【文章內(nèi)容簡介】 During the process of production scheduling, when a certain work center is overloaded – the schedule requires capacity in excess of what is available during the scheduling period, a possible course of action is for process engineering and scheduling to agree on an alternative flow to produce some of the product being across the affected work centers. Temporary or alternate routings should always be preapproved in order to maintain product quality and in order to maintain the accuracy of work center dispatching. 12 Unit 9: 流 程 Routing Lesson 3: 生產(chǎn)布局和生產(chǎn)流水線 Plant Layout Product Flow 檢討 Review 流程的設(shè)計依賴于工廠的布局 .制造工藝類型和對生產(chǎn)流程的影響 . The design of a routing depends on the layout of the plant, the type of manufacturing process, and the resulting production flow. 生產(chǎn)布局 Manufacturing Layout 生產(chǎn)布局是一個關(guān)于在生產(chǎn)場地如何放置生產(chǎn)資源的圖表 .它通常包括生產(chǎn)場地的大小 ,機器的尺寸 ,工作中心或生產(chǎn)資源和它們放置于地面的位置 . The manufacturing layout is a plan of how the mfg. resources are positioned in the mfg. area. This usually includes the dimensions of the mfg. floor, the relative size of the machines, work center or mfg. resources, and their location on the floor. 一個以生產(chǎn)功能的生產(chǎn)布局將機器或資源聚合在一起 .生產(chǎn)流水線由如何利用生產(chǎn)資源來制造產(chǎn)品來決定 . A functional mfg. layout has like machines or resources grouped together on the mfg. floor. The product flow is determined by how the mfg. resources are used to produce the product. 一個流水線產(chǎn)品的布局應(yīng)合理地按順序布置機器或生產(chǎn)原料以便利于產(chǎn)品的生產(chǎn) . A flow mfg. layout has machines or mfg. resources arranged tin the sequence they are used to product the product. 在一個以工作功能型的工廠布局中 ,資源根據(jù)不同的功能和部門而進行聚合 .在某一機器上完成的固定數(shù)量的工作將傳遞到下一個部門 .在這種布局中 ,不同部門間的物料和移動延長了總的生產(chǎn)時間 .因為每個部門的物料不得不獨立地安排 ,所以等待時間是總的生產(chǎn)交期的重要部分 . In a functionally oriented layout, resources are grouped according to their functions or depts. Jobs on the machines are usually pleted in fixed quantities in each dept. and then moved to the next dept. In this layout, the movement of material between depts. Increases the total manufacturing time. Since each mfg. Resource has to be scheduled independently, queue time is a significant portion of the total mfg. lead time. 13 在一個流水作業(yè)的環(huán)境中 ,資源排成流水線 ,產(chǎn)品按流水順序生產(chǎn) . 這里制造活動以連續(xù)線或流水線的方式進行 .當一個零件完成后被移至下一工作中心 ,如此循環(huán)下去 . In a flow environment, resources are placed at a flow line where the product is produced in a structured process. Here, manufacturing activities occur in a continuous line or flow. When one part is pleted, it is moved to the next work center and so on. 順序化的流水線布局 Structured Flow Layout 磨 床 鋸 切 車 床 磨 床 鋸 切 車 床 車床 衝壓 車床 衝壓 1 A 2 B 熱處理 流水生產(chǎn)布局的優(yōu)點 Advantages of a Flow Mfg. Layout 流水線布局比功能型布局有以下的優(yōu)點 : A flow layout has the following advantages over a functional layout: (1) 更少的等候時間 (2) Less queue time 功能型布局 Functional Layout 鋸切 鋸切 鋸切 車床 車床 車床 磨 床 磨 床 衝 壓 衝 壓 熱處理 1 2 3 4 5 6 14 在流水線的布局中 ,減少裝配時間就變得很重要了 ,因為機器和各種活動彼此相連以產(chǎn)生一個需要的產(chǎn)品 .等候時間也能大大地減少或者消除 , 這是因為物料是在流水線上進行小數(shù)量加工 .移動時間也因為產(chǎn)品是在工廠以直線型來移動而減少 .在流水線布局下 ,運行時間占了生產(chǎn)交期中最高百分比 .這樣就產(chǎn)生了一個產(chǎn)品的附加值 . 所以 ,一個工廠流水線生產(chǎn)的設(shè)計比一個功能的工廠設(shè)計更有效益 . In a flow layout, reducing setup time bees important because machines and activities are linked together to the required items. Queue time can also be substantially reduced or eliminated because materials are produced in a flow line and smaller lots. Move time is reduced since the product moves through the factory in a relatively straight line. In a flow layout, the run time accounts for the highest % of the total manufacturing lead time. This produces a value added to the product versus a cost added when materials are held in queue. Therefore, a plant designed with flow production with flow production will be more efficient than a functionally oriented plant. (2) 更少的生產(chǎn)周期時間 Less manufacturing cycle time (3) 更少庫存和工序間的庫存 Less inventory in the stockroom and workinprocess (4) 更容易和更快地更改設(shè)計 Easier and quicker engineering changes (5) 降低成本和更好地為顧客服務(wù) Lower costs and better customer service overall 流水線布局的目的是物料在最短的時間內(nèi)及最低的成本 . 這是通過減少物料在生產(chǎn)工位等候所浪費的時間而達到目的 . The goal in a flow layout is to get the material through the factory in the shortest time and at the lowest cost. This is done by reducing the time materials sit idle in queue on the manufacturing floor. 15 時 間 移 動 範 圍 收 發(fā) 接 觸 降低成本的 5T方針 減少生產(chǎn)成本 工藝技術(shù)的挑戰(zhàn) The Process Engineering’ s Challenge 對生產(chǎn)改善的影響 Impact of Manufacturing Improvements: 在一個高效率的制造環(huán)境里 ,工藝技術(shù)部有兩個主要的挑戰(zhàn) : In a high performance mfg. environment, process engineering is presented with 2 major challenges: ,它能準確地反映當前的生產(chǎn)布局和設(shè)計 . Create and maintain a routing database which accurately reflects current mfg. layout and design. ,從而簡化及降低生產(chǎn)布局和設(shè)計的成本 .這方面 ,工藝技術(shù)部可不斷做改善 . Use accurate routing data to generate ideas to simplify and reduce the cost of the manufacturing layout and design. This is the continuous improvement aspect of the process engineering job. Prove simplified mfg. design with pilot projects Plant layout production flow documented Routing equal mfg. design Mfg. design improve ment objectives 16 在一個功能型的環(huán)境里 ,基于產(chǎn)品系列或生產(chǎn)線組合 ,工藝技術(shù)部應(yīng)重新評估可否對生產(chǎn)線重新設(shè)計 .在一個流水線環(huán)境里 ,工藝技術(shù)部應(yīng)尋找機會去提高倉存的速度以減少等待 (排隊 )時間 . 在以上兩個環(huán)境中 ,進行物流分析進而轉(zhuǎn)到產(chǎn)品成本的“ 5T” 上將有利于以顧客為本的生產(chǎn)的提高 . In a functional environment process engineering should begin evaluating mfg. Redesign based on product family or product line grouping. In a flow environment, process engineering should look for opportunities to increase the velocity of inventory through the process to reduce queue time. In both environments, analyzing material flow and conversion with respect to the 5 T’s of Production Cost will help identify customerfocused mfg. improvements.