01:0900:01:0950AguardardesaceleraçãoOpB500:02:2500:01:1400:00:525aguardarchapanovaencostarnavelhaOpA600:03:1000:00:3600:00:3651EstamparfinaldabobinaeretirarcavacoOpB700:07:2800:05:0300:02:3110AvançarchapaemmanualOpA1200:06:0900:00:2300:00:1211EstamparfinaldachapaOpA1300:06:1400:00:0500:00:0512RetirarcavacoeavançarchapaemmanualOpA1400:07:1200:00:5800:00:2913EstamparfinaldachapaOpA1500:07:1800:00:0600:00:0614RetirarpontadachapaOpB1600:07:3500:00:1700:00:1752EsvaziarferramentaOpB1700:09:0200:01:3400:01:34TrocarcaixasdecavacoOpA1800:01:0000:00:0054TrocarcarimboOpB3200:11:0900:02:0600:00:00AvançodachapaemmanualOpB5400:18:0300:00:3800:00:0029Limpezaparatrocano7ºestágioFerrA3400:11:3600:00:1900:00:0031Retirar1parafusoesoltaroutro,doaneldo7ºestágioFerrA3600:12:3500:00:4800:00:4856Retirar2parafusosladodetrazFerrB3800:13:1100:00:4800:00:0057Seguraraneldo7ºestágiopararetiradaFerrB3900:13:3500:00:2400:00:2433Retiradado2ºparafusodoaneldo7ºestágioFerrA4100:13:3600:00:1300:00:1334Retiradadoaneldo7ºestágioFerrA4200:13:5000:00:1400:00:1458LimpezadoalojamentodoanelFerrB4300:13:5700:00:2200:00:2235Colocarnovoaneldo7ºestiagioFerrA4400:14:3600:00:4600:00:0059Colocarnovoaneldo7ºestiagioFerrB4400:15:0000:01:0300:01:0360Apertar4parafusosdo7ºestágioFerrB4500:15:1700:00:1700:00:1762TrocarcentradorFerrA4900:17:2100:01:4300:00:0063FecharportãotrazeiroFerrB5000:17:5000:00:2900:00:2940Regularalturado5ºe6ºestágioFerrA5200:17:0700:00:5500:00:5543EncherferramentacompeçasOpB5500:20:3600:02:3300:01:3244PegarpeçaparamediçãoOpA5600:20:4700:00:1100:00:1145MedirpeçasOpB5700:24:1100:03:2400:02:2346Acionarprensaemautomáticoeatingir25gpmOpB5800:25:2000:01:0900:00:48641811900:18:00对换型步骤进行排序Definethebettersequence:统计每个人的工作时间并确定可以同时做的工作Sichronizeactivities:OperatorAOperatorBToolMakerAToolMakerBStep4Reduceofinternalwork减少内部工作Confidential11Presentation'sTitleAfterKaizen改善后BeforeKaizen改善前在校平机上安装支架，用于存放手柄同时将手柄加长Makeasupportbesidethemachinetolaythehandleandlengthenthehandle手柄放在控制台旁边小盒内Thehandlewas