【文章內容簡介】 指 針 (一共 24個，左 邊和右 邊 各 12個 ) 消除 調試過程的幾種方式示例 運輸帶寬度 高精度 1mm以保證高可靠性 切換部件形式 數(shù)字顯示器形式 (人工調整類型 ) 伺服電機形式 (自動調整類型 ) 插桿鎖緊形式 (人工調整類型 ) 錄 像 SMED Part 2 游戲： 印刷機的切換 3 最終 的但不是至少的 PDCA ? 核查改進 后的成果 – 衡量 MTTS (平均 切換時間 ) ? 進行 一個切換的平均時間 – 衡量 切換速度 ? 切換時間占負荷時間的百分比 ? 使 切換全過程標準化 ? 操作 工的培訓和教育 – 一 點課程 – 在 職培訓 切換程序 Purfleet, 英國 LA BEL LER S I Z E C HA N GEChan g e part s kep t agai n s t S o u t h w al l 2 Pe o p l eo p p o s i t e lab el l er. T ro l l ey to be tak en to lab el l er . (W o rk i n g o p p o s i t e s i d es )West s i de1. E m p t y m ach i n e of all pro d u ct and lab el s2. Rais e m / c hei g h t . (y el l o w bu t t o n on pan el , s et t i n g s on m / c)3. O p en gu ard abo v e lab el m ag azi n es . Rem o v e Makral o n pi ece.4. Releas e and li ft off lab el m ag azi n es and sp acers5. L o o s en clam p i n g screw lo cat ed un d ern eat h so u t h gu ard by gl u e pu m p .6. Pul l lev er si t u at ed un d ern eat h gl u e bl ad e to m o v e bo t t l e tab l e back .7. L o o s en k i p l o ck s ( x 2 ) on i n feed s t arw h eel set t i n g and retract8. Pus h gl u e bl ad e un t i l it sp ri n g s in t o “ o u t ” po s i t i o n9. L i ft up hi n g ed to p beari n g ho u s i n g pl at e from gl u e rol l er10. L i ft off rou n d to p pl at e and rem o v e lab el pal l et s ( x 6 )11. D i s co n n ect lu b ri cat i o n and air li n es to g ri p p er cy l i n d ers .( l o cat ed nex t tot h e w es t si d e gu ard .) L i ft off g ri p p er cy l i n d ers ( x 2 ) and sp acers (x2 )12. Rem o v e bru s h ass em b l i es (x3 ) 切換程序 Worksop, 英國 More examples: Point Lessons/ 移走外側導軌 移走中心導軌 移走橫切星形輪 清理所有拆卸 部件并保管好 清理無外殼的機器 更換橫切星形輪 在地面上裝配中心導軌并檢查，后更換中心導軌 在地面上裝配外側導軌 并檢查，后更換外側導軌 切換完成 關于 切換的一點課程 Worksop, 英國 一 點課程 2A 固體裝填線門的裝配 工作 站 : 裝填封口機 機器 : 2A固體 裝填線 類 別 : 切換 由 DGM準備 日期 : 02/1997 方法 必須 十分小心以確保塑料門在其應有位置。裝配平臺上有一個銷子，應對應上襯套上的插孔。如果沒有對齊 ，將會出現(xiàn)以下幾個問題 : ?襯 套沒有處于扁平狀態(tài)，在接近門打開時無法接觸到其下部 . ?緊 固螺釘無法完全擰緊，會產生松動 . ?襯 套夾緊了門，使得裝填僵硬無法轉向 教育 記錄 : 發(fā)展 階段 管理 階段 完全 勝任 緊固螺釘 襯套 銷子和插孔必須對齊 裝配平臺 裝填機門手臂 經驗和教訓 ? Van den Bergh 食品 公司 , Purfleet 英國 – 應 集中 精力于工藝過程，而不僅是依靠改進設備 – 規(guī)格發(fā)生切換時的時間節(jié)省程度多與操作順序有關，在進行切換和平行工作時將切換部件移至它們應在的位置 ? 利華 , Port Sunlight No 4 英國 – 切換 的改進不應只由工程部門完成 – SMED是一種系統(tǒng)化的方法，易于團隊成員使用 – 每 個人都積極參加 Quick Changeover ? A theory and set of techniques that make it possible to set up and change over equipment in less than 10 minutes ? When to implement QCO – Demand stage – slow changeover times present a major obstacle to meeting customer demand – Continuous flow stage – implementing standardized work underscores the need for faster changeover times to reduce total cycle time and help balance operations QCO ? Begins with a thorough analysis of current setup procedures – Distinguish between internal setup tasks that can be performed only while the machine is shut down and external tasks that can be performed while the machine is running – Convert internal task to external tasks when possible。 improve storage and management of parts and tools to streamline external setup operations – Streamline all setup activities by implementing parallel operations, using functional clamping methods instead of bolts, eliminating adjustments, and mechanizing when necessary By addressing just the obvious things, like preparing and transporting tools and equipment while still running the machine , you can often cut setup by 50% Quick Change Over : Parallel Operations Leveler Roller Part Press 14 25 13 26 27 12 28 10 31 15 30 32 16 35 34 33 1 36 29 7 22 23 11 17 19 9 8 5 24 2 20 21 3 4 6 18 Materials Dryer Rail Slitter Pallet Kanban Before Improvement (oneperson changeover) Leveler Roller Part Press Materials Dryer Rail Slitter Pallet Kanban After Improvement (twoperson changeover) 1 2 3 4 5 6 6 5 4 3 2 1 7 QCO Benefits ? Increased Flexibility ? Quicker Delivery ? Better Quality ? Higher Productivity Waste Elimination ? Safer Changeovers ? Less Inventory ? Standardization Batch Size Lead Time Reduction SMED: Example 1 Internal External Close coolant cover all hydraulic valves Prepare next die Detach coolant hoses Put tools in order Remove knockout joint clamping nuts Prepare pallet for castings Loosen tie bar Remove clamps on movable die Raise die with hoist Remove knockout joint Remove clamps on fixed die With hoist, remove die from machine With hoist, insert die from machine Align sleeves (use jig) Attach fixed jig clamps Attach knockout joint Tighten knockout joint, attach nuts Attach movable die clamps Attach coolant hoses Adjust die closing force Preheat, set operation conditions Separating Internal External SMED: Example 1 Setup Steps before SMED Improvement after SMED Internal Setup 1 Close coolant cover all hydraulic valves Turn off coolant water before last shot。 do not shut hydraulic valves 4 Detach coolant hoses Concentrate coolant lines 5 Remove knockout joint clamping nuts Eliminate with a stripper plate spring extrusion rod 6 Loosen tie bar Not needed when die thicknesses are standardized 7 Remove clamps on movable die Improve clamps。 standardize bolt diameters 8 Raise die with hoist Set at specific location in external setup 9 Remove knocko