Cell-Desig單元生產(chǎn)線設計

1、 2008 Gemba Research LLCCell Design單元生產(chǎn)線的設計 2008 Gemba Research LLCElements of Good Cell Design高效率生產(chǎn)線的設計要素1.Design allows for One Piece Flow設計遵循單一流程2.Equipment and work stations are close together設備及其配備裝置共同停止運作3.Product flows from right to left 產(chǎn)品流自右向左4.There are no barriers to operator or material

2、flow對于操作者和操作流程無障礙5.Raw Materials fed from the outside of the cell by the material handler原材料由材料操作者從生產(chǎn)線外引進6.Equipment should be right sized設備應有準確的大小7.Operators are multi-skilled操作者具有多種能力8.One operator could run the cell 一個操作者能夠管理生產(chǎn)線9.Equipment and work stations are easily movable 設備及工作站易于移動 2008 Gemb

3、a Research LLCElements of Good Cell Design高效率生產(chǎn)線的設計要素10. All work areas are safe and ergonomic所有工作站是安全的且符合人體工程學11. Tools and material are presented at point of use based on frequency of use and ergonomics工具和材料所呈現(xiàn)出的使用點以使用頻率和人體工程學為基礎12. Schedule is visual 計劃是視覺化的13. Hour/Daily goals are posted and act

4、ual data is collected每時/每日的目標是清晰的，且收集實際數(shù)據(jù)14. Use visual management to manage materials and tools 使用目視化管理方法管理材料和工具15. Metrics and other key performance indicators tracked, clearly seen生產(chǎn)規(guī)律圖和其他關(guān)鍵履行指標追蹤跟進16. Root Cause Corrective Action process is in place根本原因糾正措施過程的適當實施17. Process steps are error proo

5、fed - Quality built into the process過程步驟是錯誤的證據(jù)-質(zhì)量形成于過程中 2008 Gemba Research LLCTime to first piece is 21 minutes完成第一件需要21分鐘Time to complete batch 30 minutes完成一批需要30分鐘Batch & Queue批量批量LatheMillOne-Piece Flow單件流單件流LatheMillDrillDrillMake 10, Move 10Make 1, Move 11 min. cycle times per process每個過程1

6、分鐘的周轉(zhuǎn)時間Time to first piece is 3 minutes 完成第一件需要3分鐘Time to complete batch 12 minutes完成一批需要12分鐘Make 1, Move 1Make 1, Move 1Make 10, Move 10Make 10, Move 101. Design for Single Piece Flow單件流設計 2008 Gemba Research LLC2. Equipment & Stations are Close Together設備及其配備裝置共同停止運作 2008 Gemba Research LLCMos

7、t people are more effective using their dominant hand. Most people are right-handed.大部分人更有效的使用他們受支配的手。大部分人使用右手The right brain processes spatial information with visual input from the left eye.右腦通過左眼輸入空間性的視覺信息。Race tracks are counterclockwise for this reason.跑道由于這個原因自左向右。3. Product Should Flow From R

8、ight to Left產(chǎn)品流自右向左 2008 Gemba Research LLC Focused Cell 聚集的生產(chǎn)線 2008 Gemba Research LLCh Visual Control - Easy to see the whole process 目視化控制- 容易目視整個流程h Linked Processes 連接的流程hGood Information Flow 好的信息流h Shortest Part Travel Distance短距離的物品傳送h Common Drop-off and Pick-up常見的下降和回升h Easier to implement

9、 Standard Work Sequence 較容易實現(xiàn)標準的工作次序h Easier to create multi-skilled workers 較容易培養(yǎng)多種技能的員工h Better Teamwork 較好的團隊合作12345Advantages of U-shaped Cells U型生產(chǎn)線的優(yōu)勢14 2008 Gemba Research LLC4. No Barriers to Operators or Flow對于操作者和操作流程無障礙 2008 Gemba Research LLCEntry入口Exit出口Materials物料5. Material is Present

10、ed from Outside of the Cell物料是從線外呈現(xiàn)進來的 2008 Gemba Research LLC6. Equipment Should Be Right Sized設備應有準確的大小 2008 Gemba Research LLC7. Operators are Multi-Skilled操作者具有多種能力 2008 Gemba Research LLCOutput = X units/dayOutput = 3X units/day Operator does not need to follow product flow操作者不需要遵循產(chǎn)品流程 Staffing

11、 varies based on demand根據(jù)需求員工多樣性8. Cell Could run with One Operator 單元產(chǎn)品能在一個操作者的情況生產(chǎn)ABCEDFProduct Flow產(chǎn)品的流動11Operator Flow操作者的流動1111ABCEDF122321 2008 Gemba Research LLCLean Cell精益單元LeanCycle Time = 60 Seconds / Cell4 Cells = 1 Mass Line4 Different Product Type at one time一次生產(chǎn)4種不同類型的產(chǎn)品110352345678910

12、1161514131211ABCDA= Walk Path 路徑Product OutParts InParts InParts InParts InParts In 2008 Gemba Research LLC4567The Standard Work Orchestra標準生產(chǎn)曲線圖1101132984576389121011 2008 Gemba Research LLCMachinesMachines9. Make Equipment Easy to Relocate使設備有利于再配置 2008 Gemba Research LLC10. Work Stations are Safe

13、 and Ergonomic工作站是安全且符合人體工程學的 2008 Gemba Research LLC11. Materials and tools are Managed Visually材料和工具目視化管理Tool Shadow Board工具陰影板 2008 Gemba Research LLC12. Schedule is Visual計劃是視覺化的 2008 Gemba Research LLC13. Hour/Daily Goals Posted & Tracked每時/每日的目標追蹤 2008 Gemba Research LLC14. Tools and Mater

14、ial at Point of Use工具和物料的使用要點Material 材料 2008 Gemba Research LLC15. Metrics & KPI Tracked, Clearly Seen清楚地目視被追蹤的生產(chǎn)規(guī)律&KPI 2008 Gemba Research LLCDate 10/13 ShiftATakt Time 742 secTime+/- Issues7:00 - 8:0055558:00 - 9:0051049-1 Paintline Down 10min9:00 - 10:15515514-110:15 - 11:15520418-2 No c

15、hasis 15 min11:15 - 12:45525523-212:45 - 1:45530528-21:45 - 3:00535331-4 Test equipment down 25 min3:00 - 4:15136132-44:15 - 5:155:15 - 5:30Total36363232Pareto of IssuesCountermeasuresPRODUCTION BOARDPlanActualBalancerDown TimeIssuesMonthly KPIs for cell and business measurementsSelect top 1 or 2 it

16、emsWe can see a reduction in our daily issuesReview daily issues in a weekly paretoDeliveryMonthActual ProductionQualityMonthPPMCostMonthLabor ProductivityProcess results in measurable monthly improvementsCreate an action plan with names and dates16. Root Cause Corrective Action process根本原因糾正措施過程 2008 Gemba Resea