sony廠房布置

1、Sony' s Implementation ofProduction Innovation Equipment andManufacturing System SolutionsChapter 11. Introduction1.1 Shift in production needs1.2 Importance of demand oriented production1.3 Production innovation s 3 main types of loss1.4 Cell production methodSOZYShift in Production NeedsEnviro

2、nmentMulti-functionalconomical? Worst post-war economic slumMass productionMany types,small qty Various types, variousquantitiesDecline of ConsumptionTelecommunication RevolutElectronic CommerceWell-sold products change quicklySurplus of inventory due to the fallof product pricesrotection ofDemand O

3、rientedGlobalizationProductionNo Borders? Global Standardsthe EnvironmentSONY? LSILess EnergyLess Resources, RecyclingMechanical f SoftwareImportance of Demand Oriented ProductionProduce according to demandx Line change|over, modehangeVarious demand-oriented cell production linesd ecfx Lead-time, In

4、ventory, etc. WIP loss Lead time Handling loss Products which cannot be sold Change-over lossThe Ultimate Production SystemCost Investment Lead timeInventory SpaceChange-over loss Rejected productsBreakdownSONYZeroImplementation ofProduction InnovationOnly make the required products at the required

5、timeProduction Innovation ' s 3 main types of loss1. Handling loss2. Transportation loss3. Stagnation lossMinimization of non-value added resourcesSONYProgress by Production Innovation (1)productionSmall Lot ProductionTarget:Zero InventoryLarge inventory qtyInnovationCustomer' sReduced funds

6、 turnoverRequired productsReduced spaceRequired timeReduced control costsRequired qtyMi xe d fl owIndividual 'islands 'InnovationSOZYProgress by Production Innovation (3)Inventory Reduction by Logistic Improvi Large Order/Delivery of PartsPush stylm rmStockoi-iInput_/ Innovation'KanbaHPa

7、rts InventoryDirectOutputRefrigera tor 'Provisi onProduction lineProduction lineManufacturing equipmentWIPInnovationOOSmallsize ? Low-medium speed? Functional ? Low priCeion by-production levelingIA ooSONY：Progress by Production Innovation (3)Multi-operatio nWIP reduction by production leveling(

8、Multi-skilled workers)Conveyor lineCellData management by computer Control comprehensive for anyone10000 pcs.SONYSelect&Order ? Fixed place ? Fixed qty ? Fixed markingVisual managementInnovation寸 Pat /storageXXaxBy seeingthe二二 .abnormality, a quickresponse is possiblShould be in storage OO? Ther

9、e should be OO(XXpc sAbnormal !OO pcs?Min(Y Y pcs)n Innovation: Reduction of Manpower(Actual factory example)200(persons)94/3995/3996/3997/3998/3SONV：1400012000100008000600040002000(Actual factory example)94/3995/39996/3997/3998/3SOZYExample of Benefits of Production Innovation: Reduction of Lead ti

10、me115(Actual factory example)(days)3530252015Example of Benefits of Production Innovation: Revenue&Profit0100(%)80Revenue6040-2020(Actual factory example)Production Innovation ActivitiesNote) Ratio (%) with 1992 revenue as 100SONYConveyor line? Change-over loss occurs? Line balance loss occurs?

11、Layout difficultmodification isSmall module unit type? Handling loss occursOne man 'stall ' typ IjlI IjJ LflI d e |_F3JCartSONYCell Production MethodChapter 22. Benefits of Cell Production Method2.1 Cell Production Method2.2 Benefits of Cell Production Method2.3 Examples of Cell Production M

12、ethodSmallMultilineJInspectio nfunctional workAssemblyoductsSmall lotPackagingFlow orientedproductionSOZYExample of Cell Production SystemSONYConveyor line Various i AProducti on 卜Loss in production line changeTimeCell Quantity fluctuation Various layoutConveyor lineConveyor line林isLayout modificati

13、on is difficultProducti onCell productionOperation in 3CellsCTimeBy number of workers Cells by production type Production by sales speedBu number of cellsCell production Implementation of various cell types according to products attributes, level of operators, production quantity; layoutmodification

14、s are possible flexiblySOZM Space reductionConveyor lineWork time中才 Loss timeWork tableProduc ti on qtyChange-overLossCell production Space reduction by removal of conveyor12345A B CProcess Manpower reduction by elimination of conveyor line loss Elimination of loss by reducing in-between spacesISOZY

15、Benefits of Cell Production MethodAssyAsAssysyPacka-gingInventoryPack. Insp.Stagnation of the products in processryx Stagnation, transportation loss between or within processesx Slow feedback of quality informationx Unclear responsibility concerning quality Reduction of stagnation in processesf Lead

16、 time reduction Reduction of inventory Fast feedback of quality information Clear responsibility concerning quality一 Quality improvementHigher work morale by individual performanceSOZYChapter 33. Development of Production Innovation Equipment3.1 Role of Production Technology3.2 Codependence of Men a

17、nd Machines3.3 Conditions of Production Equipment suitable forCell Production3.4 Development of Innovation EquipmentSOZYRole of Production TechnologyProduce products which have not been produced beforeBasic Technology Development which supports Products ExcellenceFurther strengthening of Product Cre

18、ation ' s QCD+FRealizationEngineering which supportsManufacturing ExcellenceSOTSTYRole of the operator:“efficiently operate production equipment“make improvements to increase capacity ”“make arrangements for next production models“design systems ”“make equipment, tools ”“Creation ”workCompactAbi

19、lity to make the required qty atsuitable to achieve early profitFlexibilityStabilityon the work floor)Simple proce change-over? Easy reflection of improvement plans for higher efficiency (reflect the feelingQ C Dfor product? Small equipment, not taking installation spacethe required pace (demand syn

20、chronized production)? Flexibility modificationsto adapt to product? Few breakdowns? No production of rejected products ? Minimum required maintenance, easy to carry outSOZYROBOKIDISakes Cell-Production Evolution RealizedDevelopment Concept:CompactMinimum Cost Costvs. conventional1/33) Flexibility:

21、WideVariety of ApplicationsSOZY(Soldering, Dispenser, Screw-Fastening, Circuit Board SplittingROBOKIDS Features Conventional TypeA4-Size4 0%SMART SYSTEM2 0%0%InstallationInstallation1 month 2 months 3 months4 monthsROBOKIDS WORLWDide Variety )Circuit Board SplittingROBOKIDSDispenser ROBOKIDSSOZYSOZY

22、Actual condition at production factoriesFlexibility is a main issue in the assembly area , as a starting point of production innovation, however in the surface mounting area -Very expensive mechanical equipment is lined up-Large qty & high speed processing is a main objective, using identical mo

23、dels of high speed surface mounters-Large scale equipment investment is still needed“A mounting process, where production innovationis still difficult tointroduce ”Large lot productionMounting line(A)assy line(a)assy line(b)Large qty of WIP, Inventoryassy line(e)Objectives of the“Cellular Mounter ”1

24、) Compatibility of both high precision and flexibility Building is possible depending on demand variation, variation of production types Realization of low investment (cost/shotsmall space2)Realization of Investment in steps to obtain a high level of investment results Procure only the requiredfunct

25、ion, at the required time, at the required levelSOZYSIE1000 SI-E1000SI-E2000ConnectedmachinesParent1Children1< Standard type connection >ParentOne machine is the parent unit and the other three machines are the children unitsChildrene of type-dependant parts, the other three machines are conne

26、cted. (type change-over only for the first machine)< PCB Mixed flow compatib le >O n e m a c hi n et a k e sc aSOZYFlexible Production Capacityin 1.2 min 2.4 m=38,571 c p h=51,428 cphin 3.6min 4.8mSOZYComparison of Conventional Mounters and Celluar Mounter20% Investment saving and 55% space sa

27、ving is possible(peMne )Investment-20%Space-55%7.2m1.2mCelluar MounterSI-E1000SI-E2000SONYxzosAjeiuiunsL fluaiudinb3uoneAOuui uoipnpojj jo “ IPQANOS,9 一女luaiudinb3uoneAOuui uoipnpojj jo uoiieiuaiuaidiui leuozuoHS 一 女sun uoipnpojj nag jo uBisaci ojsegf fuoipnpojj nag jo uoiin|OA3£ 一女lu8iu8A0jdiu

28、| uoipnpojj jo siuioj乙一次6U!J88Ul6U3 JUB|d 舊1。1一次suopios woisAs 6uunpejnue|/| pTotal Plant Engineering Elimination of waste and losses Construction of optimum operation? IE approachsystem? Reduction of resources without? Alternative scheme trade-offadded valueanalysis? Clarification of system specifi

29、cationsTotalPlantiEngineering Optimum hardware? Machining, assembly, adjustment, inspection Optimum softwareMaterial handling systemsHigh-performance CIMMounting process control software Evaluation technology? Economy analysis? System simulation?Assembly,disassembly capability evaluation method Plan

30、t layoutLayout? SLP (SystematicPlanning)? Construction specificationsSOZYEvolutionary Cell Production SystemPoints of Production Improvement1 . Design for production: Design feedback using DAC method? Design with high ' manufacturability ? Reduction of number of parts? Standardization of parts2.

31、 IE 'kaizen' : Extensive elimination of'mudf (loss) by production innovation? Transport ? Operation ? Stagnation3 . Factory automation: Low-cost, easy-to-maintain equipmentSOZYSymbiosis of Human & Machine : Evolution of Cell Production by Productionx Innovation EquipmentManual CellEa

32、sy & SmoothProduction InnovationEquipmentOperationProduction Innovation EquipmentBenefits from Evolutionary Cell ProductionHeadcount SavingQuality ImprovementReduction of Lossesat Learning StageManualtimeEvolutionCell CellStarting Upttt HBasic design of cell production line1. Production oriented

33、 design: feedback to design by using DAC analysis2. Summarized process organization3. Layout image drawing4. Application image using production innovation equipment5. Profitability investigationSOZYD ACDesign for Assembly/Disassembly Cost-effectivenessFeatures of Parts? evaluates the shape and other

34、 characteristics of a part that determines the ease with which it can be fed and acquired(picked).Features of Assembly? evaluates the ease with which the part can be oriented, retained and assembled.Features of Processing? evaluates the ease with which the base part can be retained or turned over fo

35、r thenext operation.Design with high(assemblabilitySOZYDACSheetSOZYAssembly evaluation problems, summary of suggested improvementsNo.Par tProble mImprovemen tPoints DesignBeforeduringFac1 Pinch drive armFeatures of Assembly : Difficult positioning during insertion (-10)Whenplacing Gear cover C on th

36、e Pinch drive arm, the Pinch drive arm moves, so positioning is difficult2 Gear cover CFeatures of Assembly : Difficult positioning during insertion (-10), Retain (-10)Whenplacing Gear cover C on the Pinch drive arm, the Pinch drive arm moves, so positioning is difficultWhen screw fastening (next op

37、eration), retaining is needediliFacilitatetatpositioning byetemporarilyposfixing withaitiPositioningonipin (+10)Features of Assembly： Difficult positioningng by use of a pos iti oni ng pin (+1 0)Facilitate positionin g, and make retaining unnecessar y when screw fastening (+10)(After)CommentWill be

38、considered90(100)80(100)3 Gear cover A4 Drum base5 RetainingW川 be consideredinsertionaciIitate positioning by use of a positioningcover6 Drum(-10)9D Will be conside redaster S, T inWhen placing Gear cover A, the connection with the Modegear is complicated, so positioning is difficult the Drumbase, W

39、h unstable en situation inseFeaturesFeatures of PartDuringfeeding, picking, situation is not completely stable (feed;-20、pick; -10)rtofinAssemblygC°Positioning difficult during insertion (-10), sl oFeatures of Processing : Retain (-10), pin (+10)Turn180 ° (-20)(100 )FP(-Positioning pin is

40、impossible, assembly of60redof(90)FacilitatepositioningbyWhen attachingtheRetainipositioningis70fficulto remove by temporarily fixing (+30)making temporary fixing points (+10)rocessing : Retain10)ng board,Will be conside redeaturesWhenscrewfastenirg，retainin necessgaryisFacilitate positioning, and m

41、ake retaining unnecessary when screw fastening (+10)(90)Improveme ntFeatureautionscratches,dirt(-20FeatureAssembly; Assemblyofs of Part needed forFacilitate positioning by use of a positioning guide(+10)20(30)impossibl edirection diagonally down(-20), Difficult positioning (-10)isSOZYProcess organiz

42、ationP rocess or ganZation (45 sec cycl e cel)Mech. assyRO B O K I D S scr ew ing ti me: 1 pl ace 4.5sec/scr ew ? Input/out put tim e4sec RO B O K ID S gear supply ti me: 1 place 8.0sec/1 ?nput/output ti m e 4sec RO B O K I D S grease application ti me: 1 place 4.5sec/1 ?Input/output ti me4sec ROB O

43、K IDS soldering time: 1 place 3sec/pl ace ?solder?Fixture I nput/out put4secF P C assyNoC ycleO perati onT ime K IDS C ycleM A 1S et M ode FP C i n Label ing fixture 2.944.9F1Clean w i th al cohol2.1A ttach S ensorO perati on T i me K IDST ake fixture 2.6 42.67.4P eel off FP C Label and sti ck 4.9La

44、bel, S et into f ixture8.2Rem ove1.7Set i n P hase adj ustm ent f ixture fixture, i nsert i nT ake FP C ,P eeloffA ttach T O P S ensor to f ixture 4.94.92.9 A ttach ENDS ensor t oFP CRobokids R em ove/I nsert 2.0A ttach M ode gear360A ttach R educti on gearA ttach LED w i th tw eezer s 3.2Rem ove1.7F2 Insert f ixture i nto R oboki ds 4.043.8cers0ace)ssyh pi rA ttach C am gear BRobokids R em ove/I nser