IE线平衡改善

IE线平衡改善〔46页)LineBalancingCycleTime=6secondLineBalance=(4+5+3+3+4+6+5+4+4+3+3+6+2)/(6X13)=66.66%LineBalanceConceptCycleTime=6secondLineBalance=(4+5+6+4+6+5+4+4+3+3+6+2)/(6X12)=72.20%LineBalanceConceptCycleTime=6secondLineBalance=(4+5+6+4+6+5+4+4+6+6+2)/(6X11)=78.80%LineBalanceConceptCycleTime=5secondLineBalance=(5+5+5+5+5+5+4+5+5+5+3)/(5X11)=94.50%LineBalanceConceptCycleTime=4secondLineBalance=(4+4+4+4+4+4+4+4+4+4+4)/(4X13)=100%LineBalanceConceptConveyorspeedistoomuchfasterthanoperators’ability.如果傳送帶的速度遠遠快於作業員的作業能力1.ToomuchWIPatthebottleneckstation.在瓶頸站將堆積過多的WIP2.OperatorslackconcentrationWastetimetowaitforthecomingproductorpulltheproductfromthelineinsteadofcompletingtheproductinhand.作業員無法專心作業。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。UnbalanceLinesProblems線上不平衡造成的主要問題3.QualityProblem品質問題3.1IncompleteProcess制程不完善-Insufficientparts作業不全-Partsnotproperlyinserted材料未適當裝插-Wrongpartbeinginserted插件錯件-Wrongsideisbeinginserted插件反向-Notallrequiredpointsareinspected檢查不完備-DidnotcorrectlychoosetheSelectSwitch按錯測試鍵-DidnotputallLabelsorwronglyplaced.未全面貼放標籤或錯貼-etc.UnbalanceLinesProblems線上不平衡造成的主要問題3.2Defects不良-Damageanddirty破損及污漬-Scratches刮傷-Labelscratches標籤不良等etc.4.Inspectorsneedtorepairthedefects,thuscausingadditionaltime.作業員修復不良品將花費多餘工時UnbalanceLinesProblems線上不平衡造成的主要問題5.LineleadersandothersupportingpeoplehavetowastetheirtimeinassistingandsolvingtheWIPproblematthebottleneckstation.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.Thespaceavailableinthelinearealreadyverylimited,itwillbecomeevensmaller.線上空間本來有限，還需佔據空間7.Un-forecastableanduncontrollableoutput造成無法預計和控制的產出8.DecreasedProductivity生產力降低UnbalanceLinesProblems線上不平衡造成的主要問題Whentheconveyorspeedisslowerthantheoperator’sability.當傳送帶之速度遠慢於作業員的操作能力1.Losttimewithoutoutput無產出的異常工時2.Loweroutputthanexpected低於計劃的產能3.Operatorsarenotactiveenough,becomesdull作業員無法積極作業，變得懶散UnbalanceLinesProblems線上不平衡造成的主要問題4.Musttakemoretimetorecoverthelostoutput需要安排額外的工作時間以彌補未達成的產能5.Unitcostbecomeshigher單位產品的本钱增加6.DecreasedProductivity生產力降低7.Cannotcontrolorforecasttheoutputsystematically無法系統的控制和預估產能UnbalanceLinesProblems線上不平衡造成的主要問題Stepoflinebalancing線平衡步驟LINEBALANCEisthemethodusedtosetupworkingtimeofoperatorsinonelineasthesameaspossible.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。LineBalancing線上觀察分析討論設定標準標準工時及O/I檢討起草作業指導書並檢討執行跟蹤情況正式發行O/I跟蹤及不斷的改善動作制程布局治具方便快捷平安價廉保障合併去除改善(重排、調適)簡化LineBalanceConceptProductionDesign(R&D)ProcessDesignFlowChartLayOutOperationInstructionMotion&TimeStudySeriouslycontinuousfollowup產品設計(工程)制程規劃流程圖布局安排作業指導書成效研究認真持續的跟蹤情況LineBalanceConceptObservation觀察Analyze分析SetNorm設定標準Manload安排人力Implement執行Followup跟蹤(Before&After)(Max,Min,Avg.最大值,最小值,平均數)(Observationsheet時間觀測)-Combine合併-Eliminate去除-Improve改進-Simple簡化(ProductivityPerformance生產力狀況)(Std.Time標準工時)StepoflinebalanceStep1.Observation:Observeandtimingfromthestarttoendofeachprocessassample..第一步.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..StepoflinebalanceStep2.Analyze:Analyzetimefromobservationtodefineminimum,MaximumandAverage.第二步.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.StepoflinebalanceStep3.Setnorm(standardtime):Selectthetimetobeusedasthestandardtimeateachstep.Normallywillbetheaveragetime.第三步.設定標準(標準時間):定訂每一站的標準時間.通常使用平均值.StepoflinebalanceStep4.Manload:Calculatemanpowertobeusedtoproduce.Thesenumberwillbethemosteffectiveandbalancetheproductionlineasmuchaspossible.(Comparebefore&After)第四步.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)StepoflinebalanceStepoflinebalanceStep5.Implement:UsealldatatocompareastheBeforeandAfterReport.Setuplinebalancebyusingthefollowingconcept.第五步.執行:用所有的數據比較before&after,用以下的觀念平衡生產線.-Combine合併-Eliminate去除-Improve,Re-arrange改進,重排-Simplify簡化Step6.FollowUp:Followupalltheimplementationcontinuinglyatleast2weeks.第六步.跟蹤:持續的跟蹤執行情況至少兩星期.LineBalancingBenefitsLineBalancingBenefits線平衡的優點1.Systematicproductionoutputcontrol系統的產能控制2.Constantflowanddistancebetweeneachproduct.持續的流水作業3.Reduceoperator’schancefordefectandcarelessness.降低作業員不良及忽略的錯誤4.Losstimereductionandcontrol.降低並控制異常工時.LineBalancingBenefits線平衡的優點5.PreventionofWIPintheproductionlines.防範線上WIP.6.Easeandclearidentificationoftheproblems.清楚的問題分析7.Whendefectsarefoundandseparatefromtheline,itcanbeveryclearlyidentified.不良品的明確標識，以便明確的區分.LineBalancingBenefits線平衡的優點8.Operatorsdonothavetobeworriedaboutthenextcomingmaterialwhenhis/herpresentoneisnotcompleteyet.在作業員進行當前作業時，無需擔心下一個材料.9.Operatorscanfullyconcentrateontheirjobs,theydonothavetocareaboutothersabilitytofinishtheirworkontimeornot.作業員全心投入工作,無需擔心其他組員的作業狀況.10.Theconstantdistancebetweenproductscanpreventdamagesfromdirecthits.產品之間的間隔可防止直接碰撞產生的損害THEENDLineBalanceExample線平衡範例CycleTime(Bottleneck瓶頸)=9.85secondLineBalanceefficiency=Totaltime/(Bottleneckcycletime*O/PNo.)線平衡率=總工作時間/(瓶頸站cycletime*作業員人數.)=67.45%-BeforeImprovement改善前PROCESSSECImprovement:ImproveprocessofproducingsuchasBottleneck改善:改善生產制程如瓶頸站CycleTime(Bottleneck瓶頸)=7.47second(Avgofwinding)LineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=83.80%PROCESSSECBeforeImprovement改善前AfterImprovement改善後SolderpressedwirebeforeSoldertrimmingPress焊理線站後焊壓線Separatepressingwireactivityforeachprocess壓線部份獨立出來Eliminate:DecreaseLossorunnecessaryprocess去除:去除不必要及造成延誤的制程Method:eliminatepressingMarginTapeprocessbyaskingoperatortouseTapeT26overMarginTape方法:去除壓膠布的制程,要求作業員在空白膠外使用T26膠CycleTime(Bottleneck瓶頸)=7.35secondLineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=84.58%SECPROCESSBefore&afterstationwindingwrapmargintapeCombine:combineprocessbyusingmotionandtimestudy合併:根據成效學合併制程CycleTime(Bottleneck瓶頸)=7.35secondLineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=92.14%Method:combineencasingCore(station4)andinputClip(station5)together.方法:合併包鐵芯(第4站)和上耳夾(第5站).PROCESSSECSimple:Usingfixturetohelpoperator.簡化:使用制具幫助作業員.CycleTime(Bottleneck瓶頸)=7.10secondLineBalanceefficiency線平衡率=Totaltime/(Bottleneckcycletime*O/PNo.)總工作時間/(瓶頸站cycletime*作業員人數.)=94.65%SECPROCESSBeforeImprovement改善前AfterImprovement改善後SolderinghavetopickupworkfromFixtureonebyoneafterprocess焊錫站需要從線上一個一個拿取MakeNewfixturewhichcanreleaseallworkinthesametime作新制具以便同時作業Before&AfteratstationsolderingComparingImprovement比較改善前後InthecaseofimproveBottleneckanddecreaseoperator改善瓶頸站並減少作業員IncaseofstableinputhourandimproveBottleneck如果投入不變而改善瓶頸站RemarkStd.timeperpiecewilldecreaseandlinebalanceefficiencywillbehigher說明:單位產品所需的標準工時將減少，線平衡率將提升ComparingImprovement比較改善前後AdjustlinebalanceincaseofproducelowerthanPlan調整線平衡DailyVarianceReport每日差異報表AsfollowupfromvarianceReport,thefirsthourhasvarianceof100pieceslowerthanplan.Ifproductionlinewantstoproducecovervariance,Theconveyerisneedtobeadjustedasfollow:(Cycletime5sec)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:(Cycletime5sec)IncaseofproducelessthanplanExample范例(Cycletime5sec)8.25Hoursforoneday一天8.25小時=31500sectarget6300pcs.First1.20hour第1.20小時=4800secproduced860pcs.Workhavetobeproduce必須完成=6300-860=5440Pcs=31500-4800=26700/5440=4.94secThentheconveyerhavetobeadjustto4.94secinordertocoverVariance(Incaseofoperatorscoulddo)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)MethodofincreasingProductivity生產力提升之方法OutputStable產量不變,InputDecrease投入減少Outputincrease產量增加,InputStable投入不變Outputincrease產量增加,InputDecrease投入減少OutputincreasedmuchmorethanInput產量的增加速度遠遠超出投入的增加速度OutputDecreasedmuchmorethanInput產量的減少速度遠遠超出投入的減少速度BenefitofUsingConveyerReducetheexpenseoftransportationorproductmovement.降低運輸費用及產品的搬運.Reducetimetomoveorstoreworkinprocess(Wip).降低在制品移動及儲存的時間.ReduceexpenseoftoolorpallettokeepWorkinprocess.減少制具及盤子費用以便工作在線上作業.UseveryfewspaceforproductionlinebecausetherearenoneedspaceforstoreandWipmovement.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.Ifhasagoodlinebalancing,workwillbeflownthroughfromstarttostop.工作從線頭流到線尾將會有較好的線平衡.LowerWorkinProcessinproductionline,Eachstationwillhaveonlypiecetoproduce.減少線上在制品,每一站只有一個產品生產.Iftheprocesshasbeenbalancedeffectivelytheproductionlinewillbefastandeffective如果生產線得到有效的平衡，生產線會更快捷Ifplantoproduceonlyonemodel,thequalityofworkwillbebetterbecauseoftheprocessofchecking如果只生產一個機種,品質和產量會更好。Easytocontrolquantityandqualityiftheprocessofproducingarestable.如果生產制程穩定，產品品質和產量都會更易控制.EasytotracktheNGproduct,thelinecanbestopandcorrect.更容易對不良品進行跟蹤,可以把線停下並糾正.Buildupteambuildinginbetweenoperators,Ifsomestationisslowerthanotherstheperformanceofalllinewillbelow.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.Makelineleadermoreactive,Ifsomeerrorormistakeoccurintheline,theworkwillbeNGforallthelinealso.組長會更加積極,如果線上某站出問題整條線都會被影響.BenefitofUsingConveyerPQCDSMP=ProductivityQ=QualityC=CostD=DeliveryS=SafetyM=Morale5-SProcessFlowDesign制程規劃DesignWorkFlow流程規劃LineLayout線上布局規劃EstablishStandardTimeandMan-load設定標準工時及人力需求LineBalancing線的平衡IssueOperationInstructionforLines發行作業指導書ObserveMotion,TimeStudyandMeasurement就動作的成效進行衡量及研判IEFunctionFollow-upandContinuousImprovement跟蹤情況並不斷改善DailycorrectiveandpreventivesupportsonProductionproblems每日就生產線問題進行更正及防范支援CostAnalysis本钱分析Co-operatewithotherconcerneddepartmentsforimprovinganddevelopingtheprocessandproduct,i.e.quality,costreduction,capacityupgradeetc.就制程和產品改善方面與相關的部門合作，如：產品品質、降低本钱、產能提升等等。Otherjobsasassigned其他交辦事項IEFunction