lean精益生产----03.layoutoptimization布局上优化

13
Benefits of Small Cells 小单元的好处
Small cells can minimize risk and cost ramping up products, and minimize costs ramping down endof life products
小的单元能够最小化风险和产量上升和 下降的成本.
Product Line C 生产线C
12
Small Process Units 小工序单元
The Japanese still favor small, inexpensive machines that have modest automation. 日本人喜欢用小的,不昂贵的适中自动化的机器.
4
The Importance of Layout 布局的重要性
How can we resolve these often conflicting criteria? 我们怎样解决这些经常相互矛盾的标准? Layout design is not just an Engineering exercise - it is a business decision 局部设计不只是一个工程问题,它也是一个商业问题. Requires involvement from all stakeholders to truly understand constraints & options 它要求真正理解约束和选项的所有利益相关方的参与.
5
Key Design Principle In Lean Manufacturing 精益制造的关键设计原则
Current Scenario现在的 情况
Future Scenario将来的情 况
A key principle in Lean Manufacturing is to breakdown barriers and
类似于物料的流动的是河流里的水的流动,最好的流动方式是通过一个清洁的, 宽的,很好的河道,直接到要求的地点.
11
Concept Of Flow 流动的观念
1st Process 第一工序
Product
Line A 生产线A
Product
Line B 生产线B
2nd Process 第二工序
3rd Process 第三工序
They avoid super-machines, called monuments, that require high utilization for any payback.
他们避免使用超级机器,他们叫它纪念碑,通常他们需要很高的利用率才能将投资到机器 上的钱收回来.
A
E
A
D1
E
B
D
F
B
D2
4th Process 第四工序
Small-scale and low-cost arrangement 小范围和低成本的安排
One piece production and conveyance 单件流和运输
Defect recurrence prevention is easy 坏品重新发生容易发现
Materials
A 原材料 B
C
Finished Goods 成品
10
Flow in the Factory 工厂的流动
Concept Of Flow 流动的观念
In order to eliminate and reduce NVA (Non Value Added) activities, the flow of material and components should be smooth and uninterrupted. A stop-start flow implies placing, stocking, waiting and picking.
facilities costs 设备成本
operator usage 员工利用率
operator flexibility 员工弹性
Safety 安全
ease of maintenance 容易维护 ability to ramp up/ ramp down 产能增加/减少的能力 cleanliness requirements 清洁度要求 communication & feedback 沟通和反馈 teamwork / shared responsibility 团队精神和责任共担
F
C
G
C
D3
G
D is a large machine controlling the entire product flow.D是一个大型的机器控制了整个 生产流.
If D stops, production stops 如果D机器停了,整个生产都停了.
Inventory is used as a buffer 库存用来做缓存的.
3
Layout Implications 布局的含义
batch size批 量大小
inventory levels 库存水平
material handling costs 物料操作成本
material handling damage 物料运输损坏
visual management 可视化管理
floor space usage 工厂空间管理
each stakeholder group should have the opportunity to provide input into layout, but be careful of design by committee 每一个利益相关组都应该对布局提供输入,但是要有一个委员会来设计.
Limited teamwork 团队工作受限制 Limited ‘ownership’ of finished products 成品所有权受限制 Poor control and coordination 差的控制和协调 Double or triple handling 双倍的或三倍的搬运放料时间 Difficult defect detection 难发现坏品
Traditional Batch Processing
Parts are produced in batches at Work in
every station before moving on
Process 在制品
to the next station.
传统的批量生产在每一个工位都是
以批来向下流动.
Layout Optimization 布局的优化
Layout Optimization 布局优化
Introduction 介绍 The Impact of Layout 布局的影响 Takt Time and Line Balance 节拍时间和拉平衡 Layout Case Study 布局例子研究 Detail Layout Design – Techniques 详细布局设计----技巧 Factory Exercise 工厂练习
4th Process第 四道工序
Large-scale arrangement 大范围内安排
Lot production 批量生产
Defect recurrence prevention is difficult 坏品重新发生很难预防
Difficult to balance 很难平衡
9
One Pieco传na统l /的F/u功n能cti的on布a局l Layouts
Problems With Traditional / Functional Layouts
传统的/功能的布局的问题
1st Process第 一道工序
2nd Process第 二道工序
3rd Process第 三道工序
2
Lean Layout & Flow 精益生产布局和流程
Why do we care about physical layout of processes in our factory?
为什么我们关心我们工厂的工序布局?
What is the effect of layout on the operation of a plant / site / factory ? 布局对一个车间/场所/工厂操作的影响是什么?
Grinder 磨
Plating 电镀
Storage 储存
Saw
Storage
Assembly装配
锯
储存
Mill 磨
Machines grouped together according to their function 按照机器的功能将一样的机器放在一起.
7
Traditio传na统l /的F/u功n能cti的on布a局l Layouts
The analogy for material flow is that of water in a river - the best flow is through clear, wide, well defined channels that go directly to the required destination.
为了消除或减少无附加价值的活动,原材料和元件应当顺畅和不间断的流动.一 个停—开始的流动暗示着放,储存,等待,拿起等活动.
Once the product has started on its process route, it should complete it in one single flow. 一旦一个产品开始了它的工序路程,它就应该在一个单独的流程内完成.
develop team working. 一个关键的原则是打破部门之间的障碍,发扬团队精神.
6
Traditional Layout 传统的布局
Material Flow in a Process-Orientated Layout 以工序为导向的物料流程
Receiving 接到料
Paint喷
Lathe 车
Ramping up multiple small lines only when needed 如果产量需要增加,多设几条小的生产 线就可以了.
Work in
Materials 原材料
Process 在制品
A
B Materials
原材料
Finished
C Goods 成品
Materials 材料
One Piece Flow By handling items one at a time, each employee completes work on one assembly before reaching for the next workpiece. 单件流生产,一次只拿一只产品, 在生产完一个产品之前不可以生 产下一个产品.
and flexibility 多个这种小的机器更具弹性和防止停拉..
Small facilities allow flexibility, small batch sizes, shorter lead times, improved layout and improved ownership
小的设备更有弹性,更小的批量,短的订单到订单时间,改善过的布局和物主更明确.
The problems with Functional / Traditional layout design are:
以功能/传统的布局设计出来的规划问题在于:
High motion / transportation distances 长的移动搬运距离 Long Lead Times 长的订单到订单时间 Poor labor utilization 差的人工利用率 High WIP at location changes 高的库存量 Poor housekeeping 差的工厂管理 Hard to improve or make efficient 较难提高效率
D1, D2 and D3 are small flexible machines
dedicated to the particular lines D1,D2,D3是专用于特定一条线上的小的,更有弹性 的机器.
Duplicate small scale machines give protection