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【文章內(nèi)容簡(jiǎn)介】 nterpret and organize this information? ? Do the right thing right, at the right time and right place, and at 1st time ? If you do not have the right info, the assumption might be based on inaccurate judgment or wrong data ? There’s no golden rule, a lot would be from experiences ? FM to guide the junior engineers ? ASK, do not assume Line Design – Process Mapping The first step is to Chart the information … ? PQ (ProductQuantity) Analysis ? Objective – Determine if product mix requires independent manufacturing P Q A n a l y s i s C h a r t020406080100120140160180P1 P2 P3 P4 P5 P6 P7 P8 P9P10P11P12P13P14P15P16P17P18P19P20P21P22P23P24P25P26P27P28P29A A D B C E B A C A A A B C E D A D D A G A B B A A A A F P r o d u c t / F a m i l yVolumesLine Design – Process Mapping Next … ? PR (ProductRouting) Analysis ? Results – visibility to similar types of operations and similar types of products. P r o c e s s 1 P r o c e s s 2 P r o c e s s 3 P r o c e s s 4 P r o c e s s 5 P r o c e s s 6P1 O O O OP2 O O O OP3 O O O OP4 O O O OP5 O O O OP6 O O O O OP7 O O O OP8 O O O OP9 O O O OP 1 0 O O O OP 1 1 O O O OP 1 2 O O O OP 1 3 O O O OP 1 4 O O O OP 1 5 O O OP 1 6 O O OR o u t i n gProductLine Design – Process Mapping Next … ? QR (QuantityRouting) Analysis ? Results – visibility to material handling Q R C h a r t0 50 100 150 200P 1 0P 1 1P6P4P5P7P8P2P3P9P 1 2P1Process or RoutingQ u a n t i t y Line Design – Process Mapping Next … ? PQT (ProductQuantityTime) Analysis ? Results – balance between production staff and flexibility of the line ? Results – shows variation in volumes of product over time Process Diagnosis Set a vision for the design of the process … ? Set baseline expectations centered around “zero nonvalue add”: ? No wasted time for idle inventory ? No wasted material ? No wasted effort in rework or scrap ? No wasted time for idle resources ? No wasted motion ? No wasted support ? No wasted time in unnecessary activities Process Diagnosis Develop a road map for the design of the process … ? Develop detailed Process Flow Charts: (using a mechanical assembly drawing or an actual unit and the BOM) ? Material point of view ? Operator point of view ? bird’s eye view ? motion, time, effort (physical operations) Process Diagnosis Remember to map the following … ? Chart any other functions that are related to the process: ? FVT ? ESS ? HiPot ? 5DX ? Takaya ? PackOut ? KitPrep ? Rework Area ? Reject material on the line ? Etc. Process Diagnosis MOST Survey … ? What is MOST? ? Have you used MOST at your plant? ? If yes, what value did it provide? ? Maynard’s Operation Sequence Techniques Process Diagnosis MOST Why use MOST?… ? MOST will enable the operator to bine the operator and material flow charts into one series of assembly steps. ? To determine TAKT time of each product ? When developing a
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