工厂整理整顿范例.ppt

Guide to Manufacturing PracticesExamples of bad practice and good practiceGMC Team observationsNeed to develop a manufacturing awarenessMust look at everything around youGet to know what is good and what is badDo not be afraid to point out issues or ask questionsIf unsure take a picture and send to Ivy or me第一页，编辑于星期六：二十三点 三十一分。Incoming Inspection-LightingDark,unacceptableWell illuminatedDifficult to see part detail and instrument readings 第二页，编辑于星期六：二十三点 三十一分。Incoming Inspection General AreasInadequate and badly organised areas.Well organised with good instrument storage第三页，编辑于星期六：二十三点 三十一分。Incoming Inspection Material SegregationWell marked and identified areas第四页，编辑于星期六：二十三点 三十一分。Incoming Inspection Customer Reference StandardsParts mixed,not protected,dirty Cupboard storage good,but no poly bagsGold Seal sample not identified Reference samples dirty/corroded第五页，编辑于星期六：二十三点 三十一分。Incoming Goods-Parts WarehouseBadly laid out,no racking,no identificationWell laid out,stacks in bays,racks behind,everything identified第六页，编辑于星期六：二十三点 三十一分。Incoming Goods Parts WarehousePrecision machined componentsbadly stored,probably damagedComponents not protected fromcorrosion第七页，编辑于星期六：二十三点 三十一分。Materials Handling&IdentificationNo item has any identification,cages have mixed parts第八页，编辑于星期六：二十三点 三十一分。Materials Handling&Identification-GearsMust not have tooth to tooth contact,will cause damage.Parts corrodedParts well protected from damage and corrosion第九页，编辑于星期六：二十三点 三十一分。Materials Handling&Identification Gear S/AGood handlingGear teeth not touching第十页，编辑于星期六：二十三点 三十一分。Materials Handling&Identification-Grease Bad practiceGoodContamination/quantity Clean and measured第十一页，编辑于星期六：二十三点 三十一分。Materials Handling&Identification-MotorsBadGood separation,but-Bad第十二页，编辑于星期六：二十三点 三十一分。Materials Handling&Identification-MotorsHandling methods do nothave to be high tech!第十三页，编辑于星期六：二十三点 三十一分。Materials Handling&IdentificationUse of defect and good bins for good(?)parts,no identificationCastings stacked too high,damage riskAt the same place good handling第十四页，编辑于星期六：二十三点 三十一分。Materials Handling&Identification-PackagingNo component protectionPackaging must protect from weight and damage第十五页，编辑于星期六：二十三点 三十一分。Materials Handling&IdentificationEvery container must be identified,not just one per batch第十六页，编辑于星期六：二十三点 三十一分。Materials Handling&IdentificationGood and defect part must neverbe in the same container,even ifidentifiedGood Rejected第十七页，编辑于星期六：二十三点 三十一分。Materials Handling&IdentificationMachined diameter/bearing damageHandling must take weight andComponent finish into consideration Surface finish/bracket distortion第十八页，编辑于星期六：二十三点 三十一分。Materials Handling&Identification-LiquidsOpen cans of paintOpen to dirt ingress.If solvent based,will deteriorate/present safety risk第十九页，编辑于星期六：二十三点 三十一分。Materials Handling-ProtectionDirt and corrosion are totally unacceptable第二十页，编辑于星期六：二十三点 三十一分。Materials Handling-ProtectionPoor protection between Side and layers protectedparts,none around cage第二十一页，编辑于星期六：二十三点 三十一分。Tooling Materials Handling-ProtectionWindings allowed to contact each othercables trail on floor第二十二页，编辑于星期六：二十三点 三十一分。Tooling Materials Handling-StackingToo high,no protection and unsafeDamage riskGood,but watch trailing cables第二十三页，编辑于星期六：二十三点 三十一分。Tooling Materials Handling-ContaminationAll materials should be protected from contaminationThis moulding material is open to any rubbish being thrown in第二十四页，编辑于星期六：二十三点 三十一分。Materials Handling The Right WayExcellent!第二十五页，编辑于星期六：二十三点 三十一分。Process InstructionsShould have details ofall process settings,material(inc.regrind%),tooling and gauging第二十六页，编辑于星期六：二十三点 三十一分。Process InstructionsGood display position,closeto operator and visible第二十七页，编辑于星期六：二十三点 三十一分。Process ControlTorque control inadequateParts do not fit the gaugeNo gauging on CTQ featuresNo temperature control第二十八页，编辑于星期六：二十三点 三十一分。Operator InstructionsPoor,large drawing for small detail,should just show red area in same overall sizeVery good,colour schematicwith parts identified with locationand part number第二十九页，编辑于星期六：二十三点 三十一分。Operator InstructionsSpot the instruction sheet!Good display,wrong instructionsfor the operation第三十页，编辑于星期六：二十三点 三十一分。Operator InstructionsBadly displayed,not visibleto the operators第三十一页，编辑于星期六：二十三点 三十一分。Operator InstructionsGood instructionsGood display positions第三十二页，编辑于星期六：二十三点 三十一分。Operator InstructionsGood general displayManagement must to followown adviseUpstairsDownstairs第三十三页，编辑于星期六：二十三点 三十一分。Operator InstructionsInstructions must always be visible to the operator!第三十四页，编辑于星期六：二十三点 三十一分。CalibrationEvery item that measures shoulddisplay a date coded labelEspecially process critical equipment!第三十五页，编辑于星期六：二十三点 三十一分。CalibrationAll instruments on one operation,no calibration stickers第三十六页，编辑于星期六：二十三点 三十一分。Tooling-Bearing PressingOnto shaftInto housingPress Tool Position Always on the bearing race where the press force is:i.e.The tool should touch both green points,and never the red points for each applicationTools should be clean and in good condition,see picturesLoad第三十七页，编辑于星期六：二十三点 三十一分。Tooling Bearing PressingCrude,damaging and dangerousRough and inaccurate toolingIncorrect design,pressing on wrong part第三十八页，编辑于星期六：二十三点 三十一分。Tooling&FixturesOperators should have fixtures to hold the partsand orientate the parts for ease of assembly No fixture,difficult operation Crude but effective fixture第三十九页，编辑于星期六：二十三点 三十一分。Tooling&FixturesNo fixture,awkward shaped item to assembleHalf a fixture,but operator needstwo hands to hold,and he still has to press the pin fully in第四十页，编辑于星期六：二十三点 三十一分。Tooling&FixturesCorrect tools should be usedA screwdriver as a hammerA steel hammer on aluminium第四十一页，编辑于星期六：二十三点 三十一分。Tooling&FixturesOperators should have the correct tooling for the operationLaser setting fixture Above is the old fixture,below is the new one第四十二页，编辑于星期六：二十三点 三十一分。Tooling&FixturesSimple plastic press tooling to insert field into housing,prevents damage to both parts第四十三页，编辑于星期六：二十三点 三十一分。Tooling&Fixtures-PackagingBench too smallNo bench!第四十四页，编辑于星期六：二十三点 三十一分。Product and Component QualityWould the inspector spotTable edge damageDents and scratchesDangerously sharp flash第四十五页，编辑于星期六：二十三点 三十一分。Product and Component QualityAll unacceptablePoor handlingPoor castingPoor machining第四十六页，编辑于星期六：二十三点 三十一分。Product and Component QualityPick up parts,check quality.These are not suitable for GMCBad weldingPoor paintingCorrosion under paint第四十七页，编辑于星期六：二十三点 三十一分。Product and Component QualityUnacceptable:FitLabel and over stickerGapLabel application第四十八页，编辑于星期六：二十三点 三十一分。Product and Component QualityComponents must match Gold Seal sampleNo splice on wiresNo identification on lasers第四十九页，编辑于星期六：二十三点 三十一分。Product and Component QualityThere should be no swarf on an assembly line,either transferred with machined parfts,or produced by assemblyoperations(filing&drilling)第五十页，编辑于星期六：二十三点 三十一分。Product and Component Quality-ColourHow many shades of yellow?第五十一页，编辑于星期六：二十三点 三十一分。Product and Component Quality-Packaging第五十二页，编辑于星期六：二十三点 三十一分。Product and Component Quality-Packaging第五十三页，编辑于星期六：二十三点 三十一分。Product and Component Quality-PackagingLACK OF CARE第五十四页，编辑于星期六：二十三点 三十一分。Processes Layout/Housekeeping第五十五页，编辑于星期六：二十三点 三十一分。Processes Layout/HousekeepingFirst class layout,housekeepingand staff communication第五十六页，编辑于星期六：二十三点 三十一分。Processes Layout/HousekeepingBenches can be well laid out and tidy第五十七页，编辑于星期六：二十三点 三十一分。Processes Layout/HousekeepingEvery operation must have a red defect parts bin,identified as suchRed bins must not be used for good parts第五十八页，编辑于星期六：二十三点 三十一分。Testing Finished Product AuditNo benchesNo documentationNo actionNo good!Good equipmentGood documentationGood trainingGood audit 第五十九页，编辑于星期六：二十三点 三十一分。Product Testing User Testing AreasLittle or no useWell used第六十页，编辑于星期六：二十三点 三十一分。Product Testing Life/Endurance TestCheck that every unit is actually running during the testCheck that the operator checks thisDo fixtures protect product from marking during test?第六十一页，编辑于星期六：二十三点 三十一分。Factory Standards E&E IssuesFirst aid boxes must be well stocked and cleanSigns must indicate where the first aid station is located,and who is trained to administer first aid.A log of accidents must be kept.第六十二页，编辑于星期六：二十三点 三十一分。Factory Standards E&E Issues Dangerous Items120VOpen wiresGasolineCleaning fluidGrinder第六十三页，编辑于星期六：二十三点 三十一分。Factory Standards E&E IssuesFlammable materials in production stores next to combustible materials Food items in production area第六十四页，编辑于星期六：二十三点 三十一分。Factory Standards E&E IssuesCorroded drinking water facilityDangerous live wiring第六十五页，编辑于星期六：二十三点 三十一分。Factory Standards E&E Issues-SafetyBlocked aislesNo fume extractionDangerous wiring 第六十六页，编辑于星期六：二十三点 三十一分。Factory Standards E&E IssuesBlocked/restricted fire escapes第六十七页，编辑于星期六：二十三点 三十一分。