質(zhì)量管理第7講 森口體系-文庫吧
2025-01-12 03:58 本頁面
【正文】 problems. These are easy to fix and should be a first step. 3/16/2023 14 2. Internal Elements to External ? Internal elements occur when the machine is down. Examine each internal element and see if it cannot be done externally. For example, the preheating of an injection molding die could be done before it goes into the machine. 3/16/2023 15 3. Improve Elements ? Here we examine every element to see how we can eliminate it, simplify it, reduce the time required or improve it in some other way. 3/16/2023 16 4. Eliminate Adjustments ? Adjustments are often the most time consuming, frustrating and error prone parts of a setup. There are many ways to eliminate them entirely and this is the ultimate goal. 3/16/2023 17 Setup Reduction Typical Results ? Setup reduction (SMED) techniques apply across many industries and process technologies. The list below shows some examples. 3/16/2023 18 Industry Equipment Before After % Assembly Adhesive Applicator 12:09:00 0:21:00 97% Assembly Air Cleaner Assembly 2:00:00 0:00:00 100% Cosmetics Capper Machine 0:09:36 0:03:21 65% Electronics PCB InserionICs 0:13:30 0:05:56 56% Electronics PCB InsertionAxial 0:05:18 0:04:18 19% Electronics PCB InsertionRadial 0:54:12 0:05:06 91% Foundry Molding Machine 0:10:00 0:06:12 38% Metal Cutting Casting Drill 1:00:00 0:09:00 85% Metal Cutting CNC MILLING 2:00:00 0:00:00 100% Metal Cutting FADAL HMC 1:45:00 0:15:20 85% Metal Fab 40 Ton Press 0:48:00 0:04:00 92% Metal Fab 750 Ton Hyd Press 2:10:00 0:42:00 68% Metal Fab 800 Ton Press 6:00:00 0:10:00 97% Metal Fab Aluminum Extruder 1:09:00 0:02:12 97% Metal Fab Brake Press 0:37:00 0:04:00 89% Metal Fab Draw Press 1:30:00 1:00:00 33% Metal Fab Edge Trim Press 0:24:00 0:04:00 83% Metal Fab Pilot ChangeMuffler Press 0:07:00 0:00:15 96% Packaging Flex Packaging Line 3:00:00 0:10:00 94% Paper Sheeting 0:03:00 0:00:36 80% Pharmaceutical Centrifuge 0:12:00 0:02:12 82% Plastics 250 Ton Injection Molder 1:06:00 0:09:12 86% Plastics Injection Molder 2:30:00 0:06:00 96% Plastics Injection Molder 2:00:00 0:03:00 98% Printing Kidder 6Color Web Press 4:20:00 1:10:00 73% Printing Press Make Ready 9:30:00 4:20:00 54% Wood Router 0:09:00 0:01:18 86% 3/16/2023 19 SMED案例 ? 1969年豐田汽車公司更換 1000噸級沖床的模具要花 4個小時，而德國大眾汽車公司只用 2個小時。因此，豐田制造廠的經(jīng)理大原太一下令要求趕超德國。 ? 森口花了 6個月時間將內(nèi)部調(diào)試從外部調(diào)試中分離出來，并逐步改進每一程序中所有相關操作，最后成功地將調(diào)試時間縮短到 1個半小時。接著，太一又指示他將調(diào)試時間減少到 3分鐘。一開始．森口覺得根本不可能，但很快就想出來新的方法來縮短調(diào)試時間。 3個月后，他和豐田的主管們一起實現(xiàn)了目標。 3/16/2023 20 Pokayoke 3/16/2023 21 Mistakes: to err is human. (人非圣賢孰能無過） Have you ever done the following: ? Driven to work and not remembered it? ? Driven from work to home when you meant to stop at a store? 3/16/2023 22 It happens to workers too. ? Workers finish the shift and don’ t remember what they have done. ? After building green widgets all morning, the workers put green parts on the red widgets in the afternoon. 3/16/2023 23 You have two options: ? Demand vigilance—— Exhort workers to “ be more careful!” ? Mistakeproof—— Eliminate the chance of making the mistake 3/16/2023 24 A New Attitude toward Preventing Errors ? Think of an object’ s user
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