精益生产-快速换型

Quick Changeover 快速换型

Justin Tao 陶建刚

2016

Produce Large Lot Size? 大批量生产？

• It is a reality still used by many companies to produce, and the main objective is to smooth the setup time.

事实上很多企业使用大批量生产方式进行生产，并且主要目标是使换型时间更加平稳

• This is the key of the “Mass Production”, it means:

这点是“大规模生产”意思的关键所在：

– “Produce a large amount of a only product”

“生产大批量的单一产品”

Heijunka Process 均衡化进程

Too early 过早，

inventory 库存

Too late 过晚，

out of stock 缺货

Changeover

Consequence of Long Setup Time 长换型时间导致的结果

All these factors increase the wastes in the workshop!!!

所有这些因素都在车间中增加了浪费！！！

Long Setup Time 长的换型时间

Long Production Cycle time 长的生产周期 Large amount of WIP 大量的在制品

Equipment to transport and to storage

需要设备搬运和存储 Increase manpower need 增加所需人员

Require space in the shop floor and area to storage 需要空间存储

Definition of Setup Time and Its Structure

换型时间的定义和构成：

Setup time: The last qualified product in production run and the first qualified product in the

next production run

换型时间:指介于一个生产作业的最后一件合格品和下一个生产作业的首件合格品之间的时间 Definition of setup in lean manufacturing: The last qualified product of one type to the first

qualified product of next type

精益生产的换型定义:为从前一品种最后一个合格产品，到下一品种第一个合格产品之间的

时间间隔。

Preparing time 准备时间 Setup operation

time

换型操作

时间

Adjusting time

调整时间

Sort 整理

Product A 产品A Product B 产品B

Setup time 换型时间

2

3 4

Right

First Time

(Elimination of Variables 首次做好 (消除变化)

Streamline the Process

简化过程 Separating Internal from E xternal Time 区分内部和外部时间

Continuous Improvement 持续改进 5

Understand the Process

了解过程 1

6 Teamworking 团队合作

Set-up Reduction - The 6 Stages 换型时间降低-6步

Step 1. Understanding The Process

第一步. 了解过程

Record Current Process 记录当前流程

• Introduce Change-over Chart

引进换型图

• Record Current Change-over Process

记录当前换型流程

– Videotaping 视频拍摄

– Divide into steps 分解为步骤

– Time the steps 给步骤记时

– Gather facts 收集事实

TOOL STORES 刀具库 INSPECTION 检验

Video the Complete Process 录下整个过程

Observation Sheet 观测表

• Observe the Setup, describe and measure the time of all activities. See example below:

观测换型，描述和测量所有活动的时间。举例如下：

S 开始 F 结束 1 Get tools in the wardrobe 找到工具 0 4'02" 242" 2 Loose the dragring plate 松开环板 4'02" 4'58" 56" 3 Get measuring tool on the wardrobe 获得测量工具 4'58" 5'24" 26" 4 Adjust position of support device 调整支撑位置 5'24" 7'27" 123" 5 Fix supporting plate 固定支撑板 7'27" 7'42" 15" 6 Fix new supporting plate 固定新支撑板 7'42" 7'54" 12" 7 Get fixtures 获得工装 7'54" 8'17" 23"

8 Ajust position of fixtures 调整工装 8'17" 9'32" 75" Ajust with 3/4in screwdriver

调整3/4的螺丝起子 9 Fix fixture device 固定工装 9'32" 9'55" 23"

10 Get screwdriver 获取螺丝起子 9'55" 10'22" 27" 11 Ajust mechanincal range 调整机械范围 10'22" 11'00" 38" 12 Adjust eletrical range 调整电位 11'00" 12'01"

61" TOTAL 总

721"

Coments 观测 Setup Time Observation Sheet 换型时间观测表

Step 步骤 Activity Description

活动描述

Time 时间 Time 时间