1、Date : 2007.01.17,1、CURRENT STATUS:,Line Status: Line Area: =12M*6.6M-8*1.5=67.2mm,2、MAIN LINE & SUB LAYOUT (original),12M,6.6M,8M,1.5M,3. WORK SAMPLING STATISTICS & H/C EVALUATION:,4.Main Line & Sub Layout (improved),Line Status: Line Area:12M*4.5M=54mm,12M,4.5M,5. PROCESS FLOW CHART,Main Frame,Bar
2、row,70m，40EA/time（16EA/BOX）,Assembly,Barrow,5m，36EA/time（12EA/BOX）,Left Frame,Assembly,Right Frame,ACM,Gear Train,Duplex Assy,Barrow,70m，160EA/time（80EA/BOX）,Barrow,10m32EA/time（16EA/BOX）,Main Frame,Assembly,Left Frame,Assembly,Right Frame,ACM,Gear Train,Duplex Assy,Change,6.,6.BALANCE PRODUCTION LI
3、NE,Eliminate waiting, Neither make anybody too busy, Nor make anybody too free! Only a Fair Environment is able to found high work morale.,7. DIFFERENCE,8-1. DETAIL OF KAIZEN(1),Before Improving,After Improving,Type of Waste,Improving Action,Transportation: Ops need transit printer from conveyer bel
4、t to workstation.,Use roller line, So Ops dont need to transit printer from conveyer belt to workstation. And every Op will almost reduce a little transportation.,8-2. DETAIL OF KAIZEN(2),Before Improving,After Improving,Type of Waste,Improve Action,Motion: Materials isnt appropriate level of reach,
5、Put screw driver on material bracket ,So the distance from screw driver to screw hole is much shorter then before. In line there are many station like this.,8-3. DETAIL OF KAIZEN(3),Before Improving,After Improving,Type of Waste,Improve Action,Over-processing, Transportation , Inventory, Over produc
6、tion, Defect: Pool layout make almost these five types waste in old line.,Redesign new “JIT” layout ,Reduce Batch Size to “one piece flow”. (please refer 4.Main Line & Sub Layout (improved),8-4. DETAIL OF KAIZEN(4),Before Improving,After Improving,Type of Waste,Improve Action,Motion: Switch used wit
7、h foot press, Op would keep one leg standing, that made them tired.,Put switch on collet，Op can press the switch in the same time when move to the relevant position.,Switch used with foot,Switch used with finger,8-5. OTHER KAIZEN (1),Before Improving,After Improving,Type of Waste,Improve Action,Moti
8、on/Cost: The part put one side(A side)to opposite side(B side) from A fixture to B fixture.,Improve a little A fixture ,Then the part can be put on one fixture, whenever A side or B side. Total Seven fixture eliminate in new line.,B side,Switch used with finger,A side,A side,B side,8-6. OTHER KAIZEN
9、 (2),Before Improving,After Improving,Type of Waste,Improve Action,Cost :The metal claw is expensive (142RMB/set),and they are easy to damaged, We need to replace them termly .,Replace The metal claw with rubber claw. That not only can use long time ,but also cost nothing, The rubber ring comes from PC Case Assembly Department.,Metal claw,Rubber claw,
