【正文】 l i n g C h a r t / S W C SH a n d L o a d A s s e m b l y手動(dòng)作業(yè)裝配W o r k S t a n d a r d作業(yè)標(biāo)準(zhǔn)3 Y Y N N Y YA n d o n異常報(bào)警系統(tǒng)R e c e i v i n g ,W a t e r S p i d e r ,HR,T e s t i n g收貨，水蜘蛛， HR ，測(cè)試S i gn a l Tri ge r r i ng信號(hào)觸發(fā)E x a m pl e s例子E l e m e nt s 要素S t a n d a r d W o r k標(biāo)準(zhǔn)作業(yè)Ty pe類型M a c hi ne機(jī)器M a n人To ol s工具4 3 Types of Standard Works 3種標(biāo)準(zhǔn)作業(yè) Type 1 : Standard Work to support machine (90%) man (10%) bination task. 類型 1：標(biāo)準(zhǔn)作業(yè)適用于 90%的機(jī)器作業(yè)和 10%的手動(dòng)作業(yè)的組合作業(yè)方式 。 Type 3 : Standard Work (also called as Work Standard) to support task carried out once signal is triggered. 類型 3：標(biāo)準(zhǔn)作業(yè)（也叫做作業(yè)標(biāo)準(zhǔn)）適用于當(dāng)信號(hào)產(chǎn)生時(shí)才去執(zhí)行相應(yīng)任務(wù)的作業(yè)方式 。每天工作小時(shí)是 22小時(shí)，一個(gè)月 20天。 sec 2792 ,0001,58 4,00 0pcs 792 ,000s 360 0 x days 20 x Hou rs 22 Deman d Custome r Time AvailableTime Takt????客戶需求有效時(shí)間6 How to start the Takt Time Calculation Based On Product and Process Design怎樣根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Step 2: Calculate Process Takt time Based on Product and Process Design 第二步：根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Based on Step 1, Takt Time is 2 second to produce 1 pcs. 根據(jù)步驟 1，節(jié)拍時(shí)間是每 2 秒生產(chǎn) 1 件產(chǎn)品。 制程設(shè)計(jì)治具同時(shí)放置 4 塊 PCB板，則制程的節(jié)拍時(shí)間是 48 秒 /治具。 Scenario 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec 情節(jié) 2：如果正反面產(chǎn)品同時(shí)在一條生產(chǎn)線生產(chǎn)，節(jié)拍時(shí)間則為一半， 48秒。庫(kù)存從根本上說(shuō)是“不好”的。 ? However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and bottle neck 然而，在完全達(dá)到標(biāo)準(zhǔn) WIP數(shù)量前，你需要經(jīng)過(guò)不同的階段了解制程中的浪費(fèi)和瓶頸。這是讓你理解這個(gè)定義的唯一方法。 12 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Process WIP 制程 WIP ? WIP within same process with low variation of cycle time 同一個(gè)制程中的 WIP，周期時(shí)間 CT變化很小 ? It is all that WIP in the same process, not categorized as Standard WIP or PTP WIP. 所有在同一個(gè)制程中的 WIP，不是標(biāo)準(zhǔn) WIP或制程間 WIP. ? Example: 例如 Before Kaizen, Manual Insert (MI) Line Process WIP =9 pcs. After Kaizen MI Process WIP is 3. Standard WIP for each station is 1pc. 改善前，插件拉的制程 WIP=9 pcs。每個(gè)工位的標(biāo)準(zhǔn) WIP為 1pcs. 60 sec 51 45 58 43 Person Time A B C D 60 sec 60 60 60 12 Person Time A B C D variance After Before Process WIP = 3, Standard WIP = 1 Process WIP = 9, No standard WIP 13 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Process To Process WIP (PTP WIP) 制程 間 WIP ? WIP between 2 different processes with big gap cycle time 兩個(gè)周期時(shí)間相差很大的不同制程間的 WIP. ? PTP WIP Is needed due to changeover in upstream line. 上游制程需要 轉(zhuǎn) 拉， 則 需 設(shè) 定制程 間WIP. ? Not All line need PTP WIP. 不是所有產(chǎn)線都需要制程間 WIP. ? If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期時(shí)間小于下游制程的周期時(shí)間 Example 1: SMT Cycle time (30 sec) Less then Manual Insertion (60 sec) 例 1： SMT周期 時(shí)間 (30 sec)小于 MI插件周期 時(shí)間 (60 sec) CT (Upstream process) CT (Downstream) = Need PTP WIP 需要制程 間 WIP ? If Cycle time Upstream process is Equal or greater then Down stream process, No PTP WIP required. 如果上游制程的周期時(shí)間大于或等于下游制程的周期時(shí)間，不需要制程間 WIP. 節(jié)拍時(shí)間 前工序機(jī)器轉(zhuǎn)拉時(shí)間制程間 　　 T ime T akt Mac hine Prev ious of Cha nge ove r W IP W IPProc ess to Proc ess ?14 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Process To Process WIP 制程 間 WIP 節(jié)拍時(shí)間前工序機(jī)器轉(zhuǎn)拉時(shí)間程間 　　制 T ime T akt Mac hine Prev ious of Cha nge ove r W IP W IPProc ess to Proc ess ?Example 2: Process A cycle time 15 sec. It is faster then Process B cycle time 25sec. Process A is running 2 product models as capacity requirement. In order to Keep Process line running, process to process WIP is required between Process A and B. The calculation as below: 例 2： 制程 A周期時(shí)間是 15sec，比制程周期時(shí)間 25sec快。為了保證產(chǎn)線正常運(yùn)作，需要在制程 A和制程 B之間設(shè)定制程間 WIP。 2) Is the Takt board defined (on the board)? 節(jié)拍時(shí)間確定了嗎？ (把節(jié)拍時(shí)間寫在白板上 ) 3) Are the Standard WIP defined? 標(biāo)準(zhǔn) WIP有定義嗎 ? 4) Do you know how to separate manual (person39。s) work? 你知道如何區(qū)分手動(dòng)作業(yè)和自動(dòng)作業(yè)嗎 ? 5) Is the Work load leveling defined for man， machine and C/O? 人工 ,機(jī)器以及換線使用工作負(fù)荷均衡表分析了嗎？ 6) Is the H/C calculated based on Takt time? 人力的多少是根據(jù)節(jié)拍時(shí)間計(jì)算出來(lái)的嗎 ? 7) Is the Std work (front page) SWCS (back page) posted in front of each operator? 每個(gè)工站前都有標(biāo)準(zhǔn)作業(yè) (前頁(yè) )和標(biāo)準(zhǔn)作業(yè)合并表 SWCS(背頁(yè) )嗎 ? Operations 操作 17 Operations ( continue ) 操作 (續(xù)頁(yè) ) 8) Is the std work being followed by the operator? 操作員有沒(méi)有按照標(biāo)準(zhǔn)作業(yè)流程作業(yè) ? 9) Is the std work defined for water strider? 有沒(méi)有定義物料員的標(biāo)準(zhǔn)作業(yè) ? 10) Is the operator idle at the station? 在作業(yè)過(guò)程中 ,操作員是否有等待 ? 11) Does the operator search for ponents or tools? Locate all tools and parts within easy access or reach (Doctor Nurse). 在作業(yè)中 ,操作員有沒(méi)有尋找物料或工具的動(dòng)作 ? 工具或物料應(yīng)該放置在易于獲取的位置 ,定點(diǎn)定位 .(遵循醫(yī)生和護(hù)士概念： Doctor醫(yī)生 ,指直接作業(yè)的人員 ,nurse護(hù)士 ,指輔助作業(yè)人員 ,如物料員 ) 12) Do you have std work for inspection station? 檢查工站有沒(méi)有標(biāo)準(zhǔn)作業(yè)書 ? 13) Do you have shortest cycle time for inspection? 對(duì)于檢查工站 ,有沒(méi)有定義最短周期時(shí)間 ? 18 Operations ( continue ) 操作 (續(xù)頁(yè) ) 14) At the hand load station, do you apply doctor and nurse concept? 在手工作業(yè)工站 ,有沒(méi)有運(yùn)用醫(yī)生和護(hù)士理念 ? 15) Do you meet the target of 3 sec per ponent during insertion at hand load? 在手插工站 ,有沒(méi)有達(dá)到每 3 秒一顆零件的插件速度 ? 16) SIC less at hand load station (with template). 手插工站不需要 SIC(用模板來(lái)顯示需要插件的位置 )? 17) Hand load manual CT Takt time nurse not required. Are there system in place to stop work when abnormal conditions arise? 當(dāng)手動(dòng)作業(yè)的周期時(shí)間小于節(jié)拍時(shí)間時(shí)，不需要 ” 護(hù)士 ” (護(hù)士 nurse:輔助作業(yè)人員 ) 當(dāng)異常情況出現(xiàn)時(shí) ， 有沒(méi)有系統(tǒng)來(lái)控制停止作業(yè) ? 18 ) Does the supervisor respond in a quick/crude manner? 當(dāng)異常發(fā)生時(shí) ， 管理人員的反映是快速還是遲鈍 ? 19) Do you have 6S implemented on your line? 線上有實(shí)行 6S嗎 ?(6S=5S+Safety) 19 Operations ( continue ) 操作 (續(xù)頁(yè) ) 20) Is the production qty for the day defined? 日 產(chǎn) 量有沒(méi)有定 義 ? 21) Is the Multi skill charts visible and available? 有沒(méi)有顯示和使用多技能培訓(xùn)表？ 22) Do you allow banana peeling on the line? 允許在線拆卸物料包裝嗎 ? 23) Are you able to detect bottleneck station at a glance? 瓶頸工站能一眼看出來(lái)嗎 ? 24) The operator must not reorient the part 操作員不允