工业工程技术培训01Word文档.docx

工业工程技术培训OlWord文档(八)工厂布置规划(PlantLayoutPlanning)简介L工厂布置之规划程序Keylnputs-P,Q,R,S,T&Activity-areas2.工厂布置规划之基础信息代号说明PProductorMaterial物品之特性与差异性QQuantityorVolume各单项物品之数量或者体积RRoutingorProcess物品之制造程序或者流程SSupportingServices支持生产所必需之活动TTimeorTimingConsideration包含：作业时间/期间、频率、期限、季节性，等等3.工厂布置之型态以制程为中心之工厂布置工 布 置 之 型 态制程布置(ProCeSSLayout)或者称批量作业布置(JobLayout)以产品为中心之工厂布置定位布置(FiXedPositionLayout)4.关连图(RelatiollShiPDiagram)5.关连分析（ReIatk）IIShiPAIlalySiS）6工厂布置之着眼点 人性化观点：''人、机、物之与谐关系 安全性之设计考量 生产性观点：''人、机、物之最适组合 流淌程序(FloWPn)CeSS)、动线：Ship-To-Store,Ship-To-Line,Make-TO-ShipmentMake-To-Order,etc. 流淌频率：JIT-Justintime 1.Oad&Unload之次数/频率 搬运设备之效能(九)缩短换线换模时间之要领简介ImprovementApproach改善的手法 Four(4)Steps四个步骤 Two(2)Categories两种类别 Four(4)Stages四个阶段4Steps（四个步骤） Preparation（准备） （Re）placement（更换、装置） Adjustment（调整） Completion（完成、善后）SteD工PreDaratiOn（准备）*DrawingUpChange-overInstructions.-Operations.-Toolsneeded（jigs,dies,moulds,etc.）.-Fastenersneeded（boltszscrews,washers,nuts,clamps,clips,etc.）.* Storage,MaintenanceandInspectionofToolsandFasteners.* GatheringandPreparationofNewToolsandFasteners.TransportofToolsandFastenerstotheProcess.SteP2（Re）DlaCement（更换、装置）* UnfasteningandRemovalofOldTools.* PlacingtheNewTools.* CenteringtheNewTools.StelJ3AdiUStment（调整）* FasteningNewTools.* SecuringtheNewTools.* AdjustmentoftheNewTools.SteD4ComDletion（完成、善后）* TransportofOldTools.* Cleaning,GreasingandOilingTheOldTools.* StorageofOldTools.2Categories（两种类别） On-lineChange-over（线内更换）Change-overactivitiesInterruptingtheprocess. Off-lineChange-over（线外更换）Change-overactivitiesalongsidetheprocess.On-linechangeoverProducingProducing4Stages（四个阶段）AdVanCedStage改进阶段TranSferTedStdge移转阶段SeParatedStdge分离阶段IntermingIedStage混合阶段IntermingledStage（混合阶段）* Noseparationbetween.* On-lineandoff-lineoperations.* Processisstoppedduringtotalchange.* Newtoolsarebroughtinaftertheprocesshasbeenstopped.* Neithertoolsnorfastenersareproperlymaintained,checkedorprepared.* Toolsandfastenersarenottidystored.* SeparatedStage（分离阶段）* On-lineandoff-lineoperationsarekeptseparated.* Processisstoppedforon-lineoperationsonly.* Allnecessarypreparationsarecompletedwhiletheprocessisgoingon.* Achecklistisavailableforcarryingoutoff-linework.* Maintenance,inspectionandpreparationoftoolsandfastenersarecarriedoutoff-line.* Acheckismadewhethertoolsandfastenersworkproperly.TransferredStage（移转阶段）* On-lineoperationsaretransferredtooff-lineasmuchaspossible.* Heightofdies,ramsandpressblocksarestandardized.* Allfastenersandspannersarestandardized.* Standardizedintermediateattachmentsareintroduced.* Adjustmentofmachinesstrokesisavoided.* AdvancedStage（改进阶段）* Bothon-lineandoff-lineoperationsareminimized.* Dimensionsofalltoolsarestandardized.* Handlingofmoulds,jigs,diesandformsisstandardized.* Hydraulic,pneumaticormagneticfasteningisintroduced.* Fasteningandadjustmentworkissimplifiedoreliminatedwhereverpossible.*Cassettesareintroduced.FromIntermingledtoSeparatedStage* Makeacleardescriptionofallchange-overoperationstobeexecutedtoday(seeworksheet).* Prepareasummarylistof:-alltoolsneeded(jigs,dies,moulds,etc.).-allfastenersneeded(bolts,screws,clips,etc.).*Classifyalloperationsinto:-off-lineactivities.-on-lineactivities.FromSeparatedtoTransferredStage* Transferoperationsfromon-linetooff-lineasmuchaspossible.* Theuseoffunctionalfasteners.* Thepreviousinstallationofintermediateattachments,bolstersandfasteners.*Introductionoffunctionaldialorpointerreadings.WorksheetNr.:WorkstationNr.:Change-overfromtoOperationTools&FastenersLocationStepstoberemovedtobeplacedPreparation(ReJpIacementAdjustmentCompletionoffonoffonoffonoffonFromTransferredtoAdvancedStage* Improvementofhandling,transportandstoragemethods.* Theuseofhydraulic,pneumaticormagneticmethodsforplacingand/orfasteningtools.* Theeliminationofcenteringandadjustmentactivitiesbystandardisationof:- dimensionofmoulds.- machinestrokes.- maleandfemalejigs.- centeringandfasteningmethods.* Improvemeasuringandgaugingmethods.* Eliminationoftrialruns.（十）IE改善心法WaysoflmprovingtheWorkThroughMotionStudy-EASIERWAY-approachEliminateunnecessarymotionsAvoidmovesrequiringeyedirectionShortenmotiondistanceImprove"get"motionsbypre-positioningEmploysimplefixtures,damps,andguidesReplacehandoperationswithfoot-operateddevicesVhy?QuestioneachoperationAdapttwo-handmethodYes,thereisalwaysroomforimprovement删除(Elin()改善:合并(Combination)：将数个作业或者动作合并，省略转交或者取放。重排(Re-arrangement)：将数个作业或者动作重新安排，使作业或者动作能平衡顺畅。简化(Simplification)：将数个作业或者动作加以改善，使其简化。基本I"发问J(PrimaryQuestions)进一步发问(SecondaryQuestions)ECRSApproaches目的是什么？(Whatisthepurpose?)为何务必做？(Whysitnecessary?)可否删除？(Canitbeeliminated?)何地完成？为何在那里完成？StoryoftheBedauxSystemI. StorooftheBedailXSyStemIn1911,Mr.CharlesE.Bedauxexperimentedwiththeideaofmeasuringallhumanphysicalworkintermsofacommonunit.TheunitknownastheBedauxUnitofhumanpowermeasurementor"B"wastoconsistsofacombinationofworkandrest.Theproportionsbetweenthesetwoitemsweredependentuponthephysicalnatureoftheworkandthesubsequentrestrequiredtocompensateforit.Astasksvaried,theratiooftheworktorestwithintheunitwastovary,buttheunititselfwastoremainconstantatatimevalueofonminute.II. TheBedaUXSyStemOr"E"SyStem(UilitSyStem)The“UnitE''isthequantityofworkanexperienced,skilledworkercandoperminuteundernormalconditions,takingintoaccounttheinherentallowanceforrest,personalneeds.III. The“M"SyStem(UIlitSyStem)TheUnit(M)istheamountofworkthatcanbecarriedoutinoneminutebyatrainedworker,undernormalcircumstance,andatnormalspeed,includingallowancesforinterruptionsasrestandpersonalcare.TheUnit(M)doesnotrepresenttimeinthesenseofaclocktime,butitisratherameasureofworkquantity“oriaborcontenf,.IV. EXDreSSiOiIWorkQuantityorLaborContent=Work+Rest(Bedauxdefinition)or=Work+TotalAllowance(Philipsdefinition)Example:LaborContent1MTAF-totalallowancefactor:1.14/1.18/1.2LabarContelnWork(NOrmaITime)TAF1M(60seconds)=52.6seconds+7.4seconds(14%)1M(60seconds)=50.8seconds+9.2seconds(18%)1M(60seconds)=50.0seconds+10.0seconds(20%)VIII. PerfonnalICeRatilIRPerformanceratingisexpressingnumericallythespeedandeffectivenesswithwhichanoperationisdone,inrelationtowhathasbeendefinedasnormalperformance.Tempomeanstheintensityofworking.InBedauxtime-studysystem:TempoSpeedofthemovementsSkillofthemovements(i.e.proficiency,usefuleffect,dexterity,efficiency).IX. NOrmalPerfOrmanCeNormalperformanceistheperformanceofanaverageskilledworkerdoingajobundernormalconditionswithoutbeingstimulatedbyanincentivescheme.Itmustbepossibletokeepthisperformancefromdaytodaywithoutexcessivephysicalormentalstrain.Asareferencefornormalperformancecanbetaken,asteadydeliberateandunhurriedaverageperformanceofaperson,whowalksaround4.8Km(3miles)perhourordeals52playing-cardsin30seconds.X. RemarkS- Unit(English)- Einheit(German)- Eenheid(Dutch)- 单位(ChilIeSe)- Esystem:forPerformanceorTempo(60E,75E,80E)- Msystem:forLaborContentorWorkQuantity(5M's,60.5M's)EffectsofWorkingConditionsondeterminingAllowanceAllowanceValueConstantallowanceC-IPersonalallowance5%C-2Basicfatigueallowance4%VariableallowanceV-IStandingallowance1%V-2AbnormalpositionallowanceSlightlyawkward0Awkward(Bending)2%Veryawkward(Lying,Stretching)7%V-3Useofforceormuscularenergy(Lifting,pulling,orpushing)Weightlifted:5Pounds(2.3Kg)010Pounds(4.5Kg)1%15Pounds(6.8Kg)2%20Pounds(9.1Kg)3%25Pounds(11.4Kg)4%30Pounds(13.6Kg)5%35Pounds(15.9Kg)7%40Pounds(18.2Kg)9%45Pounds(20.4Kg)11%50Pounds(22.7Kg)13%60Pounds(27.3Kg)17%70Pounds(31.8Kg)22%V-4BadlightSlightlybelowrecommended0Wellbelow2%Quiteinadequate5%V-5Atmosphericconditions(HeatandHumidity)0-10%V-6CloseattentionFairlyfinework0Fineorexacting2%Veryfineorveryexacting5%V-7NoiselevelContinuous0Intermittent-loud2%Intermittent-veryloud5%High-pitched-loud5%V-8MentalstrainFairlycomplexprocessI%Complexorwidespanofattention4%Verycomplex8%V-9MonotonyLow0Median1%High4%V-IOTediousnessRathertedious0Tedious2%Verytedious5%(CourtesyofInternationalLaborOffice,GenevaSwitzerland)PHILIPS动作分析表页次：/作业名称：产品型号：作业区域：分析人：分析日期：LHRHLHRHLHRHLHRH5玉10555玉101151515I152020202025252525301303030玉351354040玉45玉5050二二45150双手程序表：裁切玻璃管TWO-HANDEDPROCESSCHART(改善前方法)ChartNo.:SUB-0101SheetNo.:1of1材料/零件：玻璃管（长1公尺，直径3mm）作业内容：将长1公尺之玻璃管，用夹具与铿刀裁成小段玻璃管（长1.5cm）o操作地点：第三车间作业人员：李大海分析人：M.J.Hung日期：2003-02-18工作站布置图：LeftHandO<=>DOODVRighlHand1.持住玻璃管1.拿起铿刀2.移动玻璃管至夹具/2.持住铿刀3.将玻璃管插入夹具内/3.将铿刀移至玻璃管4.将玻璃管推至夹具底部4.持住神刀5.用手固定住玻璃管fc*_一5.用锌刀在玻璃管上划刻痕6.稍为拉出玻璃管>、6.稍为移开锂刀7.将玻璃管旋转约120-180sS7.持住性刀8.将玻璃管推至夹具底部>8.将铿刀移至玻璃管9.用手固定住玻璃管/9.用锂刀在玻璃管上划刻痕10.将玻璃管从夹具内移出></.10.将怪刀放至工作台上11.将玻璃管移向右手11.右手移向玻璃管12.将玻璃管折断、12.将玻璃管折断13.持住玻璃管/13.将玻璃管置于盒内14.再握住玻璃管'b14.右手移向锤刀>、8020450603方法（Method）：改善前方法改善后方法备注动作项目LH.R.H.LH.R.H.操作(OPeration)85运送(Transport)26延迟（DeIay）-持住(Hold)43检查(Inspection)-合计：1414From-ToChartAnalysisAGIFDEBCH总计箱数A1/101/101/0320G1/102/0310I1/301/01/301/40I/301/101/301/08170F1/202/602/705150D1/201/0220E1/301/10240B1/201/01/20340C1/101/10220H1/40140总计338422421×2929X箱数505018020407080020s510510行程：A-B-C-D-E-F-G-H-I行程：A-G-I-F-D-E-B-C-H对角线左下半部对角线右上半部对角线左下半部对角线右上半部1XO=O1×3=31×5=51X7=72×0=O2×4=82×2=42×2=43×2=63×6=183×3=93×4=124×2=84×0=O4Xl=44X2=85×2=105×3=155Xl=55×1=56×1=66×2=126Xl=66×0=O7×2=147XO=O7XO=O7XO=O8×2=168XO=O8XO=O8XO=O总计：60总计：56总计：33总计：36AIBHEFGDC总计箱数A1/101/01/10320I1/301/01/101/301/401/301/301/08170B1/201/201/0340H1/40140E1/301/10240F1/202/602/705150G1/102/0310D1/01/20220C1/101/10220总计3841243222929、X箱数5018080207020504005105I0行程：A-B-C-D-E-F-G-H-I行程：A-I-B-H-E-F-G-D-C对角线左下半部对角线右上半部对角线左下半部对角线右上半部1×0=O1×3=31X4=41×3=32×0=O2×4=82×4=82×0=O3×2=63×6=183Xl=33×2=64×2=84×0=O4X4=164X1=45×2=105X3=155×4=205×2=106×1=66×2=126×0=O6×3=187×2=147×0=O7XO=O7X1=78×2=168×0=O8×0=O8×0=O总计：60总计：56总计：51总计：48健保局作业程序分析与改善摘要作业程序作传检决等储合业送验策待存计一B作业名称:O=ODL自垫医疗费用核退作业程序（现况）241123341（改善后）20824231改善成果-4-3-+1-1-1-17%2.代办费作业程序（现况）9610110（改善后）6500100改善成果-3-1-1-1-33%程序符号说明:人工操作O上计算机作业/计算机处理人工传送O计算机线上传递一检验/测试上计算机检验决策O上计算机核签等待/延迟D批次作业等待B储存/归档计算机存盘作业名称：代办费作业程序流程分析表（现况）分析人：洪明智分析日期：1998年11月对象名称：作业O一传送-O一检验决策O等待,D一储存一时间分数量距离M重量Kg备注或者改善要点（删除）（简化）（合并）（重组）程序说明1.书面受理（住院组）G)2.行政审查（住院组）C)3.Key-in受理件数及给付金额PD16BE（住院组）4.打印签付单IPD64BR（住院组），可考虑删除打印签付单，利用计算机系统传送核签5.呈判（住院组承办）C4利用计算机系统传送核签6.核准（住院组课长）AD利用计算机系统核签7.过帐PD16BE（住院组）*/8.作帐（会计室）、付款（财务组）会计室、财务组作业流程610110作业名称：代办费作业程序流程分析表（改善后）IKI1Fl-.I八.、分析人：洪明智分析日期：1998年11月对象名称：程序说明传送o检验决策O等待D储存时间分数量距离M重量Kg备注或者改善要点（删除）（简化）（合并）（重组）I.书面受理（住院组）C)2.行政审查（住院组）C)3.Key-in受理件数及给付金额PD16BE（住院组）<可考虑删除打印签付单，利用计算机系统传送核签4.呈判（住院组承办）利用计算机系统传送核签5.核准（住院组课长）»利用计算机系统核签6.过帐PD16BE（住院组）*/7.作帐（会计室）、付款（财务组）会计室、财务组作业流程500100作业名称：自垫医疗费用核退作业程序流程分析表（现况）以人员。对象为主分析人：洪明智分析日期：1998年11月对象名称：传送o检验决策等待D储存时间分数量距离M重量Kg备注或者改善要点（删除）（简化）（合并）（重组）程序说明1.书面受理（外包）(P2.Key-in基本资料及申请金额PJ02BE（外包）须当天Key-in完成3.受理设定作业PJ05BBQ4.主计算机当晚作RunningCheck.打印报表、当晚作业完成5.Key-in资料检核（住院组）,资料错误：重复程序26.行政检核（住院组）,问题案件：退件或者补件7.传送案件至医审分组（住院组）8.专业审查（医审分组）,由外聘医师审查:退件或者补件X>DD:受限于外聘医师之排定时间9.行政核算（住院组）,填写核退清单可考虑用12a.之核对清单取代填写核退清单，直接Key-in金额10.复核,权限:专员$W2万，住院组长2万/$皂5万,经理5万/$/>D取消此项程序,与14.之程序合并H.Key-in核定金额（夕卜包）(可与9.之作业合并12a.打印核对清单IPJo6BR（住院组）