精益生产之快速换线技巧.ppt

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1、Quick Changeover (SMED)快速换型快速换型 An Indy 500 pit crew will do:F1 方程式赛车快速更换方程式赛车快速更换Change 4 tires 换4个轮子Top off the fuel tank 加满油箱Adjust the air wing 调整空气囊保护Check the on-board computer 检查车上计算机Give the driver a drink 给驾驶员一听饮料2We can learn from the pit crew我们从中学到了我们从中学到了什么？什么？Standardized method for a p

2、it stop 标准化的停车方法Elements of quick change are applied throughout 快速更换方法贯穿整个过程A place for everything and everything in its place 所需要的工具随手可得Things that can be done ahead of time 提前做好准备We can apply these ideas toWe can apply these ideas toour manufacturing environmentour manufacturing environment3Benefi

3、t for Setup Time Reduction减少换模时间的好处减少换模时间的好处We can produce more,because we have added capacity 我们可生产更多，因为我们增加了产能We can lower inventory levels and save the money associated with inventory 我们可减少库存和与库存有关的资金 We can approach the goals of flow manufacturing:我们可达到流动制造的目标Make only what is required 只生产需要的产品M

4、ake it when it is required 只是在需要的时候生产Zero finished goods inventory 零成品库存1 piece lot sizes 单件批量生产46 Steps To Reduce Setup Time降低换模时间的降低换模时间的6个步骤个步骤1.Select cross-functional team 组成跨部门的团队2.Observe complete set up 观察整个当前换模过程3.Separate external from internal elements 将外部和内部换模的部分离开4.Convert internal to e

5、xternal elements 尽可能的将内部换模的部分转移到外部换模5.Streamline all aspects of the setup 优化所有的换模动作的顺序6.Standardize set up procedure 标准化换模过程Repeat steps 2-6 until goal is met重复以上步骤直到达到目标重复以上步骤直到达到目标5Step 1:Select the team组建团队组建团队Kaizen Team:Ideal Size-(6-8 People)最好68人Hourly operators from all three shifts 来自不同班次的操

6、作工Someone from“outside”the process 与此过程无关的人Mfg Engineering representation 制造工程师的代表Other Technical resource(s)as appropriate 其他相关的技术支持 6Step 2:Observe the complete set up观察整个过程观察整个过程Definition:Set up time is the time from the last good piece with old tools to the first good piece with new tools 定义换模时

7、间：是指从旧模的最后合格件到新模的第一个合 格件的时间Watch and write down every activity that happens 观察并记录所有的活动Record a video of the process for the team to review 录像换模的整个过程，用来回顾Build a process map that defines the current state 建立反映当前状况的流程图7Step 3:Separate internal from external elements 将内部和外部的动作区分开将内部和外部的动作区分开External ac

8、tivities are those that can be accomplished while the machine is running 外部动作是指当即机器在运转时就能完成的动作Move material for the next job to the machine 将下个工作需要的材料移到及其附近Retrieve prints,control plans,and documentation for the next job 准备好下一个工作需要的图纸，控制计划和文件Move tooling next to the machine 将模具移到及其附近Internal activit

9、ies are those that can only be done while the machine is down 内部动作是指只有把机器停下来才可以做的动作The physical changing of tooling 实际更换模具的动作8Which are external and internal?哪些是外部和内部的动作Putting the tires in the pit 将轮胎放到现场Taking the old tires off the car 换下旧轮胎Refueling the car 给赛车加油Bringing the fuel line to the pit

10、将加油管拿到现场Getting a beverage for the driver 给驾驶员一听饮料Jacking up the car 将赛车顶起来-External-Internal-Internal-External-External-Internal9Step 4:Convert internal to external elements尽可能的将内部换模的部分转移到外部换模尽可能的将内部换模的部分转移到外部换模This is the most critical step in the process 这是再换模过程中最关键的一步This step can reduce total s

11、et up time by 60-65%这一步能减少整个换模时间的60-65%This step is based on operational improvement,not equipment improvement 这一步是依赖于操作的改进，而不是设备的改进Prepare all tools applicable 将需要的工具准备好Bring tools to convenient locations 将工具放在最方便的位置Eliminate transportation of heavy items(dies and punches)消除沉重物品的转移（注塑模）Whenever pos

12、sible,prestage tools,materials,and dies for next job while the current job is running在机器运转时，尽可能的提前为下一个工作将工具，材料和工装准备好10What does Step 4 do for us?第步作了什么Machine DownMachine StartTime LineInternalExternalCurrentAfter Step 4ExternalInternal11Step 5:Streamline all aspects of the set up process优化所有的换模动作的顺

13、序优化所有的换模动作的顺序For everything that remains internal,identify process improvements to make the internal elements quicker对内部换型的操作，识别出改进的地方是内部换模更快Eliminate nuts and bolts 消除螺栓和螺母的紧固动作Introduce quick change tools 引进快速更换的工具Standardize 标准化Eliminate adjustments 消除调整For the external activities,focus on reduci

14、ng the time that is lost searching for set up hardware and set up information对外不换型的操作，集中在由于寻找换型所需的硬件和信息所浪费的时间上Consolidate paperwork into one document 将纸面工作汇总在一个文件上Mark dies with color codes and location numbers for where they are stored 在存放模具的地方对模具用颜色和位置编号进行标示12What does Step do for us?第第步步做做了什么了什么M

15、achine DownMachine StartTime LineInternalExternalCurrentAfter Step 4ExternalInternalAfter Step 5ExternalInternalAfter Step 513Step 6:Standardize the set up procedure标准化快速换型的过程标准化快速换型的过程Determine the one correct way to perform the activities决定正确的方式进行快速换模的活动Document the standard way in the SOE/OMS在SOM/OMS建立标准的规范Train and Certify all operators to the standard按新标准培训操作员并进行确认新标准得以实施14What does Step do for us?第步做了什么Time LineExternalInternalAfter Step 5Machine DownMachine StartInternalExternalCurrentAfter Step 4ExternalInternalAfter Step 5What does Step 6 do for us?第6步做了什么15What Is The Next?16