1、1,CHANGE OVER REDUCTION缩短设备工装更换时间,2,Definition 定义,Set-up Time 更换时间Set-up time is the amount of time taken to change a machine from the last part of a production lot to the first good part of the next production lot.更换时间是指从生产完上一批产品到为生产下一批产品而更换设备的时间(Clock time, not Labor time) (物理上的时间而非工时时间),3,Set-up
2、Reduction 缩短更换时间,Why do set-up reduction activities? 为什么要缩短更换时间Lower set-up times 更少的更换时间More frequent set-ups 更频繁地更换Smaller batch sizes 更小的批量Shorter lead times 更短的交付时间Competitive advantage 更具竞争力,4,Example 举例,Before Improvements 改进前Product demand= 400/day (天)产品需求Product variety= 5 models(种)品种Product
3、 cycle time= 60 sec (秒)节拍时间Avg. Set-up time= 50 min (分)平均更换时间Net opr. Time= 450 min (分)净生产时间No. Set-ups= 1/day (天)更换次数Avg. Batch size= 400平均批次大小Avg. Lead time= 5 days (天)平均交付时间,After Improvements 改进后Avg. Set-up time= 10 min (分)平均更换时间No. Set-ups= 5/day 天更换次数Avg. Batch size= 80平均批次大小Avg. Lead time= 1
4、day 天平均交付时间,Do More Set-ups! 更多的更换,5,Typical Process 典型的工艺,Typical Setup Process 典型更换的过程Gathering necessary items25%收集必须的物品Exchanging parts10%更换零件Positioning parts20%零件的定位Making adjustments45%进行调整,6,Set-up Activity 更换工作,Internal Activity内部工作All activities that must be performed while the machineis t
5、urned off, not while making parts.所有必须在停机状态下进行的更换工作External Activity外部工作Any activity that can be performed while the machine is turned on,making parts.任何可以在机器运转并正常操作下进行的更换工作,7,Improvement Stages 改进阶段,Set-up Reduction Improvement Stages缩短更换时间的改进阶段Original Set-up Time 以前的更换时间Time from the last good pi
6、ece of product A从生产上一件合格的A产品的时间to the first good piece of product B.到生产第一件合格的B产品的时间1. Separate internal and external activities. 不同的内部和外部工作External Internal External 外部 内部 外部 Machine Running | Machine shutdown | Machine Running 设备运转 设备停机 设备运转Convert internal to external activity.使内部工作转换到外部工作 Externa
7、l 外部 Int 内部 External 外部 Machine Running | stopped | Machine Running 设备运转 停机 设备运转,8,Improvement Stages Cont 改进阶段(续),Set-up Reduction Improvement Stages缩短更换时间改进阶段3. Reduce all remaining activities. 减少所有多余工作活动Ext外部 Int内部 Ext 外部 Machine Running |Stop | Machine Running设备运转 停机 设备运转4. Repeat and track Impr
8、ovements. 重复并跟踪改进,9,Set-up Improvement Summary 工装更换改进总结,0,10,20,30,40,50,60,70,Original以前l,Stage 1阶段1,Stage 2阶段2,Stage 3阶段3,10,Observation 观察,Set-up Observation 对更换的观察(Stage 0 阶段)Team Activities 小组活动Identify all parts that run on this machine确认所有在此设备上进行加工的零件Select 2-3 part numbers for setup observat
9、ion选2-3种零件作为对更换的观察的样件Determine setup elements确定更换单元Setup elements should be less than 3 minutes更换单元应少于3分钟Videotape the process对工艺进行摄像录象Assign roles to team members:对小组成员进行分工Timer 计时的Recorder 记录的Tools/fixture observer 刀具/工装的观测人Information observer 信息观察者Others improvements 其他 改进,11,Using Videotape 使用录
10、象,Using Videotape 使用录象(All Stages 所有阶段)Use during long changeovers在长时间的更换中使用Set camera up high - focus on work area将摄像机放置高处 对准工作区域Do not follow operator around不要跟者操作者转Set timer on camera对摄像机定时Review video - define elements and element times回放摄像机 确定单元和单元时间Analyze/Improve element by element分析 / 单元逐个改进
11、Use the videotape as a teaching tool, not just a recording of what is happening.把摄像机做为一个教学工具, 而不仅仅对活动进行摄像.,12,Separating internal from external区分内部外部活动Ensure that all items necessary for the changeover are organized and on hand - “operating room” analogy 确保所有更换所需的必须品都已排列好放在手边 ”类似手术室”Tool boards 刀具板D
12、ie carts 模具车Tools, gauges, materials, etc. 刀具, 量具, 材料, 等Use Checklist for each Job 每项使用点检表Perform checks on all items to insure proper function and fit.对所有项目打勾确保正常运转Tools sharpened and preset刀具韧磨和预设置Paperwork/drawings ready准备好文件/图纸Its OK to move arms, but not legs.动手可以, 但尽量不跑腿,13,External Set-up Che
13、cklist 外部更换检查表,零件号,设备,刀具和夹具,检验量具,工艺信息,14,Set-up Observation Form 观察表,15,Stage 2 阶段,Converting Internals to Externals由内部转换到外部Prepare operating conditions prior to the changeover更换前做好准备Preset tools 预设置刀具Position test heads 放置测试头Prepare gauges 准备量具Simplify and standardize functions简化和标准化Replace the few
14、est possible parts 尽可能少的更换零件Do not remove bolts completely 不要完全去除螺栓Regard bolts as enemies to eliminate 把螺栓当做敌人来消灭Minimize/eliminate adjustments 减少/ 消除调整Standardize die and jigs 标准模具和夹具Select- do not adjust 选择 不要调整Use gauge blocks (hard stops) instead of visual or scale adjustments使用量规块(硬块), 不要用目测或刻
15、度调整Use setup fixtures/jigs 使用工装 / 夹具,16,17,之前,之后,4条螺栓4分钟固定螺帽,1秒锁紧,18,One-Motion Methods 一次动作方法,凸轮紧固,弹簧销止位,真空吸附,锥度销,19,20,老式方法必须完全取掉螺杆才能取下夹板,新方法松动螺栓即可取下夹板,21,请记住最快的更换是无需更换,22,安装前,将所有材料和工具放在设备旁,安装后,锁住设备,准确地按标准程序操作,小心设备噪音, 热, 震动,均衡拧紧螺丝,进行测量,确认所有开关设置正确,23,安装后,确认没有剩下的零件,确认是否有剩下的金属片或残骸,将设备周围打扫干净,再检查所有螺栓,
16、废品, 工具,测试新的安装,观察设备运转,鉴定此次的安装供今后改进参考,放置好工装夹具为下次换装做准备,24,Separate external set-up from internal 将内部外部安装分开Convert internal set-up to external把内部安装转换为外部安装Kaizen the set-up改进安装Standardize all steps将所有步骤标准化Simplify the process简化过程Adopt Parallel operations采用平行操作方法Eliminate adjustments消除所有的调整,Techniques to
17、reduce changeover time 缩短更换时间的方法,25,5 Whys Must ask the right questions5个为什么- 必须要问的问题What is the purpose? 5 Whys. Is this necessary 目的是什么? 5个为什么 是有必要的吗?Where is this being done? 5 Whys. Why in this place? 在什么地方做? 5个为什么 为什么在这个地方?When is this being done? 5 Whys. Why at this time? 什么时候做? 5个为什么 为什么这个时间做
18、?Who is doing this? 5 Whys. Who should do it? 谁来做? 5个为什么 谁应该做?How is this being done? 5 Whys. Why are we doing it this way? 应该怎么做? 5 个为什么 我们为什么这样做?,26,Whats holding you back?什么阻碍了你Scheduling / hot jobs 时间安排 / 热点工作Special tools / available tools 特殊工具 / 现有的工具Skills / number of people / adherence and /
19、 or lack of SOP 技能 / 人数 / 坚持和 / 或缺少?“Here we go again” “又来了”Machine and tooling design / different size bolts, screws 设备和工装设计 / 不同尺寸的螺栓, 螺丝Training / communicaiton between shifts 培训 / 每班的沟通Contactual restraints 接触限制Centralized tool and gauge stores 集中存放工具和量具Work place organization 现场管理And Gotta wantta do it! 一定是想要做的事情,27,机会,80%现场管理,10% 设备管理,生产设计,5% 工装,28,模具标准化方法,29,快速换螺栓方法,30,快速换螺栓方法,31,One-Turn Methods,
