精益生产快速换模改善案例(经典作品)-精品课件.ppt

1、ConfidentialManzoniSMEDStamping WorkshopApr, 12th16th 2010现场改善现场改善GK 1291000T 快速换型快速换型Confidential2Presentations Title GK129 team 改善团队改善团队 奔驰奔驰Team members 团队成员团队成员冲压主任冲压主任 龚小范龚小范维修主任维修主任张建强张建强模修领班模修领班王佑春王佑春传播者传播者 王伟王伟操作工操作工 张传有张传有模修模修王树林王树林维修计划维修计划刘景鹏刘景鹏电子工程师电子工程师 刘伟东刘伟东860项目组项目组胡智平胡智平860项目组项目组高洋高洋

2、巴西专家巴西专家Silviu巴西专家巴西专家Evandro Speckhahn巴西模修巴西模修Renato精益精益 张春杰张春杰Confidential3Presentations TitleThe source of the GK 项目来源项目来源Kaizen 改善SMED1. VSM 价值流程图价值流程图2. 860项目组项目组 Capacity Expansion project 8.6 M/yConfidential4Presentations TitleObjective and Goal 目的与目标目的与目标降低降低1000T换型时间换型时间 =从从35分钟至分钟至20分钟分钟De

3、crease the setup model time (1000T) = From 35mins to 20 mins人因工程改善人因工程改善 =1项项 Ergonomic Improvement =1 Item安全改善安全改善 =1项项 Safety Improvement =1 Item可视化管理可视化管理 =1项项 Visual Management=1 Item5S改善改善 =1项项 5S Improvement =1ItemObjectives and Goal 目的目的 与目标与目标35200510152025303540AntesMetaHistoryGoalConfident

4、ial5Presentations TitleBenefits of SMED 快速换型的好处快速换型的好处Reduces unproductive time减少非生产时间减少非生产时间Allows to improve the client service (lead time, quantity)有利改善客户服务有利改善客户服务(交交货周期、数量等货周期、数量等)Enlarges real capacity of machines扩大机器实际产能扩大机器实际产能Reduce the investment and production cost减少投资，降低成本减少投资，降低成本SMED快速

5、换型快速换型Allows to reduce the stocks有利降低库存有利降低库存Shorter series becomes cheaper (reduce batch size)产品系列更换时间更短产品系列更换时间更短、成本更低、成本更低 (缩小批量缩小批量)Confidential6Presentations TitleStep 1 步骤一步骤一Step 2 步骤二步骤二Step 3 步骤三步骤三Step 4 步骤四步骤四Step 6Changeover method not rationalised没有理顺换模方法没有理顺换模方法 Study of the actual sit

6、uation研究实际情况研究实际情况Separate internal work From external work将内部工作与外部工作分开将内部工作与外部工作分开Convert internal work in external work将内部工作转化为外部工作将内部工作转化为外部工作Step 5 步骤五步骤五Reduce of internal work减少内部工作减少内部工作 Absence of method 没有方法没有方法 Preparation time with big variations 准备时间变化太大准备时间变化太大 There is no distinction b

7、etween external work and internal work 内部和外部工作没有什么区别内部和外部工作没有什么区别Improvement of logistic support改善物流运输改善物流运输Improvement serviceability改善可用性改善可用性 Pre-assembly 预先装配预先装配 Pre-adjustments 预先调整预先调整 Pre-heating 预热预热 Previous work before the machine stop 停机前的准备工作停机前的准备工作 Work to be done with the machine sto

8、pped 停机时要做的工作停机时要做的工作Work to be done after stopping 停机后要做的工作停机后要做的工作Register and classified all the necessary working elements 将所有必要的工作进行登记和分类将所有必要的工作进行登记和分类 Video 视频视频 Chronograph 计时器计时器The 5 Steps of SMED 快速换型的五个步骤快速换型的五个步骤Starting point始点始点SMED 快速换型快速换型Eliminate adjustments and settings 消除调整和设定消除

9、调整和设定 Simplify fixation and tightening 简化固定和上紧程序简化固定和上紧程序 Parallel work 平行作业平行作业Internal Work: Operations which have to happen when the machine is not running外外部工作：机器没有运作时要进行的工作部工作：机器没有运作时要进行的工作External work: The operations which can take place when the machine is running内部工作：内部工作：机器运作时要进行的工作机器运作时要进

10、行的工作Reduce of external work减少外部工作减少外部工作Confidential7Presentations TitleStep1: Study of the actual situation 步骤一：研究实际情况步骤一：研究实际情况Make the list of setup step through film观看录像列出换型步骤观看录像列出换型步骤(共共59步）步）Confidential8Presentations TitleStep 2 Separate internal work From external work 步骤二：区分内部工作和外部工作步骤二：区分内

11、部工作和外部工作对对59步换型步骤进行内部外部工作的区分步换型步骤进行内部外部工作的区分Confidential9Presentations TitleAfter Kaizen改善后改善后 Before Kaizen改善前改善前Step 3 Convert internal work to external work 将内部工作转换成外部工作将内部工作转换成外部工作工具准备工具准备 Prepare and Organize toolsPhoto将换型工具按照模型摆放在车上，便于取将换型工具按照模型摆放在车上，便于取放。同时增加放。同时增加1个套筒和个套筒和1个六角扳手个六角扳手Put the

12、tools in the car according the former in order to take easily and at the same time add 1 steel tube and 1 wrench工具在车上摆放无序工具在车上摆放无序, 只有只有1个个套筒和套筒和1个六角扳手个六角扳手 The tools were put without order in the car and there was 1 steel tube and 1 wrenchConfidential10Presentations TitleNmeroAtividades / Tarefas /

13、 ElementosPessoaPassosHoraTempo (Segundos) 0 000:00:45 1Operar desbobinador para nova bobinaOpA100:00:57 2Cortar fitaOpA200:01:17 3Introduzir chapa at o roloOpA300:02:0200:00:4500:00:45 49Abrir porto e limpar respingos de leoOpB400:01:1100:00:2300:00:23 19Regulagem dos 4 rolosOpA2200:09:0000:01:0900

14、:01:09 50Aguardar desaceleraoOpB500:02:2500:01:1400:00:52 5aguardar chapa nova encostar na velhaOpA600:03:1000:00:3600:00:36 51Estampar final da bobina e retirar cavacoOpB700:07:2800:05:0300:02:31 10Avanar chapa em manualOpA1200:06:0900:00:2300:00:12 11Estampar final da chapaOpA1300:06:1400:00:0500:

15、00:05 12Retirar cavaco e avanar chapa em manualOpA1400:07:1200:00:5800:00:29 13Estampar final da chapaOpA1500:07:1800:00:0600:00:06 14Retirar ponta da chapaOpB1600:07:3500:00:1700:00:17 52Esvaziar ferramentaOpB1700:09:0200:01:3400:01:34 Trocar caixas de cavacoOpA18 00:01:0000:00:00 54Trocar carimboO

16、pB3200:11:0900:02:0600:00:00 Avano da chapa em manualOpB5400:18:0300:00:3800:00:00 29Limpeza para troca no 7 estgioFerrA3400:11:3600:00:1900:00:00 31Retirar 1 parafuso e soltar outro, do anel do 7 estgioFerrA3600:12:3500:00:4800:00:48 56Retirar 2 parafusos lado de trazFerrB3800:13:1100:00:4800:00:00

17、 57 Segurar anel do 7 estgio para retiradaFerrB3900:13:3500:00:2400:00:24 33Retirada do 2 parafuso do anel do 7 estgioFerrA4100:13:3600:00:1300:00:13 34Retirada do anel do 7 estgioFerrA4200:13:5000:00:1400:00:14 58Limpeza do alojamento do anelFerrB4300:13:5700:00:2200:00:22 35Colocar novo anel do 7

18、estiagio FerrA4400:14:3600:00:4600:00:00 59Colocar novo anel do 7 estiagio FerrB4400:15:0000:01:0300:01:03 60Apertar 4 parafusos do 7 estgioFerrB4500:15:1700:00:1700:00:17 62Trocar centradorFerrA4900:17:2100:01:4300:00:00 63Fechar porto trazeiroFerrB5000:17:5000:00:2900:00:29 40Regular altura do 5 e

19、 6 estgioFerrA5200:17:0700:00:5500:00:55 43Encher ferramenta com peasOpB5500:20:3600:02:3300:01:32 44Pegar pea para medioOpA5600:20:4700:00:1100:00:11 45Medir peasOpB5700:24:1100:03:2400:02:23 46Acionar prensa em automtico e atingir 25gpmOpB5800:25:2000:01:0900:00:48 64 1811900:18:00 对换型步骤进行排序对换型步骤进

20、行排序 Define the better sequence: 统计每个人的工作时间统计每个人的工作时间 并确定可以同时做的工作并确定可以同时做的工作Sichronize activities:Operator A Operator B ToolMaker A ToolMaker B Confidential11Presentations TitleAfter Kaizen改善后改善后Before Kaizen改善前改善前在校平机上安装支架，用于存放手柄在校平机上安装支架，用于存放手柄同时将手柄加长同时将手柄加长Make a support beside the machine to lay

21、the handle and lengthen the handle手柄放在控制台旁边小盒内手柄放在控制台旁边小盒内The handle was in the box of console(1)制作存放手柄支架制作存放手柄支架 Make a supportConfidential12Presentations TitleAfter Kaizen改善后改善后Before Kaizen改善前改善前(2) 拆除校平机护板拆除校平机护板 Remove the protective net需将校平机护板拆下，用手柄调整参数需将校平机护板拆下，用手柄调整参数Need to remove the prote

22、ctive net, adjust the parameter with handle将护板更换为有机玻璃并开四个小窗口，将护板更换为有机玻璃并开四个小窗口，直接用手柄调整参数直接用手柄调整参数Change the protective net into organic glass and open 4 small windows,Adjust the parameter with handle directlyConfidential13Presentations TitleAfter Kaizen改善后改善后Before Kaizen改善前改善前(3) 可视化调整参数可视化调整参数 Mak

23、e the parameter visual操作工在调整参操作工在调整参4个调整轮参数时需来回到控个调整轮参数时需来回到控制台查看制台查看POPThe operator moved to the console to check the POP when he adjusted the parameter将将4个调整轮的调整参数按照顺序贴在校个调整轮的调整参数按照顺序贴在校平机上，调整时操作工无需来回走动平机上，调整时操作工无需来回走动Put on the parameter card into the glassConfidential14Presentations TitleAfter K

24、aizen改善后改善后Before Kaizen改善前改善前(4)制作尼龙挡块制作尼龙挡块 Make nylon block新料料头出校平机后向上弯，与旧料对接不新料料头出校平机后向上弯，与旧料对接不好，操作工必须用撬棍对接好，操作工必须用撬棍对接The new coil was bent at the exit of machine, and bad connect the end of old coil. The operator must using crowbar to press在校平机出口安装尼龙挡块在校平机出口安装尼龙挡块Make nylon block at the exit

25、of machineConfidential15After Kaizen改善后改善后Before Kaizen改善前改善前(5) 制作存放字头支架制作存放字头支架 Make a support to lay stamping punch 字头放在换型车上字头放在换型车上The stamp punch and the tool were on the setup model car制作字头存放支架，放在冲床旁，换型时制作字头存放支架，放在冲床旁，换型时方便取放，减少走动方便取放，减少走动Make a support to lay the stamp punch and the tool besi

26、de the machine, in order to takeConfidential16After Kaizen改善后改善后Before Kaizen改善前改善前(6) 制作检具支架制作检具支架 Make a support to lay gauge检具摆放不便于拿取检具摆放不便于拿取The gauge was put not easy to take重新制作检具支架重新制作检具支架Make a new support to lay the gaugeConfidential17结果结果 Result352018.30510152025303540AntesMetaReal After G

27、KSetup time result 换型结果换型结果HistoryResultGoal以前目标结果分钟Confidential18Presentations Title换型时间跟踪换型时间跟踪 Setup time controlConfidential19Presentations Title标准化标准化 Standardization对换型过程对换型过程进行标准化，进行标准化，编到编到POP中。中。明确明确2名操作名操作工和工和2名模修名模修的分工的分工Make a standard about the setup model and add this item into POP and

28、 define each operator and each toolmakers workConfidential20Presentations TitleTraining 培训培训Training record 培训记录培训记录培训三个班的操作工和模培训三个班的操作工和模修修Training the operators and toolmakers of 3 shiftConfidential21Presentations TitleSafety Improvement 安全改善安全改善After Kaizen改善后改善后Before Kaizen改善前改善前安全隐患安全隐患Acciden

29、t risk 防护门打开时冲床可以冲活防护门打开时冲床可以冲活The press is working with the opened gate 只有在防护门关上的情况下才可以冲活只有在防护门关上的情况下才可以冲活,在防护门上在防护门上开推拉窗便于操作工钩三角废料开推拉窗便于操作工钩三角废料The press is working with the closed gate only，open a window on the gate easy to take out the scrapConfidential22Action 行动计划行动计划共制定共制定17项行动计划，已全部完成项行动计划，已

30、全部完成 Made 17action plan and finished allConfidential23Gemba Kaizen Results 改善结果改善结果Gemba Kaizen Results (GK)现场改善收益统计表现场改善收益统计表Indicator项目项目Before GK改改善前善前Goal GK目标目标Results of GK改善收益改善收益Value%Value%生产能力生产能力 Production Capacity (百万百万 台台/年年 Mi unidades / year) 换型时间换型时间 Change over Time (m)35mins20mins

31、18.3 minsOEE (%)OEE (%)生产速度 Production Rate (p/h)加班费节省加班费节省 Overtime Saving (IOP) (h)防错防错 Poka yoke人因工程人因工程Ergonomic 313安全安全 Safety111可视化可视化VisualVisual111环境环境 EnvironmentConfidential24Gemba Kaizen Results 改善结果改善结果Gemba Kaizen Results (GK)现场改善收益统计表现场改善收益统计表Indicator项目项目Before GK改改善前善前Goal GK目标目标Resu

32、lts of GK改善收益改善收益Value%Value%在制品在制品WIP(个个 Pcs) 9783830%31%换型时间换型时间 Change over Time (m)清洗机清洗能力清洗机清洗能力Capacity of washing machine5 pcs/ row6 pcs/ row20%加班费节省加班费节省 Overtime Saving (IOP) (h)质量质量QualityQuality11人因工程人因工程Ergonomic 11安全安全 Safety可视化可视化VisualVisual环境环境 EnvironmentConfidential25Presentations

33、TitleMonitoring 改善结果跟踪改善结果跟踪 Espao (opcional) para concluso 1 mn 13 pts.) Espao (opcional) para concluso 2 (fnt mn 13 pts.)实施改善后的一个月内，实施改善后的一个月内，LPO和精益传播者每周一次对改善项目进行跟踪和精益传播者每周一次对改善项目进行跟踪Confidential26Presentations TitleThoughts 感言感言减少多余动作同时也降低了风险打破常规，勇于创新只要用心观察，就能找到过程中的不足，并加以精益改善Confidential27Presentations TitleQ&A问题和解答问题和解答GK0129