【文章內(nèi)容簡介】 6 0 0T e m p e r3 6 0 T e m p e r Ha r d e n Dr a wN C o o l p ro d u ct t o ro o m t e mp . b e t w e e n t e mp e rs.N N o mo re t h a t 1 2 h o u rs b e t w e e n t e mp e rs.N 3 6 0 F t e mp e r mi n i mu m 3 0 mi n . so a k.N 1 5 6 0 F f o r mi n i mu m 3 0 mi n . so a k.N 1 0 H o u r t o t a l d ra w cyc l e .N 1 1 0 0 F t e mp e ra t u re .N D ra w w i t h i n 1 2 h o u r s o f c a r b .F u rn a ce cl e a n Pa rt s co n d i t i o n e d C o o l e d p ro p e rl y F u rn a ce p re p a re d Pro p e r ca sePro p e r se t t i n g sPro p e r h a rd n e ssMe t a l l u rg i ca l p ro p e rt i e sMe t a l l u rg i ca l p ro p e rt i e s169。2022 The Timken Company 23 Home Center 11,400/ Mo. Flat 3,500/Mo. Phil. 745 / day 20 box/pallet Betty?s Pete?s 1500 lb coils 500 lb Box 3 mo. Forecast Daily Orders MRP Production Control Weekly Schedule Daily Ship Schedule Weekly FAX 10 days sec 40 sec 71 sec 54 sec 59 sec days days days 7 days 7 days Production Lead Time days Value Added Time sec. 4,400 flat 800 phillips SHIPPING Staging Assembly Mark sec CT 90 min c/o 80% U/T 2 shifts Press Material Stores Area Coils 10 days Handles 6 days 10,000 flat 8,000 phillips 3,200 flat 1,100 phillips 2,200 flat 1,000 phillips 1,200 flat 4,000 phillips 1 1 1 Sub Assy 2 Sub Assy 1 1 I I I I I I 40 sec CT 5 min c/o 100% U/T 2 shifts 71 sec CT 5 min c/o 100% U/T 2 shifts 54 sec CT 10 min c/o 90% U/T 2 shifts 59 sec CT 5 min c/o 100% U/T 2 shifts (10,000 + 8,000)/745 = days Value Stream Map 24 M A I C D ? Run Charts. ? A run chart is a form of SPC chart. The run chart is a chart using limited singlepoint data that looks for evidence of patterns in the data. ? The run chart can be used to determine nonrandom behavior by detecting trends, oscillation, mixtures, and clustering. ? Such patterns suggest that the variation is due to special causes (causes arising from outside the system that can be corrected). ? Histograms. ? A histogram is a graph using frequency columns displaying a static picture of process behavior. ? Histograms require a minimum of 50100 data points. ? They are characterized by the number of data points that fall within a given bar or interval (called frequency). ? The graph is displayed as lowest to highest. 25 Run Chart Zero thru 449 New Drills % Rejects 450 thru 788 Kennematel Regrinds % Rejects Gainey Regrinds 61% Rejects 169。2022 The Timken Company 26 Histogram 70 110 150 190 230 270 169。2022 The Timken Company 27 M A I C D ? Pareto Analysis. ? Specialized forms of column graphs. ? Used to prioritize problems so the “significant few” can be identified from the “trivial many”. ? Used to analyze a problem from a new perspective, prioritize attention on problems, pare data changes during different time periods. 28 Pareto Analysis Den tBe ndChi pSc rat ch11241 2 . 51 2 . 52 5 . 05 0 . 01 0 0 . 0 8 7 . 5 7 5 . 0 5 0 . 0876543210100806040200D e f e c tC ou ntPe rc en tC um %PercentCountP a r e t o C h a r t f o r D a m a g e29 M A I C D ? Measurement Plan. ? Develop operational definition for the measurements. ? Develop the measurement plan.. ?Make sure the data collected is meaningful. ?Make sure the data collected is valid. ?Make sure all data is collected at the same time. ? Collect the data. ?Follow the plan, note any exceptions from the plan. ?Be consistent, avoid bias. ?Observe the data collection process. ? Display and evaluate the data. ?Look for data errors and outliers. ?Determine if the methods used to collect the data have been consistent and representative of the population. 30 Measurement Plan P e r f o r m a n c e M e a s u r eO p e r a t i o n a l D e f i n i t i o nD a t a S o u r c e a n d L o c a t i o nS a m p l e S i z eD a t a C o l l e c t i o n R e s p o n s i b i l i t yT i m e Fr a m e o f D a t a C o l l e c t i o nH o w i s D a t a C o l l e c t e dO t h e r D a t a C o l l e c t e d a t t h e S a m e T i m e O D S i z e D e t e r m i n e a m o u n t o f v a r i a t i o n i n t h e p l u g g i n g o p e r a t i o n f o r t h e S a l e m f u r n a c e s .S a l e m H a r d e n i n g Fu r n a c e s E 1 , E 2 , a n d E 3 .1 0 0 p c s . f o r e a c h f u r n a c e p e r c u p a n d c o n e ( 6 0 0 p c s . t o t a l )K . R y a n / C . L i t t e n Fe b r u a r y / M a r c hD a t a c o l l e c t e d b y t h e H e a t T r e a t C h e c k e r s a n d r e c o r d e d o n a s p r e a d s h e e t a f t e r a g e .D u r i n g