装配线设计 Assembly Line Design_原创精品文档.ppt

附录 1 Appendix 1 :装配线设计 Assembly Line Design 传统装配线设计 Traditional Assembly Line Design 精益生产系统装配线模式特点 Lean Production SystemAssembly Line Model Characteristics 工人灵活 Flexible operators 走动方便 Freedom of movement 标准化操作 Standard operations 目视工场 Visual workplace 最少线上存货 Minimal line stock 柔性生产 Flexible production 调速器 Pacemakers 保证质量 Quality ensured 装配线布置目的 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 物料/工人流畅 Flow of material and operators 信息即时反馈 Immediate flow of information / feedback 问题立即暴露 Immediately expose problems U型线 U - Shaped Line 直型线 Straight Line 有供应线的直型线 Straight Line With Feeders 开放式平行线布置 Parallel (Open Room) Layout 开放式布置举例 Open Room Layout Example 开放式布置举例 Open Room Layout Example * ? 2005TBM Consulting Group, Inc. All Rights Reserved. SKB Time Based Management ? 2005 TBM Consulting Group, Inc. All Rights Reserved. SKB TBM Consulting Group, Inc. is the sole licensee of LeanSigma, a service mark of Maytag Corporation. 物料储存 Material Storage 悬挂式电动输送带 Powered free conveyor 物料储存 Material Storage 物料储存 Material Storage 物料储存 Material Storage 物料储存 Material Storage 原料 RM 成品 FG 信号灯 Andon 时间标记 Timing mark 指挥棒 Baton-pass 交接区 Zone 1 2 3 4 1 2 3 4 5 Major subassembly Line 主分装线 一人单元 1-operator Cell 两人单元 2-operator Cell 单元1 Cell 1 4 3 4 3 5 2 5 2 6 1 6 1 RM FG RM FG 单元2 Cell 2 4 3 4 3 5 2 5 2 6 1 6 1 RM FG RM FG 需求大 High demand 节拍时间短 Shorter takt time 两个工人 2 operators 需求小 Low demand 节拍时间长 Longer takt time 一个工人 1 operator 熔铅炉 Lead Pot 盒子 Boxes 箱子 Carton 铸造 Die Cast WIP on Shelves 架上半成品 Pallets of Boxes 卡板 Pallets of lead slugs Carts of lead wheel Weights 铅轮配重车 改善前 Before Kaizen 铅胚卡板 改善后 After Kaizen 1 2 3 4 8 7 6 5 1 2 3 4 8 7 6 5 1 2 3 4 8 7 6 5 FG RM 新的工区布置 New Work Area Layout 铸造Die Cast 熔铅炉Lead Pot 输送带 Conveyors 盒子 Boxes 箱子 Carton 新的单元布置 New Cell Layout Classical assembly lines run efficiently at only one output level. Typically, production i