《[精选]IE线平衡改善.pptx》由会员分享，可在线阅读，更多相关《[精选]IE线平衡改善.pptx（47页珍藏版）》请在taowenge.com淘文阁网|工程机械CAD图纸|机械工程制图|CAD装配图下载|SolidWorks_CaTia_CAD_UG_PROE_设计图分享下载上搜索。
1、When are you going to finish your job?I have been waiting so long!你到底要在什麼時間才能做完你到底要在什麼時間才能做完,我要等我要等到什麼時候到什麼時候?My cycle time is too quick for me!我來不及做了！我來不及做了！Operation Training-線平衡改善線平衡改善Line BalancingCycle Time=6 secondLine Balance=4+5+3+3+4+6+5+4+4+3+3+6+2/6X13=66.66%Line Balance ConceptLine Balan
2、ce ConceptCycle Time=6 secondLine Balance=4+5+6+4+6+5+4+4+3+3+6+2/6X12=72.20%Line Balance ConceptLine Balance ConceptCycle Time=6 secondLine Balance=4+5+6+4+6+5+4+4+6+6+2/6X11=78.80%Line Balance ConceptLine Balance ConceptCycle Time=5 secondLine Balance=5+5+5+5+5+5+4+5+5+5+3/5X11=94.50%Line Balance
3、ConceptLine Balance ConceptCycle Time=4 secondLine Balance=4+4+4+4+4+4+4+4+4+4+4/4X13=100%Line Balance ConceptLine Balance ConceptConveyor speed is too much faster than operators ability.如果傳送帶的速度遠遠快於作業員的作業能力1.1.Too much WIP at the bottle neck station.Too much WIP at the bottle neck station.在瓶頸站將堆積過多
4、的WIP2.Operators lack concentration Waste time to wait for the ing 2.Operators lack concentration Waste time to wait for the ing product or pull the product from the line instead of pleting the product or pull the product from the line instead of pleting the product in hand.product in hand.作業員無法專心作業。
5、等待材料及從正在作業的產品中分心以拿取線上流過的材料。Unbalance Lines Problems 線上不平衡造成的主要問題3.Quality Problem 3.Quality Problem 品質問題3.1 In plete Process 3.1 In plete Process 制程不完善-Insufficient parts -Insufficient parts 作業不全-Parts not properly inserted -Parts not properly inserted 材料未適當裝插-Wrong part being inserted -Wrong part b
6、eing inserted 插件錯件-Wrong side is being inserted -Wrong side is being inserted 插件反向-Not all required points are inspected -Not all required points are inspected 檢查不完備-Did not correctly choose the Select Switch -Did not correctly choose the Select Switch 按錯測試鍵-Did not put all Labels or wrongly placed.
7、-Did not put all Labels or wrongly placed.未全面貼放標籤或錯貼-etc.-etc.Unbalance Lines Problems 線上不平衡造成的主要問題3.2 Defects 3.2 Defects 不良-Damage and dirty -Damage and dirty 破損及污漬-Scratches -Scratches 刮傷-Label-Label scratches scratches 標籤不良等 etc.etc.4.Inspectors need to repair the defects,thus causing additional
8、 4.Inspectors need to repair the defects,thus causing additional time.time.作業員修復不良品將花費多餘工時Unbalance Lines Problems 線上不平衡造成的主要問題5.Line leaders and other supporting people have to waste their 5.Line leaders and other supporting people have to waste their time in assisting and solving the WIP problem a
9、t the bottle time in assisting and solving the WIP problem at the bottle neck station.neck station.組長及其他線外支援人員不得不耗費時間以解決瓶頸站的WIP6.The space available in the line are already very limited,it will be 6.The space available in the line are already very limited,it will be e even smaller.e even smaller.線上空
10、間本來有限，還需佔據空間7.Un-forecastable and uncontrollable output 7.Un-forecastable and uncontrollable output 造造造造成無法預計和控制的產出 8.Decreased Productivity 8.Decreased Productivity 生產力降低Unbalance Lines Problems 線上不平衡造成的主要問題When the conveyor speed is slower than the operators ability.當傳送帶之速度遠慢於作業員的操作能力1.Lost time w
11、ithout output 1.Lost time without output 無產出的異常工時2.Lower output than expected 2.Lower output than expected 低於計劃的產能3.Operators are not active enough,be es dull 3.Operators are not active enough,be es dull 作業員無法積極作業，變得懶散Unbalance Lines Problems 線上不平衡造成的主要問題1.1.4.Must take more time to recover the lost
12、 output 4.Must take more time to recover the lost output 需要安排額外的工作時間以彌補未達成的產能2.2.5.Unit cost be es higher 5.Unit cost be es higher 單位產品的成本增加3.3.6.Decreased Productivity 6.Decreased Productivity 生產力降低4.4.7.Cannot control or forecast the output systematically 7.Cannot control or forecast the output sy
13、stematically 無法系統的控制和預估產能Unbalance Lines Problems 線上不平衡造成的主要問題Step of line balancing線平衡步驟LINE BALANCE is the method used to set up working time of operators in one line as the same as possible.線平衡是盡可能把線上作業員的作業時間安排一致的方法。Line Balancing線上觀察線上觀察分分 析析討討 論論設定標準設定標準標準工時及標準工時及O/IO/I檢討檢討起草作業指導書並檢討起草作業指導書並檢討執
14、執 行行跟蹤情況跟蹤情況正式發行正式發行O/IO/I跟蹤及不斷的改善跟蹤及不斷的改善動動 作作 制制 程程 布布 局局治治 具具方便方便快捷快捷平安平安價廉價廉保障保障合併合併去除去除改善改善重排、調適重排、調適簡化簡化Line Balance ConceptProduction DesignR&DProcess DesignFlow ChartLay OutOperation InstructionMotion&Time StudySeriously continuous follow up產品設計產品設計工程工程制程規劃制程規劃流程圖流程圖布局安排布局安排作業指導書作業指導書成效研究成效研
15、究認真持續的跟蹤情況認真持續的跟蹤情況Line Balance ConceptObservation 觀察觀察Analyze 分析分析Set Norm 設定標準設定標準Man load 安排人力安排人力Implement 執行執行Follow up 跟蹤跟蹤Before&AfterMax,Min,Avg.最大值最大值,最小值最小值,平均數平均數Observation sheet 時間觀測表時間觀測表-bine 合併合併-Eliminate 去除去除-Improve 改進改進-Simple 簡化簡化Productivity Performance 生產力狀況生產力狀況Std.Time 標準工時標
16、準工時 Step of line balanceStep 1.Observation:Step 1.Observation:Observe and timing from the start to end of each process as sample.第一步第一步第一步第一步.觀察觀察:如下所示,按制程從第一站到最後一站觀查並測量時間.Step of line balanceStep 2.Analyze:Step 2.Analyze:Analyze time from observation to define minimum,Maximum and Average.第二步第二步第二步第
17、二步.分析分析:從觀察得出的數據中分析得到最小值，最大值及平均值.Step of line balanceStep 3.Set norm Step 3.Set norm standard timestandard time :Select the time to be used as the standard time at each step.Normally will be the average time.第三步第三步第三步第三步.設定標準設定標準標準時間標準時間:定訂每一站的標準時間.通常使用平均值.Step of line balanceStep 4.Manload:Step 4.M
18、anload:Calculate manpower to be used to produce.These number will be the most effective and balance the production line as much as possible.pare before&After 第四步第四步第四步第四步.人力安排人力安排:計算生產所需的人力.這個數據最有效並能最好的達到線平衡.比較 before&After Step of line balance Step of line balanceStep 5.Implement:Step 5.Implement:U
19、se all data to pare as the Before and After Report.Set up line balance by using the following concept.第五步第五步第五步第五步.執行執行:用所有的數據比較before&after,用以下的觀念平衡生產線.-bine 合併合併-Eliminate 去除去除-Improve,Re-arrange改進改進,重排重排-Simplify 簡化簡化 Step 6.Follow Up:Step 6.Follow Up:Follow up all the implementation continuingly
20、 at least 2 weeks.第六步第六步第六步第六步.跟蹤跟蹤:持續的跟蹤執行情況至少兩星期.Line Balancing BenefitsLine Balancing Benefits 線平衡的優點1.Systematic production output control1.Systematic production output control 系統的產能控制2.Constant flow and distance between each product.2.Constant flow and distance between each product.持續的流水作業3.Red
21、uce operators chance for defect and carelessness.3.Reduce operators chance for defect and carelessness.降低作業員不良及忽略的錯誤4.Loss time reduction and control.4.Loss time reduction and control.降低並控制異常工時.Line Balancing Benefits 線平衡的優點5.Prevention of WIP in the production lines.5.Prevention of WIP in the produ
22、ction lines.防範線上WIP.6.Ease and clear identification of the problems.6.Ease and clear identification of the problems.清楚的問題分析7.When defects are found and separate from the line,it can be very 7.When defects are found and separate from the line,it can be very clearly identifiedclearly identified.不良品的明確
23、標識，以便明確的區分.Line Balancing Benefits 線平衡的優點8.Operators do not have to be worried about the next ing material 8.Operators do not have to be worried about the next ing material when his/her present one is not plete yet.when his/her present one is not plete yet.在作業員進行當前作業時，無需擔心下一個材料.9.Operators can fully
24、 concentrate on their jobs,they do not have to 9.Operators can fully concentrate on their jobs,they do not have to care about others ability to finish their work on time or not.care about others ability to finish their work on time or not.作業員全心投入工作,無需擔心其他組員的作業狀況.10.The constant distance between prod
25、ucts can prevent damages from 10.The constant distance between products can prevent damages from direct hits.direct hits.產品之間的間隔可防止直接碰撞產生的損害THE ENDLine Balance Example線平衡範例線平衡範例Cycle Time Bottle neck 瓶頸瓶頸 =9.85 secondLine Balance efficiency =Total time/Bottle neck cycle time*O/P No.線平衡率線平衡率 =總工作時間總工
26、作時間/瓶頸站瓶頸站cycletime*cycletime*作業員人數作業員人數.=67.45%-Before Improvement 改善前PROCESSSEC-Improvement:Improve process of producing such as Bottle neck-改善改善:改善生產制程如瓶頸站改善生產制程如瓶頸站Cycle Time Bottle neck瓶頸 =7.47 second Avg of winding Line Balance efficiency 線平衡率 =Total time/Bottle neck cycle time*O/P No.總工作時間/瓶頸
27、站cycle time*作業員人數.=83.80%PROCESSSECBefore Improvement 改善前改善前After Improvement 改善後改善後Solder pressed wire before Solder trimming Press 焊理線站後焊壓線焊理線站後焊壓線Separate pressing wire activity for each process壓線部份獨立出來壓線部份獨立出來-Eliminate:Decrease Loss or unnecessary process-去除去除:去除不必要及造成延誤的制程去除不必要及造成延誤的制程Method:e
28、liminate pressing Margin Tape process by asking operator to use Tape T26 over Margin Tape方法方法:去除壓膠布的制程去除壓膠布的制程,要求作業員在空白膠外使用要求作業員在空白膠外使用T26T26膠膠 Cycle Time Bottle neck 瓶頸 =7.35 secondLine Balance efficiency 線平衡率 =Total time/Bottle neck cycle time*O/P No.總工作時間總工作時間/瓶頸站瓶頸站cycle time*作業員人數作業員人數.=84.58%S
29、ECPROCESS Before&after station winding wrap margin tape station winding wrap margin tape-bine:bine process by using motion and time study-合併合併:根據成效學合併制程根據成效學合併制程Cycle Time Bottle neck瓶頸 =7.35 secondLine Balance efficiency線平衡率 =Total time/Bottle neck cycle time*O/P No.總工作時間總工作時間/瓶頸站瓶頸站cycle time*作業員人
30、數作業員人數.=92.14%Method:bine encasing Corestation 4 and input Clipstation 5 together.方法方法:合併包鐵芯合併包鐵芯第第4 4站站 和上耳夾第和上耳夾第5 5站站.PROCESSSEC-Simple:Using fixture to help operator.-簡化簡化:使用制具幫助作業員使用制具幫助作業員.Cycle Time Bottle neck 瓶頸 =7.10 secondLine Balance efficiency 線平衡率 =Total time/Bottle neck cycle time*O/P
31、 No.總工作時間總工作時間/瓶頸站瓶頸站cycle time*作業員人數作業員人數.=94.65%SECPROCESSBefore Improvement 改善前改善前After Improvement 改善後改善後Soldering have to pickup work from Fixture one by one after process 焊錫站需要從線上一個一個焊錫站需要從線上一個一個拿取拿取Make New fixture which can release all work in the same time 作新制具以便同時作業作新制具以便同時作業 Before&After
32、at station soldering paring Improvement 比較改善前後比較改善前後In the case of improve Bottle neck and decrease operator改善改善 瓶頸站瓶頸站 並減少作業員並減少作業員In case of stable input hour and improve Bottle neck如果投入不變而改善瓶頸站如果投入不變而改善瓶頸站Remark Std.time per piece will decrease and line balance efficiency will be higher說明說明:單位產品所
33、需的標準工時將減少，線平衡率將提升單位產品所需的標準工時將減少，線平衡率將提升 paring Improvement 比較改善前後比較改善前後 Adjust line balance incase of produce lower than Plan 調整線平衡調整線平衡Daily Variance Report 每日差異報表每日差異報表As follow up from variance Report,the first hour has variance of 100 pieces lower than plan.If production line wants to produce co
34、ver variance,The conveyer is need to be adjusted as follow:Cycle time 5 sec從每日差異報表的跟蹤情況可知,第一個小時較計劃有100個差異.如果生產線希望趕上計劃,傳送帶需做如下調整:Cycle time 5 sec In case of produce less than planExample范例范例 Cycle time 5 sec 8.25 Hours for one day一天8.25 小時=31500 sec target 6300 pcs.First 1.20 hour第1.20小時=4800 sec pro
35、duced 860 pcs.Work have to be produce必須完成必須完成=6300-860 =5440 Pcs =31500-4800 =26700/5440 =4.94 secThen the conveyer have to be adjust to 4.94 sec in order to cover Variance In case of operators could do 為了去除差距傳送帶速度需調整為為了去除差距傳送帶速度需調整為 4.94 假設作業員能做到假設作業員能做到 Method of increasing Productivity生產力提升之方法生產力
36、提升之方法Output Stable 產量不變,Input Decrease投入減少Output increase 產量增加,Input Stable 投入不變Output increase 產量增加,Input Decrease 投入減少Output increased much more than Input產量的增加速度遠遠超出投入的增加速度Output Decreased much more than Input產量的減少速度遠遠超出投入的減少速度 Benefit of Using Conveyer1.Reduce the expense of transportation or pr
37、oduct movement.降低運輸費用及產品的搬運降低運輸費用及產品的搬運.2.Reduce time to move or store work in process Wip.降低在制品移動及儲存的時間降低在制品移動及儲存的時間.3.Reduce expense of tool or pallet to keep Work in process.減少制具及盤子費用以便工作在線上作業減少制具及盤子費用以便工作在線上作業.4.Use very few space for production line because there are no need space for store and
38、 Wip movement.生產線使用少量的空間因沒有必要為線上儲存材料而佔據空間生產線使用少量的空間因沒有必要為線上儲存材料而佔據空間.5.If has a good line balancing,work will be flown through from start to stop.工作從線頭流到線尾將會有較好的線平衡工作從線頭流到線尾將會有較好的線平衡.6.Lower Work in Process in production line,Each station will have only piece to produce.減少線上在制品減少線上在制品,每一站只有一個產品生產每一站
39、只有一個產品生產.7.If the process has been balanced effectively the production line will be fast and effective 如果生產線得到有效的平衡，生產線會更快捷如果生產線得到有效的平衡，生產線會更快捷8.If plan to produce only one model,the quality of work will be better because of the process of checking 如果只生產一個機種如果只生產一個機種,品質和產量會更好。品質和產量會更好。9.Easy to cont
40、rol quantity and quality if the process of producing are stable.如果生產制程穩定，產品品質和產量都會更易控制如果生產制程穩定，產品品質和產量都會更易控制.10.Easy to track the NG product,the line can be stop and correct.更容易對不良品進行跟蹤更容易對不良品進行跟蹤,可以把線停下並糾正可以把線停下並糾正.11.Build up team building in between operators,If some station is slower than others
41、 the performance of all line will be low.在作業員中建立團隊合作意識在作業員中建立團隊合作意識,如果一些站別較慢，整條線都會受影響如果一些站別較慢，整條線都會受影響.12.Make line leader more active,If some error or mistake occur in the line,the work will be NG for all the line also.組長會更加積極組長會更加積極,如果線上某站出問題整條線都會被影響如果線上某站出問題整條線都會被影響.Benefit of Using ConveyerlPQCD
42、SMP=ProductivityQ=QualityC=CostD=Delivery S=SafetyM=Morale 5-S1.Process Flow Design 制程規劃制程規劃2.Design Work Flow 流程規劃流程規劃3.Line Layout 線上布局規劃線上布局規劃4.Establish Standard Time and Man-load 設定標準工時及人力需求設定標準工時及人力需求5.Line Balancing 線的平衡線的平衡6.Issue Operation Instruction for Lines 發行作業指導書發行作業指導書7.Observe Motio
43、n,Time Study and Measurement 就動作的成效進行衡量及研判就動作的成效進行衡量及研判IE Function8.Follow-up and Continuous Improvement 跟蹤情況並不斷改善跟蹤情況並不斷改善9.Daily corrective and preventive supports on Production problems 每日就生產線問題進行更正及防范支援每日就生產線問題進行更正及防范支援10.Cost Analysis 成本分析成本分析11.Co-operate with other concerned departments for i
44、mproving and developing the process and product,i.e.quality,cost reduction,capacity upgrade etc.就制程和產品改善方面與相關的部門合作，如：產品品質、降就制程和產品改善方面與相關的部門合作，如：產品品質、降低成本、產能提升等等。低成本、產能提升等等。12.Other jobs as assigned 其他交辦事項其他交辦事項IE Function9、静夜四无邻，荒居旧业贫。11月-2311月-23Sunday,November 26,202310、雨中黄叶树，灯下白头人。05:13:1105:13:1
45、105:1311/26/2023 5:13:11 AM11、以我独沈久，愧君相见频。11月-2305:13:1105:13Nov-2326-Nov-2312、故人江海别，几度隔山川。05:13:1105:13:1105:13Sunday,November 26,202313、乍见翻疑梦，相悲各问年。11月-2311月-2305:13:1105:13:11November 26,202314、他乡生白发，旧国见青山。26 十一月 20235:13:11 上午05:13:1111月-2315、比不了得就不比，得不到的就不要。十一月 235:13 上午11月-2305:13November 26,2
46、02316、行动出成果，工作出财富。2023/11/26 5:13:1105:13:1126 November 202317、做前，能够环视四周；做时，你只能或者最好沿着以脚为起点的射线向前。5:13:11 上午5:13 上午05:13:1111月-239、没有失败，只有暂时停止成功！。11月-2311月-23Sunday,November 26,202310、很多事情努力了未必有结果，但是不努力却什么改变也没有。05:13:1105:13:1105:1311/26/2023 5:13:11 AM11、成功就是日复一日那一点点小小努力的积累。11月-2305:13:1105:13Nov-232
47、6-Nov-2312、世间成事，不求其绝对圆满，留一份缺乏，可得无限完美。05:13:1105:13:1105:13Sunday,November 26,202313、不知香积寺，数里入云峰。11月-2311月-2305:13:1105:13:11November 26,202314、意志坚强的人能把世界放在手中像泥块一样任意揉捏。26 十一月 20235:13:11 上午05:13:1111月-2315、楚塞三湘接，荆门九派通。十一月 235:13 上午11月-2305:13November 26,202316、少年十五二十时，步行夺得胡马骑。2023/11/26 5:13:1105:13:
48、1126 November 202317、空山新雨后，天气晚来秋。5:13:11 上午5:13 上午05:13:1111月-239、杨柳散和风，青山澹吾虑。11月-2311月-23Sunday,November 26,202310、阅读一切好书如同和过去最杰出的人谈话。05:13:1105:13:1105:1311/26/2023 5:13:11 AM11、越是没有本领的就越加自命非凡。11月-2305:13:1105:13Nov-2326-Nov-2312、越是无能的人，越喜欢挑剔别人的错儿。05:13:1105:13:1105:13Sunday,November 26,202313、知人者
49、智，自知者明。胜人者有力，自胜者强。11月-2311月-2305:13:1105:13:11November 26,202314、意志坚强的人能把世界放在手中像泥块一样任意揉捏。26 十一月 20235:13:11 上午05:13:1111月-2315、最具挑战性的挑战莫过于提升自我。十一月 235:13 上午11月-2305:13November 26,202316、业余生活要有意义，不要越轨。2023/11/26 5:13:1105:13:1126 November 202317、一个人即使已登上顶峰，也仍要自强不息。5:13:11 上午5:13 上午05:13:1111月-23MOMODA POWERPOINTLorem ipsum dolor sit amet,consectetur adipiscing elit.Fusce id urna blandit,eleifend nulla ac,fringilla purus.Nulla iaculis tempor felis ut cursus.感感 谢谢 您您 的的 下下 载载 观观 看看专家告诉