1、,IE Training,Whats IE? IE organization chart MSD BOM setup Preplanning Flow-Chart / PFMEA PFP / OBC WSD SMED,Whats IE?,Include Everything,“IE, is.,&,IE is Industrial Engineering,工业工程简介,什么是工业工程？ 美国质量管理权威朱兰博士说：美国值 得向全世界夸耀的东西就是IE，美国之 所以打胜第一次世界大战，又有打胜第 二次世界的力量，就是美国有IE。,IE-INDUSTRIAL ENGINEERING-工业工程，简称I
2、E，是世界上公认的能 杜绝各种浪费，有效地提高生产率和经 济效益的把技术与管理有机地结合起来 的一门边缘学科。,Definition:,Goal:,Industrial Engineering,工业工程的特点,IE的核心是降低成本，提高质量和生产率。 IE是综合性的应用知识体系（技术和管理） 注重人的因素是IE区别于其他工程学科特点 之一。 IE是系统优化技术。 IE的面向-由微观向宏观管理。,IE的意识：,成本和效率意识 问题和改革意识 工作简化和标准化意识 全局和整体化意识 以人为中心的意识。,通常IE有哪些方法呢?,方法研究：寻求完成任何工作的最经济合理的方法，达到减少人员、机器、无效动
3、作和消耗，并使方法标准化。作业测定：制定用经济合理的方法完成工作所需的时间标准，达到减少人员 、机器设备的空闲时间.,方法研究内容包括：1。程序分析2。操作分析3。动作分析4。路线分析,作业测定内容包括：1。秒表时间研究2。工作抽样3。预定时间标准法,IE分析过程的四大原则,(1)取消（Eliminate):(2)合并(Combine)：(3)重排(Rearrange):(4)简化(Simplify):,Whats IE? IE organization chart MSD BOM setup Preplaning Flow-Chart / PFMEA WSD PFP / OBC SMED,E
4、ngineering Manager Lee Cheng,Industrial Engineering manager Terry Wang,Engineer SupervisorEuro Tom Ding,FA Engineer Supervisor NA Daniel Zong,FA Engineer Supervisor Nissan Weiqing Li,James zhang IE engineer,Bob Zheng IE engineer,Andrew guan IE engineer,Emily Qiu IE engineer,VOLVO&WULING,PSA&Sumida,G
5、MX&GMT,Ford FN,Ford EN,Ting Zeng IE engineer,IE 的组织架构: 是按项目分类的,ME & PE,Yukun Zhang IE engineer,Loger Zhou IE engineer,Chaolong Yang IE engineer,Nissan IP,Nissan EN,Nissan JA,Whats IE? IE organization chart MSD BOM setup Preplaning Flow-Chart / PFMEA WSD PFP / OBC SMED,What is manufacturing system de
6、sign (MSD)?,MSD,MSD is a Delphi-P globally common tool to develop and document manufacturing system design alternatives,Alt 1 Alt 2 Alt 3Alt n,MSD,Comparison,Decision,The Delphi Manufacturing Engineering Philosophyis to design Manufacturing Systems that achievea balance between operators , equipment
7、, andmaterial resulting in:,What is the purpose of MSD?,The best LIFE CYCLE manufacturingsystem COST,MSD,For example:,Should I buy a car ($20,000) Should I take a taxi ($10/trip) to work?,MSD use many form to calculate the life cycle cost,Whats IE? IE organization chart MSD BOM setup Preplaning Flow
8、-Chart / PFMEA WSD PFP / OBC SMED,Bom Setup,IE Clerk,Analyze drawing,IE Engineer/Technician,Create Excel BOM,IE Engineer/Technician,Input EBOM,IE Clerk,Create Item Master,PE Engineer,Transmit into 4-Shift,IT Server,Release,Purchasing Engineer,Check BOM according to 4-S,IE Engineer/Technician,Whats I
9、E? IE organization chart MSD BOM setup Preplaning Flow-Chart / PFMEA WSD PFP / OBC SMED,Preplanning (工艺策划) is a process to standardize the process of preplanning traditional final assembly harness for Delphi Packard1. Maximum utilization of our operators skills and attention.2.Operator Focused Plan(
10、以人为本)3.Smooth flow of material4.Optimum parts presentation to the operator,1.Preplan schedule,2.harness design analysis,3. Labor estimates,DFM/BOM,Time study(theory)/control 17/19,4. Pegboard review,5. Build sequence,6. Work content define,7.Production plan,8.Paper breakdown,9.Rough breakdown,10.Fin
11、al breakdown,11. layout and flow,12.PFMEA & flowchart,13.Master board release,14. Labor standard,15.System release,16. Line start,Ergonomic/ECF,Note: ECF:Ergonomic Correlation Factor ECF=Actual ergonomic work summary/Ideal ergonomic work summary,CTS/Total build sheet,Time study sheet(detail),Final c
12、ontrol 17/layout,WI(theory),Final WI,Practise WI,Workshop design,material rack,QA/WLL,Quota,QA,Ramp up plan,Whats IE? IE organization chart MSD BOM setup Preplaning Flow-Chart / PFMEA WSD PFP / OBC SMED,PFMEA-Potential Failure Mode and Effects Analysis(Process FMEA) Identifies potential product rela
13、ted process failure modes Assesses the potential customer effects of the failures Identifies the potential manufacturing or assembly process causes and identifies process variables on which to focus controls for occurrence reduction or detection of the failure conditions. Develops a ranked list of p
14、otential failure modes, thus establishing a priority system for corrective action considerations. Documents the results of the manufacturing or assembly process.,Whats IE? IE organization chart MSD BOM setup Preplaning Flow-Chart / PFMEA WSD PFP / OBC SMED,Whats WSD? Work Standard Data is a tool for
15、 calculating standard work time of wiring harness Whats WSD used for? Quotation Labor estimate Line balance What types of WSD do we use? European WSD AP WSD,Example: European WSD,Example: AP WSD,Whats IE? IE organization chart MSD BOM setup Preplaning Flow-Chart / PFMEA WSD PFP / OBC SMED,PFP - Peop
16、le Focused Practice,OBC - Operator Balance Chart,Improvement opportunities,Whats IE? IE organization chart MSD BOM setup Preplaning Flow-Chart / PFMEA WSD PFP / OBC SMED,SMED - Single Minutes Change Die,Quick Setup Definition : The minimum amount of time needed to change over from the last good part
17、 of one production run to the first good part of the next production run. Objective : The objective of Quick Setup / Changeover is to minimize the amount of time required to changeover from one activity to the next so that changeover time is not an obstacle in achieving Flow Manufacturing.,Implement
18、ation Guide:Quick Setup Install Steps,1. Set up best sequence to reduce complex changeover time. 2. Separate Internal and External Setup Elements. Internal Setup Element : is one that must be performed while the machine or operation is stopped such as removing the die. External setup element : is one that can be performed while the operation is running such as gathering material, tools and equipment. 3. Convert Internal Steps to External Steps. 4. Reduce Internal Setup Time (Changeover Time). 5. Reduce External Setup Time. 6. Standardize the Setup and Continuously Improve.,THE END,Thank You!,
