精益生产之降低设设定时间-Setup-Reduction(中英文对照)课件.ppt

1、MeasureAnalyzeControlImproveLean Six SigmaSetup ReductionuOverviewuThe 4 Step Method1.Documentation and Separation2.Conversion to External Events3.Streamlining Internal Events4.Eliminating AdjustmentsuWrap-UpuAppendices for Each StepRD010402MeasureAnalyzeControlImproveLean Six Sigma设定时间降低u总体介绍u 4 步骤

2、模式1.文件化和分离2.转变到外部事件3.流水化内部事件4.减少调试u简讯u每个步骤的附录RD010402ControlSetup Reduction3Lean Six Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Busin

3、ess ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause

4、Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation Opportu

5、nitiesMeasureDefineProject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck Sheets

6、Run ChartsControl ChartsGage R&RCp&CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogram

7、sScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-02ControlSetup Reduction4精益6 过程改善流程分析分析控制控制改进改进定义定义选定题目列出客户从顾客之声中列出关建需求定出项目焦点和重要指标完成 PDF测量测量绘制业务流程图绘制价值流程图制定数据收集计划测量系统分析收集数据过程能力分析分析分析提出关键因子区分关键因子验证关键因子评枯每个关键因子对结果的影响量化机会根本原因排序寻找根本原因针对关键因子改进改进关键因子确认发掘潜在的解决方法选择方案优化方案

8、实行方案控制控制过程变革和控制制定控制计划计算最终财务过程指标项目过渡给未来项目管理者项目鉴 别转化机会测量测量定义定义项目编号工具项目定义表净现值分析内部回报率分析折算现金流分析？（按现值计算的现金流量分析）PIP管理过程RACIQuad 表过程图价值分析脑力风暴投票归类法柏拉图因果图/鱼骨图FMEA查检表运行图控制图量具 R&RCp&Cpk供应链加速器分析多变动图i盒状图交互作用图回归分析ANOVAC&E 矩阵图FMEA脑力风暴拉系统减少设置TPM流程图标杆管理亲和图DOE 假设检验力场分析图树状图甘特图查检表运行图柱状图散布图控制图柏拉图互动回顾愚巧法Revised 1-12-02Con

9、trolSetup Reduction5Learning ObjectivesuUnderstand how setup time influences process cycle efficiency.uLearn the 4 Step Method for Setup Reduction.uUnderstand the preparation necessary to undertake Setup Reduction.ControlSetup Reduction6课程目的u理解设定时间是如何影响流程的周转效率.u学习降低设定时间的4步骤方法.u理解为了降低设定时间的必须准备工作.Meas

10、ureAnalyzeControlImproveLean Six SigmaOverviewMeasureAnalyzeControlImproveLean Six Sigma总 览ControlSetup Reduction9ProductionDowntimeRamp-up timeJob#1Job#2What Is Set-Up Reduction?uSet-Up Reduction is a process in which the time and effort for equipment changeover is reduced to an absolute minimum wi

11、thout adversely affecting quality.uTwo components of set-up reduction that must be addressed are:nMachine down time or set-up timenMachine ramp-up time ControlSetup Reduction10生产停机时间恢复时间工作工作#1工作工作#2设定时间降低到底是什么?u设定时间降低是指在对设备装备等的完全改变所花费的精力和时间过程被降低到一个绝对的小，同时又不影响质量.u设定时间降低必须抓住的两个部分:n机器停机时间或设定时间n机器恢复上升时间

12、 ControlSetup Reduction11Video:The Winners CircleuHow long does it take to change a tire on your car?ControlSetup Reduction12视频:The Winners Circleu你的车换个胎要多长时间？ControlSetup Reduction13Setup Time Defined50%30%5%15%Last GoodProduct of RunFirst GoodProduct(s)of RunPreparationTrial RunsAdjustmentsActual

13、SUABSetup TimeSetup Time is the length of time from the last good product of a production run to the first good product(s)of the next production runControlSetup Reduction14设定时间的定义50%30%5%15%最后一个成品最后一个成品首件合格品首件合格品准备试运行调整实际的设定AB设定时间设定时间设定时间是从生产的最后一个成品结束到下一次生产的首件合格品的产出的时间长度ControlSetup Reduction15Benef

14、its of Setup ReductionDrivesDrivesDrivesDrivesDrivesLeads toLeads toLeads toControlSetup Reduction16设定时间降低的好处驱动驱动驱动驱动驱动致使致使致使ControlSetup Reduction17Effect of Setup ReductionQuestion:If we reduce the setup time from 4 hours to 2 hours,can we reduce the batch size from 1000 to 500 and still produce 3

15、5.71 units/hour?Analysis:Answer:PRA=_PRB=_PRB YC TIiiiiBASetup A2 hoursProcess A5 hours500 partsSetup B2 hoursProcess B5 hours500 partsBBWCT=_BASetup A4 hoursProcess A10 hours1000 partsSetup B4 hoursProcess B10 hours1000 partsBBWCT=_ControlSetup Reduction18设定时间降低的效果问题问题:如果我们降低设定时间从4个小时到2个小时，我们是否可以降低

16、批数量从1000到500，但是仍然生产35.71单位/小时?分析分析:回答回答:PRA=_PRB=_PRB YC TIiiiiBA设定 A2 小时流程 A5 小时500 零件流程 B2 小时流程 B5 小时500 零件BBWCT=_BA设定A4 小时流程 A10 小时1000 零件设定 B4 小时流程 B10 小时1000 零件BBWCT=_ControlSetup Reduction19Advantages of Rapid Setup Over Typical SetupuCut scrap and rework risk by 50%uCut inventory investment b

17、y 50%uAble to introduce quality improvements at twice the rate(more cycles of learning)uAble to change the schedule twice as often to meet changing customer demandsuAble to introduce design changes at twice the rateuIncrease available floor space,ControlSetup Reduction20快速设定的优势 超越典型的设定u减少报废和返工风险50%u

18、减少库存投资50%u能够倍速引入质量改善(更多的学习周期)u能够倍速改变计划以满足客户经常的需求变化u能够倍速引入设计变化u增加楼层的可用空间,ControlSetup Reduction21ConclusionsuSetup time reduction and batch size reduction have linear relationship.uBatch size reduction must be implemented to gain greatest benefits from setup reduction.uA decrease in batch size withou

19、t a decrease in setup time can affect capacity.ControlSetup Reduction22结论u设定时间的降低和批数量降低有着线性的关系.u批数量的降低必须被实施来获得设定时间降低的最大收益.u只降低批数量而不降低设定时间将影响我们的产能.MeasureAnalyzeControlImproveLean Six SigmaThe Four Step MethodMeasureAnalyzeControlImproveLean Six Sigma四步曲ControlSetup Reduction25Step 1 of 4STEP 1Docume

20、nt the setup and separate events into internal or externalSTEP 3Streamline internal events(Simplify,Reduce,Eliminate)STEP 2Convert Internal to External eventsSTEP 4Eliminate adjustments internal to the setupStep 1 is done first to attain benefits quickly“Corresponding”DMAIC phase for a stand-alone S

21、etup Reduction projectControlSetup Reduction26第一步第一步第一步文件化设定并且将设定事件区分为内部的和外部的第三步第三步优化内部事件(简单化,减少,排除)第二步第二步转变内部事件为外部事件第四步第四步剔除在内部设定中的调整第一步设定的完成获得快速的收益对于一个独立的设定时间降低项目的“相对应的”DMAIC 阶段ControlSetup Reduction27Step 1uDocument all the setup activities and separate those activities into internal and external

22、 where:nInternal Setup is an activity that must be performed while the equipment is down.lExchanging dies/fixtures in the machinenExternal Setup is an activity that could be performed while the equipment is producing parts.lRetrieving tools and hardwarelLoading programs ControlSetup Reduction28步骤1u文

23、件化所有的设定活动，并且分开这些活动为内部的和外部的:n内部的设定内部的设定 是指必须在设备停机时才能执行的活动.l在机器上换模具/备件n外部的设定外部的设定 是指在设备运转时仍然可以执行的活动.l寻找工具和硬件l装填流程 ControlSetup Reduction29Application of Step 1uPre-Workshop PreparationuDocument Setup Activities by Performing“Dry-Run”of the SetupuDocument the Actual(Live)SetupuRecord All Events and Tim

24、es in the“Setup Timeline”uSeparate Events into Internal Setup and External SetupuBrainstorm Around Setup Reduction OpportunitiesControlSetup Reduction30步骤1的应用u预先工作现场的准备u文件化设定活动u文件化实际的设定u记录所有的事件和时间在“设定时间表”上。u区分事件为内部设定和外部设定u脑力风暴围绕设定时间降低的机会ControlSetup Reduction31Step 1 Tools:Setup Documentation Worksh

25、eetuThe Setup Documentation Worksheet is used to document the events performed during the setup.uThe worksheet is used to provide a time stamp for each event during the setup.uThe worksheet is used to identify internal events and external events.ControlSetup Reduction32步骤1的工具:设定文件表u设定文件表是用来文件化在设定过程中

26、所执行的事件.u这个工作表是被用来提供在设定期间内每个事件的时间标记.u这个工作表被用来定义内部事件和外部事件.ControlSetup Reduction33Setup D ocum entation W orksheetSetup D ocum entation W orksheetM ACH IN E:M ACH IN E:D O CU M EN TO R:D O CU M EN TO R:D ATE:D ATE:PAG E 1 O F 1PAG E 1 O F 1SEQ#SEQ#START START TIM ETIM EEVEN TEVEN TELA PSED ELA PSED TI

27、M ETIM EIN TIN TEXTEXT10Shut down m achi ne:30:3020:30G et change part s3:003:0033:30Rem ove change part s f rom m achi ne3:303:3047:00Pl ace new change part s on m achi ne3:303:30510:30Ret urn change part s t o st orage3:003:00613:30Load m at eri al ont o m achi ne1:001:00714:30G enerat e t est pi

28、ece:30:30815:00M easure and i nspect2:002:00917:00Adj ust di es1:001:001018:00G enerat e t est pi ece:30:301118:30M easure and i nspect1:301:301220:00G enerat e f i rst good pi ece1:001:00TO TAL TIM E TH IS PAG E:TO TAL TIM E TH IS PAG E:21:0021:00TO TAL TIM E ALL PAG ES:TO TAL TIM E ALL PAG ES:21:0

29、021:00Step 1 Tools:Setup Documentation WorksheetControlSetup Reduction34Setup D ocum entation W orksheetSetup D ocum entation W orksheetM ACH IN E:M ACH IN E:D O CU M EN TO R:D O CU M EN TO R:D ATE:D ATE:PAG E 1 O F 1PAG E 1 O F 1SEQ#SEQ#START START TIM ETIM EEVEN TEVEN TELA PSED ELA PSED TIM ETIM E

30、IN TIN TEXTEXT10Shut down m achi ne:30:3020:30G et change part s3:003:0033:30Rem ove change part s f rom m achi ne3:303:3047:00Pl ace new change part s on m achi ne3:303:30510:30Ret urn change part s t o st orage3:003:00613:30Load m at eri al ont o m achi ne1:001:00714:30G enerat e t est pi ece:30:3

31、0815:00M easure and i nspect2:002:00917:00Adj ust di es1:001:001018:00G enerat e t est pi ece:30:301118:30M easure and i nspect1:301:301220:00G enerat e f i rst good pi ece1:001:00TO TAL TIM E TH IS PAG E:TO TAL TIM E TH IS PAG E:21:0021:00TO TAL TIM E ALL PAG ES:TO TAL TIM E ALL PAG ES:21:0021:00步骤

32、 1 的工具:设定文件表ControlSetup Reduction35Step 1 Tools:Area LayoutuThe Area Layout is used to both understand the relative position of cabinets,tools,dies/fixtures,hardware,etc.in relation to the setup activities and determine the movements of the operators/setup personnel throughout the setup activities.

33、uIt is key to track each foot traffic movement of key operators/setup personnel to determine the total distance traveled during the operation.This will be key in gaining buy-in(especially from the operators)to the improvement suggestions.ControlSetup Reduction36步骤 1 工具:区域排布u区域排布是用来了解橱柜、工具、模具/备件、硬件等的

34、关联位置.了解设定动作的关系以及决定贯穿整个设定活动中的运作/设定人员的动作.u它可以追踪关键操作员/设定人员的每个脚步移动来决定在整个操作中的总的距离.这将是获得改善建议的好买卖（特别是从操作员那里）.ControlSetup Reduction37Step 1 Tools:Using the Area LayoutPunchPress#1465Tool CarouselControlsTool/Die&Fixture RoomHardware CageProductionControlQualityControlHand ToolCabinetControlSetup Reduction3

35、8步骤 1 工具使用区域排布图打孔冲压#1465工具制作控制工具/模具及备件房间硬件房生产控制质量控制手动工具箱ControlSetup Reduction39Step 1 Tools:Before and After Setup TimelinesuThe Before Setup Timeline is used to graphically show each event within the setup.The timeline will indicate which events are the longest within the setup.The timeline will h

36、elp focus our efforts on reducing the time for the long events.uAn After Setup Timeline is generated after the improvements have been implemented.Comparing the Before and After timelines will visually indicate the improvements.ControlSetup Reduction40步骤 1 工具:前端设定时间线VS后端设定时间线u“前端设定时间线”被用来显示在设定中的每个事件，

37、时间线会帮助我们显示在设定中的最长的事件。它会帮助我们关注降低时间最长的事件而降低设定时间.u“后端设定时间线”是在改善已经被实施后而产生的，用以比较“前”和“后”的时间线，指示改善的目视效果.ControlSetup Reduction41Setup Tim elineSetup Tim elineEVEN T TIM E:EVEN T TIM E:SEQ#SEQ#EVEN TEVEN TBEFO RE/BEFO RE/1 M IN U TE1 M IN U TE2 M IN U TES2 M IN U TES3 M IN U TES3 M IN U TES4 M IN U TES4 M I

38、N U TESAFTERAFTER1515 3030 45451 11515 3030 45451 11515 3030 45451 11515 3030 45451 11Shut down m achi neBEFO REAFTER2G et change part sBEFO REAFTER3Rem ove change part sBEFO REf rom m achi neAFTER4Pl ace new change part sBEFO REon m achi neAFTER5Ret urn change part sBEFO REt o st orageAFTER6Load m

39、at eri alBEFO REAFTER7G enerat e t est partBEFO REAFTER8M easure and i nspectBEFO REAFTER9Adj ust di esBEFO REAFTER10G enerat e t est pi eceBEFO REAFTER11M easure and i nspectBEFO REAFTER12G enerat e f i rst goodBEFO REpi eceAFTERN O TES:N O TES:Step 1 Tools:Setup TimelinesControlSetup Reduction42Se

40、tup Tim elineSetup Tim elineEVEN T TIM E:EVEN T TIM E:SEQ#SEQ#EVEN TEVEN TBEFO RE/BEFO RE/1 M IN U TE1 M IN U TE2 M IN U TES2 M IN U TES3 M IN U TES3 M IN U TES4 M IN U TES4 M IN U TESAFTERAFTER1515 3030 45451 11515 3030 45451 11515 3030 45451 11515 3030 45451 11Shut down m achi neBEFO REAFTER2G et

41、change part sBEFO REAFTER3Rem ove change part sBEFO REf rom m achi neAFTER4Pl ace new change part sBEFO REon m achi neAFTER5Ret urn change part sBEFO REt o st orageAFTER6Load m at eri alBEFO REAFTER7G enerat e t est partBEFO REAFTER8M easure and i nspectBEFO REAFTER9Adj ust di esBEFO REAFTER10G ener

42、at e t est pi eceBEFO REAFTER11M easure and i nspectBEFO REAFTER12G enerat e f i rst goodBEFO REpi eceAFTERN O TES:N O TES:步骤 1 工具:设定时间线ControlSetup Reduction43Step 1 Tools:Improvements WorksheetuList sequence number that corresponds to sequence on Setup Documentation Worksheet.uBrainstorm and list

43、improvement opportunities:nDiscovered during setup documentationnIdentified during brainstorming sessionnDeveloped during application of the Four Step MethoduIdentify the Step#the improvement is related to in the Four Step Method and estimate the net setup time reduction resulting from the improveme

44、nt.ControlSetup Reduction44步骤 1 工具:改善工作表u列出在设定文件化工作表的相对应的顺序号码u脑力风暴和列出改善的机会:n在设定文件化的时候发现n在脑力风暴中发现n在四步曲的应用中发展u在四步曲模式中定义每个改善的步骤号码，然后估计在这个改善中会降低多少净设定时间ControlSetup Reduction45Step 1 Tools:Improvements WorksheetIm provem ents W orksheetIm provem ents W orksheetSEQ#SEQ#IM PRO VEM EN TIM PRO VEM EN TSTEP 1

45、STEP 1STEPS 2,3,&4STEPS 2,3,&41M ovi ng get change part s t o ext ernal3:002M ovi ng ret urn change part s t o ext ernal3:00SETU P RED U CTIO N BY STEP SETU P RED U CTIO N BY STEP 6:006:00TO TAL SETU P RED U CTIO N (STEP 1 and 2,3,&4)TO TAL SETU P RED U CTIO N (STEP 1 and 2,3,&4)(BST)BEG IN N IN G S

46、ETU P TIM E (BST)BEG IN N IN G SETU P TIM E%SETU P RED U CTIO N%SETU P RED U CTIO N (TSR/BST)100(TSR/BST)100ControlSetup Reduction46步骤 1 工具:改善工作表SEQ#IMPROVEMENTSTEP 1STEPS 2,3,&41将“获得要更换的零件”移到外部去3:002将“放回更换的零件”到外部去3:00由步骤降低的设定时间由步骤降低的设定时间6:00合计设定时间降低合计设定时间降低(STEP 1 and 2,3,&4)(BST)开始的设定时间开始的设定时间%设定时

47、间降低设定时间降低 (TSR/BST)100ControlSetup Reduction47Step 2 of 4STEP 1Document the setup and separate events into internal or externalSTEP 3Streamline internal events(Simplify,Reduce,Eliminate)STEP 2Convert Internal to External eventsSTEP 4Eliminate adjustments internal to the setupStep 1 is done first to

48、attain benefits quicklyControlSetup Reduction48第二步第一步第一步文件化设定并且将设定事件区分为内部的和外部的第三步第三步优化内部事件(简单化,减少,排除)第二步第二步转变内部事件为外部事件第四步第四步剔除在内部设定中的调整第一步设定的完成获得快速的收益ControlSetup Reduction49Step 2uConvert Internal to External SetupnConvert any internal setup events to external setup events using focused,engineered

49、methods.nRe-examine internal events from Step 1 and verify that they are actually internal.ControlSetup Reduction50第二步u转变内部设定为外部设定n用集中的、工程化的方式转变任何内部的设定事务为外部设定事务.n重新检查第一步中的内部事务，核实它们都真的是内部事务.ControlSetup Reduction51Ti m eAct i on Part s89Set upA101112Set upB13Part#432543Press#P-10 Revi ew C heck Tabl

50、eD i e 274 Funct i onal C hecksD i e Locat i on Shel f 4 Ret ri eve C hange Part sCRESCENTWRENCHSCREWDRIVERALLENWRENCHStep 2 ToolsuOrganizationuChecklistsuCheck TablesuBattle PlansuFunctional ChecksuImproving Transportation ControlSetup Reduction52Ti m eAct i on Part s89Set upA101112Set upB13Part#43