第十四章 单元式生产布局CELL

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wk.baidu.com
工位设计目标
Work Station Design Objectives
单元式生产布局CELL
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议程 Agenda
1. 传统组装线设计Traditional Assembly Line Design 2. 工位设计 Work Station Design 3. 物料展示 Material Presentation
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精益生产系统组装线 模式特点
工人灵活Flexible operators(multiprocessing and cross-trained) 走动方便Freedom of movement (standing +moving operations) 标准化作业Standard operations(assembly only, Water spiders+standard operations) 目视化工场Visual workplace(A place for everything, everything in its place) 最少线上存货Minimal line stock(no mini-w/h, max.2-h Line stock) 柔性生产Flexible production(variations in either mix or volume , No islands!) 节拍器Pacemakers(Lines incorporate pacemakers to set pace to TT, not to selfLean Production System Assembly Line Model Characteristics
按照节拍时间, 生产优质产品Quality products produced at takt time 有效利用人力Productive utilization of people
• 装配工只做装配Assemble product only • 按节拍分配任务达到高生产力High operator productivity through loading to takt time • 工人能完成整个流程Operator to complete the full process
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B. 组装线设计
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直型线 Straight Line
例如，汽车组装线
当产品结构和物料展示能够保证时使用Used when product configuration and material presentation warrant
按使用次序安排物料 Material is sequenced in order of use
柔性生产时
For mixed-model production
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非整合分装(预装)按配套供料Non-integrated sub-assemblies are supplied as completed kits 必须建立信息与反馈系统Communication and feedback must be established 例如喇叭､灯号 e.g., speaker, lights 时间标记 Timing
We’re operators.
成品 FG
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B. 组装线设计
线体设计: 物流从右至左
线体设计：最大偏差为 20%
线体设计 :工具伸手可及
拉动信号: 目视化和在制品控制 线体管理：本独立工作 单元中操作工的数量 （1~8人）
U型线
线体设计:模块化和 可连接的工位设计
线体设计: 每条槽 里放2个料箱 线体管理 : 过道里不 许放料箱
物料/工人流畅Flow of material and operators
• 优化工位以方便摆放零件､物料､工具Work stations optimized for presentation of parts, materials, and tools • 工位设计减少走动Work station design minimizes operator movements
两人单元 o将会出现这种重大变化的分装线从总装线中分离出来 2-operator Cell
Used when a subassembly cycle time exhibits major variations in a mixed-model production environment Shifts the subassembly experiencing the wide variation off the main assembly line
为方便车间目视化 和沟通: 建议料架高 度不超过1.5米
目视化及5S管理:例： 划线并确定相关货架 占地面积
线体设计: 工作 区间距 > 1.6米
线体设计: 所有料箱都放 置于工位前方 线体管理 : 禁止订单在缺少 零配件的情况下进行生产 线体设计:空料箱 Nagoya · Shanghai ·Guangzhou ·Tianjin ·Hangzhou ·Suzhou ·Wuxi ·Qingdao·Chongqing ·Wenzhou 从料架下方回收 防错 : 一旦发现缺 陷立即停止生产
Multi-operator sub-assembly subassembly cell is on the “back”, since its output is presented to the main line operators just like other parts and materials. 按使用次序安排物料 Materials sequenced in order of use Line 主分装线
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2. 工位设计Work Station Design
典型工位 Typical Workstation
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U型线 U Shaped Line
按灯 Andon
I’m water spider.
原料 RM
最少走动 工人间的平衡 避免产生孤岛 多工序作业 促进沟通 按灯识别异常 WS负责所有物料需求 o从“U” 型线外送料 o取走成品 节拍变，你也变 o人员安排可以应变 ·Hangzhou ·Suzhou ·Wuxi ·Qingdao·Chongqing ·Wenzhou Nagoya · Shanghai ·Guangzhou ·Tianjin
物料储存 Material Storage-QP 物料储存 Material Storage-QP
悬挂式电动输送带 Powered & free conveyor
物料储存 Material Storage-QP
物料储存 Material Storage-quality problems
物料储存 Material Storage-quality problems
e.g., automobile assembly Line paced by product movement
生产线的速度由产品的移动速度决定
随时掌握装配进展
已经设立了工人区
Assembly progression on line
Worker zones are established
已经定义了交接区(交接指挥棒) Overlap (baton passing) is defined
线体设计: 预留 30% 的工位空间
线体设计: 工作台高度 0.8~1.2米 (人机工程)
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U型线 U - Shaped Line
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4. 物料补充 Material Resupply
5. 物料储存 Material Storage
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1.传统组装线设计 Traditional Assembly Line Design
pacing)
保证质量Quality ensured(go or no go, 3 Nos)
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组装线布局的目的 Assembly Layout Goals
mark
指挥棒交接区
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Baton-pass Zone
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有"喂料”的直型线 Straight Line With Feeders 当进行柔性生产，分装线周期时间会出现重大变化时，使用此类生产线。
总装线上设有“节拍器” “Pacemaker” established on final assembly line o例如，生产线按节拍时间连续移动i.e., continuous movement of the line at the takt time rate 总装线 “拉动”分装线 Final assembly “pulls” from subassembly o分装线的工作与总装线分开 Subassembly work separated from final assembly work o适应产品的变化 Facilitates product variation o在生产支线/生产单元完成分装工作 Subassemblies completed on “spur” line / cell o例如，附属于总装线的生产支线/生产单元 i.e., attached to main line o分装线在需要使用零件的地方才介入总装线 Subassemblies enter at point of use 从后面供应物料 Material supplied from back o多人的分装线单元要放在“背后”，因为分装线的输出是以其它零件和 一人单元 1-operator Cell 物料一样的方式，供应给总装线的。 Major
信息即时反馈Immediate flow of information / feedback 问题立即暴露Immediately expose problems
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