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1、The Lean EnterpriseThe Lean EnterpriseSet-up Reduction/Quick ChangeoverLean FoundationsLean FoundationsContinuous Improvement TrainingContinuous Improvement TIntroduction to Set-up Reduction/Quick Changeover Conceptsbased on a technique commonly calledbased on a technique commonly called SMED-Single
2、 Minute Exchange of DieSMED-Single Minute Exchange of DieUnderstand the concepts and principles of Set-up Reduction.Share some ideas and understand the benefits of Set-up Reduction.Apply the concepts,principles and techniques of SMED to accomplish Quick Changeovers!OTeam BeliefsFSafety comes firstFQ
3、uality and superior customer satisfaction is our ultimate goalFPeople are our most valued resource FBlameless environmentFContinuous improvement is a way of lifeFTeamwork(customer,supplier,associates)FIntegrity is never compromisedFWe manage by facts(with data)?What is SMED?SMED stands for:Single Mi
4、nute Exchange of Die Ideally,set-up time should be anything less than 10 minutes Decreased set-up time;reduces the need for inventory,provides more flexibility and capacity,enables us to better serve our customer!Benefits of Quick ChangeoverLess adjustments means less chance for errorsElimination of
5、 trial processing reduces material wastePreparation of operating conditions in advance helps stabilize product qualityIncreases scheduling flexibility/capacityReduces need for on-hand inventoryImproved service levels for customersSmaller runs means less likelihood of large scale defect problems in S
6、et-up TimeDiesToolsMaterialsFirst Good PieceLast Good PieceTotal elapsed TimeFSet-up Timeany set-up time can be reduced by 59/60ths!Shigeo Shingo(wrote the book on SMED)believed that:Set-up TimeThere are two types of setup time:Internal Set-up:Those activities that must be performed while the machin
7、e is shut down.(Work content done in addition to Machine Time.)Example:Removing dies and toolingExternal Set-up:Those activities that are performed while the machine is operating.Example:Preparing tooling for the next set-Set-up Reduction Process1.Observe and document the current set-up.2.Separate I
8、nternal and External elements.3.Improve each element.4.Observe and document the new set-up process.5.Standardize the new set-up procedure.6.Celebrate your success!Observe and Document the Current Set UpA.Select a specific set-up for improvementB.Identify a set-up“kaizen”team.C.Observe the set-up pro
9、cess:Video Record the set-up processComplete the Set-up Operations Analysis chart(before Kaizen).D.Prepare a Pareto chart for each time Record and Recommend During this phase we:Observe and document the existing set-up procedure usingTime Observation and Video Recording techniques-Analyze all work e
10、fforts-Identify short-term solutions that can be implemented with procedural changes,modifications to existing fixtures and minor investment in toolingVideo Recording Tipsw Collect background data-Select regular production“Parts”-Determine equipment and operationw Prepare/Evaluate site-Where does op
11、erator stand?-Where is the best position for the camera?-Is there adequate lighting?w Narrate-Describe what is happening when the operator blocks the camera or leaves the area.Analyze theTime Observation&Video w Review Time Observation and Video with the teamw Identify opportunities-Internal vs.Exte
12、rnal-Value Added Vs Non-Value Added-Normal vs.Abnormal-Seven Types of Waste-Automatic,Manual,Walking,-and Waiting timesw Solicit ideas for countermeasures/improvementsObserve and Document the Current Set UObserve and Document the Current Set-up Searching-Looking for tools,jigs,fixtures,etc.Fixture C
13、hange-Replacing one fixture with another Tool Change-Replacing existing tooling Programming-Making adjustments or changes to a CNC program in order to accommodate the new set-up Walk time-The time an operator must walk to retrieve a fixture,tools etc.1st Piece-The time required to produce a good uni
14、t after the initial set-up Gage-The time required to qualify the 1st Pareto Analysis on each Time CSeparate the ElementsInternal:Those activities that must be performed while the machine is shut down.Example:Removing dies and toolingExternal:Those activities that are performed while the machine is o
15、perating.Example:Acquire fixture/tools for next set-upBoth types of actions must be separated.Once the machine is stopped,the associate should never depart to perform any part of the external set Separate the EDevelop Improvement Plan5S+1(6S)discipline is the key to quick changeover!Every minute spe
16、nt looking for tools,fixtures,drawings,dies,jigs or other materialsadds to the set-up time.A strong 5S foundation,with a point-of-use(POU)methodology,will ensure that all required materials are in place when needed,are clean,and in working Develop Improvement PlanRemember the Wastes?(refer to the 7W
17、s)Defects Over-Production(inventory)Transportation Waiting Inspection(mass)Motion Processing,itself+“Unused Creativity”Storage areafor DiesTool CartPunch PressTool RDevelop Improvement PlanSpecifically:A.Convert as much of the internal set up to the external set up.B.Eliminate or reduce the internal
18、 and external set up.C.Eliminate the adjustment process.Ultimate Goal:Eliminate Set-up! Steps:Reduce internal work gradually Steps:Reduce internal work gradually eliminate unecessary work eliminate unecessary work measureseparatereduce/eliminateconvertinternalinternalinternalexternalexternalexternal
19、(repeat)Employ Improvement InitiativesOnce as much of the internal set-up has been converted to external set-up and waste has been eliminated:standardize the external set-up actionsutilize quick fastenersuse supplementary tools at the point of use(POU)Employ Improvement InitiativesDeveloping the Imp
20、rovement Plan:What must be done while the machine is shut down?8What can be done while the machine is running?8Challenge every element in the set-up!8Establish a sound 6S(5S+1)Improvement Checklist an example Station tools,jigs,dies,etc.near the machine.(POU)Assure that all jigs,gauges,dies,tools,et
21、c.function before the set-up begins.Perform as many External elements as possible prior to the set-up.Two people working together may reduce net set-up timeUse functional clamps:One turn/One motionUse visual control to eliminate Application Best Practices1)Make minor modification to the existing fix
22、tures.2)Implement Point-of-Use(POU)techniques.3)Identify additional tooling to remove attachment from internal to external.4)Adopt standardized tooling.5)Document time savings.Application Best Practices-ContinuedFor example:w Slots in fixture and T-Bolts reduce attachment time.w A new part holder re
23、duced the time required to load and unload parts to fixture.Swing hook eliminated the need to remove nut from bolt.w Extra set slides allow detach to be completed on external time.Other ideas1.Quick Changeover begins and ends with the 5Ss.2.Change the Internal set-up into External,then improve the r
24、emaining Internal set-up time.3.Bolts are our Enemies.4.If you have to use your hands make sure your feet stay put.5.Dont rely on Special Fine-tuning skills.6.Standards are standard:they are NOT flexible.7.Standardize all SMED OIdeasThe die heights of a punch press or molding machine can be standard
25、ized by using the liner(spacer)so that stroke adjustment will be unnecessary.Source:Toyota Production System-Yasuhiro MIdeasExamples of Quick Fasteners Usually a bolt is the most popular fastening tool.But because a bolt fastens at the final turning of the nut can loosen at the first turn,a convenie
26、nt fastening tool that would allow only a single turning of the nut should be devised.Source:Toyota Production System-Yasuhiro M I IFor example:w A slide clamp reduced the time required to load and unload parts to fixture.w 2 hold-down clamps eliminated the need to tape parts during a glue-up operat
27、ion.w Set slide allows quick(temporary)alignment of 2 parts.IdeasDocument the New Set-upA.List each element on the Set-up Operations Standard Chart(after Kaizen)B.Video tape the new set-up procedure.C.Record the set-up time for each elementD.Note areas for future Standardize the New PStandardize the
28、 New ProcedureThe Set-up Operations Standard chart will become the basis for the new set-up procedure.Prepare the appropriate detail and work instructions that will be included on the Set-up Operations Standard chart.Assure that all appropriate personnel are trained in the new The Lean EnterpriseThe Lean EnterpriseSet-up Reduction/Quick ChangeoverLean FoundationsLean FoundationsContinuous Improvement TrainingContinuous Improvement T