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【正文】 be kept to around width. ? Eliminate spaces and surfaces where inventory can accumulate ? Put the start and finish processes close together. ? Keep a constant height for work surfaces and inventory points ? Keep all material transfers horizontal. ? Use gravity to assist movement of materials 15 單元生產(chǎn)布局貼士 (續(xù) ). ? 將所有的工具都擺放在靠近操作點(diǎn)的位置 ,并使用有伸縮性的低垂軟管 ? 使用無(wú)需安裝的專用工具 . 如果可能 ,將兩個(gè)以上的工具組合在一起 ? 布局要有彈性 ,以便將來(lái)調(diào)整 —在工位上使用滾動(dòng)裝置 ? 設(shè)計(jì)良好的工效學(xué)及新五常法現(xiàn)場(chǎng)管理，包括足夠的照明 ? 將品質(zhì)內(nèi)化到每個(gè)步驟的流程中 ,采取防錯(cuò)法 ? 消除起重設(shè)備的使用 16 Tips for cell layout (continued). ? Keep all tools close to the operation and use flexible hose drops. ? Use dedicated tools to avoid setup. Where possible bine two or more tools together ? Make the layout flexible so changes can be made in future – Use rollers on work stations. ? Design good ergonomics and good New 5S including lighting. ? Build quality into the process at each step. Mistake Proofing. ? Eliminate use of cranes. 17 機(jī)器貼士 ? 單項(xiàng)任務(wù)使用專用的小型設(shè)備 ， 不要使用多功能設(shè)備 ? 在操作人員需要使用雙手操作的地方引進(jìn)自動(dòng)彈出機(jī)構(gòu) （ 彎曲機(jī) ） ? 機(jī)器加工應(yīng)按單件流方式（一個(gè)合約流動(dòng)） ? 使用探測(cè)器來(lái)檢查異常情況 ? 以可維護(hù)性為宗旨進(jìn)行設(shè)計(jì) ? 定拍機(jī)器流程加上安裝的時(shí)間要少于一個(gè)節(jié)拍時(shí)間周期 ? 消除安裝時(shí)間 18 Tips for machines ? Use dedicated and small equipment for single task rather than multi task equipment. ? Introduce autoeject mechanisms where operators need to use both hands (Bending machines) ? Machines should process one piece flow (One Contract flow) ? Incorporate sensors to check for abnormal conditions ? Design in maintainability ? Pace maker machine processes with setup less than one Takt time cycle ? Eliminate setup time 19 物料管理貼士 ?不要關(guān)注安排車間生產(chǎn)進(jìn)度的物料需求規(guī)劃 (MRP) ? 將零件擺放在最靠近應(yīng)用現(xiàn)場(chǎng)的地方 ,但是不要阻塞操作人員的行走通道 ? 將需更換的各種配件放在操作人員的附近以減少轉(zhuǎn)換時(shí)間 ? 切勿在中斷操作人員的工作周期的情況下補(bǔ)充零件 ? 在應(yīng)用現(xiàn)場(chǎng)擺放的存貨不得超過(guò) 2小時(shí)用量 ? 通過(guò) ―水蜘蛛” /物料輸送系統(tǒng)來(lái)實(shí)現(xiàn) ―單合約流” ?使用看板系統(tǒng)來(lái)聯(lián)接供應(yīng)鏈 ? 容器的尺寸要便于操作人員操作或單位生產(chǎn)時(shí)間的生產(chǎn)量 20 Tips for materials management ? Switch off MRP for scheduling the shop floor. ? Place parts close as possible to point of use but not in the walking path of the operator. ? Keep all variation of parts close to the operator to eliminate changeover time. ? Never interrupt the operator work cycle to replenish parts. ? Keep no more than 2 hours inventory at point of use ? Make ?One Contract Flow‘ with use of ?Waterspider‘ / material handler ? Use Kanban to link supply chain ? Size containers for the convenience of operators or pitch quantity. 21 當(dāng)前狀態(tài) 20m 沖孔機(jī) 2天 裝貨 出 10天 原材料 通道 3天 裝配站 1 點(diǎn)焊機(jī) 裝配站2 3 天 1 天 2 天 3 天 無(wú)連續(xù)流 —訂貨至交貨的時(shí)間按天 /周計(jì)算 無(wú)人員流 未按照節(jié)拍時(shí)間生產(chǎn) 過(guò)多的操作人員 節(jié)拍時(shí)間 22 Current State 20m Punching Machine a 2 Days Load Out 10 days Raw Material Aisle way 3 Days Assembly station 1 Spot Weld machine Assembly Station 2 3 Days 1 Day 2 Days 3 Days ? No continuous flow – Lead time is days / weeks ? No people flow ? Not working to Takt time ?Too many operators Ta
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