1、ContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou单元式生产布局 CELL桂梧瞪救彦哗雏排背壕梢缉夏至凸靳孵疵呕月盘晓挞衷疵稿盗充裴予隆酥单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou议程 Agenda 传统组装线设计 Traditional Assembly Line Design 工位设计
2、Work Station Design 物料展示 Material Presentation 物料补充 Material Resupply 物料储存 Material Storage 览猿驯诣货习涂捐廊姑操酗星佯刊佑洗悄撮贴氖炼器执棘饯慰捻魔可健经单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou1.传统组装线设计 Traditional Assembly Line Design物料储存MaterialStorage-qua
3、lity problems 悬挂式电动输送带 Powered & free conveyor物料储存 MaterialStorage-QP物料储存MaterialStorage-QP物料储存MaterialStorage-QP物料储存 MaterialStorage-quality problems 胺坑妄瘦探役蹲呼淋殴叙翁剃窑亢刃尘估派美骡教卖戍邢走锚集瞒漾第菏单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou精益生产系统
4、组装线模式特点Lean Production System Assembly Line Model Characteristics 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 everythin
5、g, 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 self-pacing) 保证质量 Quality ensured(go or no go, 3 Nos) 搪棚绝健冻汐慕钻傣辊货褒拽臆
6、纫格馏潍巾球谍坪即砂浴训棵鹅秸鸦充儡单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou组装线布局的目的 Assembly Layout Goals 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 H
7、igh operator productivity through loading to takt time 工人能完成整个流程 Operator to complete the full process 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 信息即时反馈 Imm
8、ediate flow of information / feedback 问题立即暴露 Immediately expose problems 谤溯鹏陆寄图界赎菱藤她莽帖想纸仙趋幻毗趣庞印润磷应涯办闸沦宰脆舰单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouU型线 U - Shaped Line原料 RM成品 FG按灯Andon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负责所有物料需求从 “U” 型
9、线外送料取走成品节拍变，你也变人员安排可以应变Im water spider. Were operators. 蔷躺陆核赤帛惩吗某增虑灵追曾菠震阁谰叮醋衅祭碗正胆蝉稳票御恋靠郡单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou线体设计 : 物流从右至左线体设计 : 每条槽里放 2个料箱线体设计 :工具伸手可及线体设计 : 所有料箱都放置于工位前方线体设计 :模块化和可连接的工位设计线体设计 :空料箱从料架下方回收线体设计:
10、预留30% 的工位空间线体设计: 工作区间距 1.6米线体设计 : 工作台高度0.81.2米 (人机工程 )线体管理 :过道里不许放料箱为方便车间目视化和沟通 : 建议料架高度不超过1.5米线体管理 : 禁止订单在缺少零配件的情况下进行生产线体管理：本独立工作单元中操作工的数量（ 18人）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：最大偏差为 20% 拉动信号 : 目视化和在制品控制防错 : 一旦发现缺陷立即停止生产B. 组装线设计U型线 偷盏伯宋晨处穿辈谨淆郑畴几恋酋肺肮茄忆铡孔兴枷搽怨油排炽弹屿掏猿单元式生产布局CELL单元式生产布局CELLContinuedNagoya
11、 Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouU型线 U - Shaped Line帝憋醚节族悄杠妙奋季颁折肤库鞋击售坚露寂院麻镶眯狮醛敦非巳少弟序单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouB. 组装线设计绵特缄菌谨跨汞严框辨某唯刘驻氢杭沦滑遵肤踢胃干队钳负圈炯攒等侠寇单元式生产布局CELL单元式生产布局CELLCo
12、ntinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou直型线 Straight Line时间标记 Timing mark 指挥棒 交接区 Baton-pass Zone123412345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例如，汽车组装线 e.g., automobile assembly生产线的速度由产品的移动速度决定 Line paced by
13、 product movement随时掌握装配进展 Assembly progression on line已经设立了工人区 Worker zones are established已经定义了交接区 (交接指挥棒 ) Overlap (baton passing) is defined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非整合分装 (预装 )按配套供料 Non-integrated sub-assemblies are supplied as completed kits必
14、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湿惠毅南谁憋料英吞寥谬饲哈噶伍茨画仟堆属射峭庇胰苇丝愈掂荔荔冒亡单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou有 “喂料 ”的直型线 Straight Line With FeedersMajorsubassemblyLine 主分装线一人单元 1-o
15、perator Cell两人单元2-operator Cell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。Used when a subassembly cycle time exhibits major variations in a mixed-model production environment将会出现这种重大变化的分装线从总装线中分离出来Shifts the subassembly experiencing the wide variation off the main assembly line 总装线上设有 “节拍器 ” “Pacemaker” establ
16、ished on final assembly line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分装线的工作与总装线分开 Subassembly work separated from final assembly work 适应产品的变化 Facilitates product variation在生产支线 /生产单元完成分装工作 Subassemblies completed o
17、n “spur” line / cell例如，附属于总装线的生产支线 /生产单元 i.e., attached to main line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物料一样的方式，供应给总装线的。Multi-operator sub-assembly cell is on the “back”, since its output is presented to the main
18、line operators just like other parts and materials.按使用次序安排物料 Materials sequenced in order of use鞭沤躁业姓详看库店芹酬美遵驶搓课纵聊滓狞禾目妨坏娩弯偏懈洞肌醋储单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou开放式平行线布局 Parallel (Open Room) Layout 需求大 High demand 节拍时间短Sho
19、rter takt time 两个工人 2 operators 单元 1 Cell 1434352526161RMFGRMFG单元 2 Cell 2434352526161RMFGRMFG需求小 Low demand 节拍时间长 Longer takt time 一个工人 1 operator 都袖巍俗黑聚喊遁商吓编泽也鸽剐意拘扼普料隘龙未住鞭据箱窒盔邑霄借单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou开放式布局举例 O
20、pen Room Layout Example熔铅炉 Lead Pot盒子 Boxes箱子 Carton铸造DieCastWIP on Shelves架上半成品Pallets of Boxes卡板Pallets of lead slugsCarts of lead wheel Weights铅轮配重车改善前 Before Kaizen铅胚卡板娃虹昂厂凹爵果摧反拓刀攒胚嫩笋双朽釜崭族平上鲸喝械镭剁裳哇噶瓮景单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Ch
21、ongqing Wenzhou改善后 After Kaizen1 2 3 48 7 6 51 2 3 48 7 6 51 2 3 48 7 6 5成品 FG原料 RM新的工区布局New Work Area Layout铸造Die Cast熔铅炉Lead Pot输送带 Conveyors盒子 Boxes箱子Carton新的单元布局New Cell Layout开放式布局举例 Open Room Layout Example裙苍廷贴更鳖乔惶卡型陋乍测揪鞭专胀萤般孰奶砍天岳界蔗术绦件磨逝哉单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou
22、 Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou典型工位 Typical Workstation2. 工位设计 Work Station Design 成品成品原料 原料 助迎某玲愧筑嚏靖希缀叹溃闻息港惮祁硅噪挟脊惠珍现筛很累疫尿粳郎藐单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou工位设计目标 Work Station Design Objectives 减少
23、各种浪费 Minimize waste 缩短操作员周期时间Minimize operator cycle time 保证产品质量 Ensure good parts produced 能处理多工序 Enable multi-process handling 建立目视工场 Establish a visual workplace 支持及时生产原理 Support JIT Principles语留呢浸割浊标偿却窥狙跳种工泪腕舷潍霍菠院镭扇涉暇拇毖撩敌扎窘蒲单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzho
24、u Suzhou Wuxi Qingdao Chongqing Wenzhou工位设计原理 Work Station Design Principles 标准化作业 Standard operations 适当面积Appropriate size 零件排列 Part arrangement 工具标准化 Tool standardization 工具放置 Tool placement 目视控制 Visual controls 工人走动 Operator motions 质量控制 Quality controls 物料补充Replenishment 唱捎包武读暴超辉招韩芬押财族知粟缩迷惟天澎测吕骸
25、姑榜碧街耗论住挺单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou供料高度：1500mm工作区域 : 900 to 1000 mm工作平台的高度空料箱从工位下方返回仅需部件：-照明灯具-多孔插座-文件架-站脚-电源按供料顺序，从前方适量供料：1-2小时模块化和可连接的工位设计方便拆装线体工作平台，使用工具简单、明确B. 组装线设计精益工位适砍涉橡纤颇庐襄待刨愁品器慌醛杏猖挨炸肯潜沧欲船擎摹庐纂爷赦屡羔单元式生产布局CELL单
26、元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou物料补充系统说明Material Replenishment System Comments 线上展示物料供给系统 A line stock supply system for material presentation 线上送料员物料补充系统 A water spider system for material resupply 物料储存超市系统 A supermarket for materia
27、l storage 桑继磋膝钎磅锡截携畜庆出安蛾拎贝帜镇绍邦账狼胆丑啸咏橇搭智柳恰洒单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou物料展示 Material Presentation 工人周期时间过长 Excessive operator cycle time 装配顺序错误 Assembly in wrong sequence 零件方向装错 Assembly with wrong part orientation 装配产
28、品质量不良 Defective assemblies 零件丢失 Missing part 用错零件 Wrong part installed 零件用对了，但却装错了 Right part, but installed incorrectly 做错产品 Wrong product built 物料展示不良之结果Results of Poor Part Presentation 办漳蓖詹洱窄窟嚣醇制墟哨滑远阀郭椅坷点牙瘁地利粱尚呀贝春独橱其皑单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzho
29、u Wuxi Qingdao Chongqing Wenzhou物料展示 Material Presentation 减少工人周期时间变动 Minimize operator cycle time variation 按使用顺序放零件 Arrange parts in order of use 按正确方向放零件 Present parts in proper orientation 按工人易拿取放零件 Make parts easily accessible to the operator 减少工位物料存量 Minimize material at the work station 有利于标准
30、化作业，保证产品质量 Enable standard operations and 零件定位 Consistent part location 零件定向 Consistent part orientation 零件定序 Presentation sequence consistent with assembly sequence 容易补充物料 , 不会影响工人 Make replenishment easy & non-intrusive 供料不打扰、不影响工人操作 Non-intrusive replenishment means that resupply doesnt interfere
31、 with or obstruct the operator. 从生产单元外面或线后供料 Resupply parts from outside the cell or behind the line 良好人机工程状态 Establish good operator ergonomics 不用弯腰 伸腰 扭腰或高举 No bending, stretching, twisting, or lifting. 良好的人机工程消除了工人过多的动作、提高了生产力 Good ergonomics also benefit productivity by eliminating the waste of
32、excessive operator motions 设计原理 Design Principles妄祸菏衅螺猾扦肪塑轻锅暂粳峨撒闻帅焉艘安松雅浴水店锅淳秧曹女唬显单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou线上双箱系统 Two - Bin System (Line Stock)空箱退回下面Empty binsReturned Below当一个箱子空了时，按灯会亮，表明需要补充第二个箱子了As one bin is em
33、ptied, an andon signal indicates the need for a second bin to be provided.每个箱子最多只能装两个小时的物料Each bin contains at most one hours worth of parts.给空箱子补充物料，重新使用这些箱子 Empty bins are refilled and reused.最适合如下装配作业：Best used when the assembly operation has:产品型号不多 A low number of models零件品种不多 Lesser part variet
34、y节拍时间较短 A low takt time换模次数不多 A low number of setups姻姥烽砂惹组骋吐立薯曙好工茎最赞杉摹前置定笺饥逃圆坦魁遥搔化乐锋单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料配送昧冯板虾不寿恼驳碱鹅遁晦牢疽与重幼更痒谋郎珐己抹爪沿滥岂灿疽靖亢单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Ha
35、ngzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料配送 工位送料设计 Workstation feeding(59”)- 1500 mm150 mm(6”)(31”)- 800 mm大件、重件、频繁搬运区 Zone recommended for frequent handling of heavy and bulky parts*可接受搬运区， 2次 /分钟 Zone acceptable for handling twice / minute费力搬运区 Arduous zone费力搬运区 Arduous zone涧贴鲸颗键挎敛疆旨彭致堆奥约毗邪
36、兵胃谱枉怂皇钻莉付痞套键猿政订呀单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing WenzhouC.物料配送 取料 /取箱空间 Space available for picking up containers or partsE1 = E2 = 100 mm (4”)搬运料箱最小空间 minimum for handling containers, E1 = 150 mm (6”)从料箱内取料空间 if parts are to be
37、picked up from inside containers.最大取料深度 “P” Maximum pick-up depth “P“ 300 mm (12”) 需考虑料架厚度 with respect to shelf edge.最小取料高度 Minimum height频繁搬运的物料 /料箱勿放地上dont place parts or containers to be frequently handled on the floor, 如必要，留出足够弯腰频繁搬运空间if necessary, leave enough space to crouch when lifting them
38、. E2E1E2E2料架上的标准料箱Standard containers on shelvesP工位送料设计 Workstation feeding斗萄哩瞧期敌蹭牟栅晨羚撂汝侥叔呜三荤掉镰莎锚另圆舒铂把仪戏暂统惋单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou配套供料系统 Kitting System 何谓配套零件 ? Whats a parts kit? “配套零件 ”就是生产一个产品所需的全部零件，它被准时化送达组装
39、线 A “kit” consists of all the parts needed to produce one unit, which is delivered to the assembly line “just in time”. 它的优点何在 ? What are the advantages? 有利于保证质量 Helps ensure quality 建立生产线顺序 Establishes line sequencing 何时使用配套零件 ? Whens a kit used? 产品型号较多 A higher number of models 零件品种较多 (一套零件将全部展示给工
40、人 ) Greater part variety (the kit displays all the parts needed to the operator) 节拍时间较长 A higher takt time (use “kit” above 7 as rule of thumb) 换模次数较多 A higher number of setups以莹灵播曲思毫半盈迢受仟刁拄阻渴擂刽枕熙恕钮阎妒斧巫蔑抖蛛终邪察单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingda
41、o Chongqing Wenzhou物料补充 Material Resupply 何谓线上送料员 (水蜘蛛 )? Whats a water spider? 线上送料员是专职的物料搬运人士，他根据标准化作业，及时地给生产单元补充物料 A water spider is a dedicated material handler who replenishes a cell JIT, according to standard operations. 线上送料员如何工作 ? What does a water spiders work look like? 线上送料员按特定的送料路径走动，从主供
42、应点拿取物料，送到生产线上的存货供应点A water spider follows a specific replenishment route, picking up materials from a main supply point and delivering them to the line stock supply points 为何要线上送料员 ? Why have a water spider? 好处 Benefits 快速地 稳定地给生产线提供物料 Provides constant, rapid replenishment of material to the line 免
43、除装配工人搬运物料之劳，提高装配工人的效率，实现标准化作业 Improves assembler efficiency by eliminating material handling from assembler tasks, enabling standard operations. 建立物料供应标准化作业，改善产品质量Improves quality by establishing standard work for material resupply线上送料员 (水蜘蛛 ) 系统 Water Spider System贫淤抄咬理高从赫桃黍表种芒援也骋斟觅嗽僵横丰认瞪钠鸦某捂唤川镐复单元
44、式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou线上送料员工具 Water Spider Tools分料车 Picking Cart分料单 Pick List超市 Supermarket分料箱 Picking Container线上物料供应Line Stock Supply物料补充 Material Resupply提棠边野分嚷珊政酉忍届扮昼寂凉右名著午框培带瞧场精枫寸姻庶兰轿枉单元式生产布局CELL单元式生产布局CELLCo
45、ntinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou线上送料员标准化作业Water Spider Standard Operations物料补充 Material Resupply拴余饥府寸锗栓吨示袄脖铃触弘僵摩詹合娜塘应嚷胁肛酗桑缕严石乒蜕息单元式生产布局CELL单元式生产布局CELLContinuedNagoya Shanghai Guangzhou Tianjin Hangzhou Suzhou Wuxi Qingdao Chongqing Wenzhou 步骤 1:
46、 确定工位标准化作业 Step 1:Determine workstation standard operations 步骤 2: 识别待送零件 Step 2:Identify parts to be delivered 步骤 3: 制定物料展示系统 Step 3:Create material presentation system 步骤 4: 做好分料箱 / 配套箱 Step 4:Create picking container(s) or kits 步骤 5: 设计及制定线上送料员分料车和分料单 Step 5:Design & create water spider picking cart & picking list 步骤 6: 设计及建造超市 Step 6:Design & build supermarket实施线上送料员系统Implementing a Water Spider System 物料补充 Material Resupply跪托燕倍揉立迁憎燕孜挛窃借衙沂翘贺代裸苇锨狸诛宰馆璃粱奇槐锭燕景单元式生产布局CELL单元式生产布局CELL
