delta_leantoolsused(ppt27)-經(jīng)營管理(參考版)
2024-08-20 15:43本頁面
【正文】 assuming leveldemand Low volume products: – Number of product ponent – Line configuration – Low line change over time – High number of feeders slots available UHV/HV products: – Number of product ponents – Line configuration – Machine capacity – Number of feeders slots – High OEE – High quality Criteria for assigning SMD lines to products EXAMPLE DET020815HKDEQ0021pr 23 2B. NUMBER OF CHANGEOVERS: COMBINE SEGMENTATION WITH BETTER SCHEDULING TO REDUCE CHANGEOVERS AND INVENTORY Current state 1 2 2 4 5 6 7 7/1 2 3 4 5 6 7 8 9 10 Production hours 26 8 45 49 12 3 41 23 18 19 Total 244 Line 1 Line 2 Line 3 Line 4 Line 5 Line 6 Line 7 7/1 2 3 4 5 6 7 8 9 10 Production hours 12 24 24 36 24 18 0 21 36 48 Total 244 1 2 3 4 5 6 7 8 9 10 Inventory level* 02 , 0 0 04 , 0 0 06 , 0 0 08 , 0 0 01 0 , 0 0 01 2 , 0 0 01 4 , 0 0 01 6 , 0 0 0Inventory level* 7/1 2 3 4 5 6 7 8 9 10 Number of changeover = Avg. inventory XXX PCs/ 23 hours Avg. inventory XXX PCs/ 5 hours PRELIMINARY Number of changeover = of lines 2 1 4 3 3 1 2 2 2 2 Improved state XX% reduction in the of changeover and inventor level of lines 1 1 1 2 1 1 0 1 2 2 DET020815HKDEQ0021pr 24 2C. MATERIAL REPLACEMENT: STANDARDIZE PROCEDURES TO DECREASE VARIABILITY AND DOWNTIME BY 40% Improvement potential ?Get rid of variability in the material replacement process could reduce observed downtime by XX% (up to XX% OEE) Key levers ?Process stabilization by workstation improvement, 5S and process standardization ?Standard time reduction for material replacement for high frequency ponent (from 1 minute to XX seconds) Machine downtime caused by material replacement* min Stoppages 0 10 1 XX XX% of the observed material replacement took more than 1 minute Observed problems ?XXX stoppages for material replacement (total loss XXX minutes) ?Time lost for looking for the right reel in the material box ?Component reel not present at the line ?Required team leader intervention DET020815HKDEQ0021pr 25 2C. MATERIAL REPLACEMENT: ADOPT NEW PROCEDURE FOR MATERIAL REPLACEMENT OF HIGH CONSUMPTION COMPONENTS TO REDUCE DOWNTIME Material replacement procedure Current state Machine stoppage Remove empty feeder Pull out empty reel Replace reef on the feeder Fit feeder in the machine Restart the machine Improved state XX sec. XX sec. Machine stoppage EXAMPLE 1 2 3 4 5 6 Machine stoppage Remove empty feeder Fit feeder in the machine Restart the machine Pull out empty reef on old feeder Replace reef on the feeder and place the feeder ready for usage on a cart 1 2 3 4 5 6 Internal activities External activities ? Reduction of machine downtime related to material replacement by XX% (from XX sec. to XX sec.) Improvement potential ? Standardization of procedures ? Prepare feeders in advance ? Maintenance of feeders ? Analysis of frequency of usage for ponent Key levers Introduce initially the new procedure for high frequency ponent to reduce the total number of feeders required DET020815HKDEQ0021pr 26 3A. CYCLE TIME IMPROVEMENT: DETAILED OBSERVATIONS REVEALED SIGNIFICANT CYCLE TIME VARIABILITY 76 78 80 82 84 86 88 90 92 12:30 13:30 14:30 15:30 16:30 cycle time Seconds Lowest cycle time Potential issues: ?Poor maintenance ?Machines not optimized ?Suboptimal placement of ponents ? Total losses estimated to XX minutes/day (XX% OEE)* Improvement potential ? Verify impact CT variability in lines with high C/O and low C/O Key analysis ? Monitoring continuously machine CT to identify variability trend ? Use high speed cameras to record machine movement and better understand the root causes of CT variability Key levers DET020815HKDEQ0021pr 27 4. MACHINE BREAKDOWN: USE ROOT CAUSE PROBLEM SOLVING LOADER BREAKDOWN IS A LEADING CAUSE OF STOPPAGE
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