Cell-Desig单元生产线设计

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Output = X units/day
Output = 3X units/day
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Lean Cell精益单元
Lean Cycle Time = 60 Seconds / Cell 4 Cells = 1 Mass Line 4 Different Product Type at one time 一次生产4种不同类型的产品
Time to first piece is 21 minutes完成第一件需要21分钟 Time to complete batch 30 minutes完成一批需要30分钟
One-Piece Flow单件流
Lathe
Make 1, Move 1
Mill
Make 1, Move 1
Drill
Make 1, Move 1
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9. Make Equipment Easy 来自百度文库o Relocate 使设备有利于再配置
Machines
Cell Y - Skills Matrix
Manual Colin Desi Jeff Richard Susan Tim In Training Certified Trainer Wave Mechanical Pack
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8. Cell Could run with One Operator 单元产品能在一个操作者的情况生产
1. Design for Single Piece Flow单件流设计
Batch & Queue批量
1 min. cycle times per process 每个过程1分钟的周转时间
Lathe
Make 10, Move 10
Mill
Make 10, Move 10
Drill
Make 10, Move 10
Seq. No. Seq. Description of Time Operation Working Time (in seconds)
Description of Man Auto Walk Time Operation Working Time (in seconds) Operation 5 10 15 20 25 30 TT35 40 Seq. Description of Time Operation Working Time (in seconds) No. Operation Man Auto Walk 5 10 15 20 25 30 TT35 40 Pick-up, unload/load, 4 10 3 Man Auto Walk 5 10 15 20 25 30 TT35 40 Operation cycle start Pick-up,No. unload/load, cycle start unload/load, Unload/load, cyclePick-up, 1 start 3 8 cycle start Unload/load, cycle start

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4. No Barriers to Operators or Flow 对于操作者和操作流程无障碍
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5. Material is Presented from Outside of the Cell 物料是从线外呈现进来的
Entry入口 Exit出口
Materials物料
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6. Equipment Should Be Right Sized 设备应有准确的大小
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7. Operators are Multi-Skilled 操作者具有多种能力
Parts In Parts In Parts In
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= Walk Path 路径
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3 2 1
35’
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Parts In
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Parts In
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Product Out
110’
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The Standard Work Orchestra 标准生产曲线图
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Time to first piece is 3 minutes 完成第一件需要3分钟 Time to complete batch 12 minutes 完成一批需要12分钟
© 2008 Gemba Research LLC
2. Equipment & Stations are Close Together 设备及其配备装置共同停止运作
Product Flow产品的流动 Operator Flow操作者的流动
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• Operator does not
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need to follow product flow 操作者不需要遵循产
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品流程
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• Staffing varies based on demand
根据需求员工多样性
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Focused Cell 聚集的生产线
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Advantages of U-shaped Cells U型生产线的优势
Visual Control - Easy to see the whole process 目视化控制- 容易目视整个流程 Linked Processes 连接的流程 Good Information Flow 好的信息流 Shortest Part Travel Distance短距离的物品传送 Common Drop-off and Pick-up常见的下降和回升 Easier to implement Standard Work Sequence 较容易实现标准的工作次序 Easier to create multi-skilled workers 较容易培养多种技能的员工 Better Teamwork 较好的团队合作
Cell Design 单元生产线的设计
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Elements of Good Cell Design 高效率生产线的设计要素
1. Design allows for One Piece Flow设计遵循单一流程 2. Equipment and work stations are close together设备 及其配备装置共同停止运作 3. Product flows from right to left 产品流自右向左 4. There are no barriers to operator or material flow对于 操作者和操作流程无障碍 5. Raw Materials fed from the outside of the cell by the material handler原材料由材料操作者从生产线外引进 6. Equipment should be right sized设备应有准确的大小 7. Operators are multi-skilled操作者具有多种能力 8. One operator could run the cell 一个操作者能够管理 生产线 9. Equipment and work stations are easily movable 设备及工作站易于移动
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3. Product Should Flow From Right to Left 产品流自右向左
Most people are more effective using their dominant hand. Most people are right-handed.大部分人更有效的使用他们受 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.右脑通过左眼输入空间性的视觉信息。 Race tracks are counterclockwise for this reason.跑道由于这 个原因自左向右。
© 2008 Gemba Research LLC
Elements of Good Cell Design 高效率生产线的设计要素
10. All work areas are safe and ergonomic所有工作站是 安全的且符合人体工程学 11. Tools and material are presented at point of use based on frequency of use and ergonomics工具和材 料所呈现出的使用点以使用频率和人体工程学为基础 12. Schedule is visual 计划是视觉化的 13. Hour/Daily goals are posted and actual data is collected每时/每日的目标是清晰的，且收集实际数据 14. Use visual management to manage materials and tools 使用目视化管理方法管理材料和工具 15. Metrics and other key performance indicators tracked, clearly seen生产规律图和其他关键履行指标追踪跟进 16. Root Cause Corrective Action process is in place根本 原因纠正措施过程的适当实施 17. Process steps are error proofed - Quality built into the © 2008 Gemba Research LLC process过程步骤是错误的证据---质量形成于过程中
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8 3 Check quality 2 Unload/load, 4 cycle start 3 10 3 Check quality 4 Unload/load, cycle start, 4 4 12 5 11 put down part 3 Check Unload/load, cycle quality start, 4 4 12 put down part Unload/load, cycle start, Move Widgit to Fixture 5 4 3 4 put down part 5 Move Widgit to Fixture 4 3 6 Insert Screws 5 Move Widgit 10 to Fixture 6 Insert Screws 10 8 7 Put on S/N Label 3 5 6 Insert Screws 9 7 Put on S/N Label 3 8 Put in Bag 7 Put on S/N 3 Label 3 in foam Bag packing 8 Put 3 Insert into 9 3 4 Put inpacking Bag5 8 foam material Insert into 9 5 foam packing Label 5 Insert into 10 Put onmaterial 3 9 10 Put on Labelmaterial 3 11 Pack Unit 10 3 5 6 Put on Label 11 Pack Unit 3 7 11 Pack Unit