装配线设计 Assembly Line Design

5
直型线 Straight Line
54321 4 3 2 1
指挥棒 Baton-pass 时间标记 Timing mark 交接区 Zone
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
6
有供应线的直型线 Straight Line With Feeders
传统装配线设计 Traditional Assembly Line Design
物料储存
Material Storage
物料储存
Material Storage
悬挂式电动输送带 Powered & free conveyor
物料储存
Material Storage
物料储存 Material Storage
需求大 High demand
节拍时间短 Shorter takt time
两个工人 2 operators
需求小 Low demand
节拍时间长 Longer takt time
一个工人 1 operator
SKB
单元1 Cell 1
FG 6 5 4
单元2 Cell 2
FG 6 5 4
物料储存 Material Storage
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
2
精益生产系统装配线模式特点 Lean Production System
Assembly Line Model Characteristics
改善前 Before Kaizen
铸造 Die Cast
熔铅炉 Lead Pot
Pallets of lead slugs 铅胚卡板
Pallets of Boxes
卡板
WIP on Shelves 架上半成品
Carts of lead wheel
Weights 铅轮配重车
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
Time Based Management
附录 1 Appendix 1 : 装配线设计 Assembly Line Design
SKB
© 2005 TBM Consulting Group, Inc. All Rights Reserved.
TBM Consulting Group, Inc. is the sole licensee of LeanSigma, a service mark of Maytag Corporation.
两人单元 2-operator Cell
Major subassembly
Line 主分装线
SKB
一人单元 1-operator Cell
© 2005TBM Consulting Group, Inc. All Rights Reserved.
7
开放式平行线布置 Parallel (Open Room) Layout
9
开放式布置举例 Open Room Layout Example
改善后 After Kaizen
新的单元 布置
New Cell Layout
新的工区布置 New Work Area Layout
FG
箱子
Carton
输送带 Conveyors
铸造
Die Cast
熔铅炉
Lead Pot
盒子 Boxes
8
7
6
5
8
7
6
5
8
7
6
5
1
2
3
4
RM
SKB
来自百度文库
1
2
3
4
1
2
3
4
© 2005TBM Consulting Group, Inc. All Rights Reserved.
10
RM 1 2 3 FG 6 5 4
RM 1 2 3 FG 6 5 4
RM 1 2 3
RM 1 2 3
© 2005TBM Consulting Group, Inc. All Rights Reserved.
8
开放式布置举例 Open Room Layout Example
盒子 Boxes 箱子 Carton
有效利用人力 Productive utilization of people
物料/工人流畅 Flow of material and operators
信息即时反馈 Immediate flow of information / feedback
问题立即暴露 Immediately expose problems
工人灵活 Flexible operators
走动方便 Freedom of movement
标准化操作 Standard operations
目视工场 Visual workplace
最少线上存货 Minimal line stock
柔性生产 Flexible production
调速器 Pacemakers
保证质量 Quality ensured
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3
装配线布置目的 Assembly Layout Goals
按照节拍时间, 生产优质产品 Quality products produced at takt time
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
4
信号灯 Andon
SKB
U型线 U - Shaped Line
原料 RM
成品 FG
© 2005TBM Consulting Group, Inc. All Rights Reserved.