单元生产方式(cell)全面讲解.ppt
Cell生产方式简介,IE：王红日期：2009/12/10,目 录,1.Cell的基本概念,2.Cell Line的优点,3.Cell Line的基本布线规则,4.单件流,1.每个细胞均具有独立功能2.可与其他单元任意组合3.自主性/灵活性4.细胞间活动协调一致,1 Cell的基本概念(1),它代表着创造性与灵活性!,1.1 Cell:“单元/细胞”的意思,1.如同蜜蜂群的组织分工2.如同蜜蜂群的团结合作,1 Cell的基本概念(2),1.2 Cell:“蜂窝”的意思,它代表着Team Work的概念!,1.增加产线灵活性(型号、产量、布局）2.库存降低3.可依实际订单决定开几条线(弹性)4.后工序等待时间减少5.可快速换线(插入急单),优点：,2 Cell Line的优点,2.1 同步化生产,1.换线容易(减少延误工时)2.减少因线不平衡带来的损失3.便于保养,2.2 设备小型化,优点：,1.生产率提升2.工序的前置时间改善3.减少生产中的工作量4.减少因线不平衡带来的损失5.品质提升6.人员的减少,2.3 多能工的培养,优点：,多能工,Before,1.按需生产2.生产排程的灵活性增强3.多机种混合生产4.换线容易5.小批量生产,After,2.4 弹性（灵活）排程,优点：,1.节省取放材料的时间2.控制WIP,1.A工序做完后材料无须送往下一工序,由B工序同事来取；2.有用到工装的站别，通常该工序员工只负责上工装，做完后由下一站员工负责下工装,(测试站别无人化操作)。,2.5 拉式生产方式,优点：,从上一工序拉(PULL)而非传送下一工序(PUSH),1.生产排程的灵活性增强2.换线容易(减少延误工时)3.作业员之间的沟通更容易、有效4.品质提升5.制程的前置时间改善6.减少制程中的工作量7.减少因线不平衡带来的延误8.作业员责任明确,从左往右,3 Cell Line的基本布线规则,3.1 站立、从左往右,优点：,3.2 人在内转,600/天,300/天,300/天,够小,够精,够活,3.3 cell越小越好,1.不落地生根,传统观点认为设备越大效率越高，通常将设备固定在地面而无法移动。设备不能移动，自然缺乏弹性，也就失去了改进布置、应对市场变化的能力。,3.4 架线的三不政策(1),改采设备小型化或设备可动化。,管线不像常青藤,设备“寄居”在固定的管、线及中央式装置之下而无法移动。,3.4 架线的三不政策(2),2.不寄人篱下,放弃中央式设施,改采用分离式设备如：快速接头、弹性接口。,1.品质提升2.WIP减少3.前置时间减少4.消除搬运,离线,随线,工序2,切勿离线作业,只能以“主流,支流”的概念进行站别布置!,3.4 架线的三不政策(3),3.不离群索居（IN LINE）,优点：,工序1,工序2,工序2,工序1,工序2,工序2,工序2,一笔画布置,3.5 工厂一笔画布置,工厂/生产流程在整体上呈一笔画布置,1,2,3,4,IO一致原则,1,2,3,4,空手走动浪费,Input,Output,Input,Output,生产投入点与完成品取出点尽可能靠近，以避免作业返程造成的时间和体力浪费。,3.6 生产线U形化(1),IO一致原则同样适用于设备布置，亦可节省空间占用。,1.以U字型布置方式按工艺流程排列生产。2.入口和出口尽量由同一作业者负责，能够以产距时间按标准数量进行生产及管理，也便于补充生产。3.便于作业者相互协作，异常时能停线，及时暴露问题并改善之。4.步行最短，可单件流动，人员可增可减。,1,2,3,4,5,8,14,13,12,11,7,10,9,6,成品,材料,3.6 生产线U形化(2),各站产出状况,数量,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,站1,站2,站3,站4,站5,站6,平常堆货的生产模式,每站看似都很忙,也能一直保障3pcs的产出,所以看不到线平衡的问题,单件流(站6只需要1pcs)的拉动式生产模式可轻易看到线平衡的问题,我只要1pcs,4 单件流,单件流真的能节约时间吗?时间会不会变长?单件流到底有什么好处?我们可以通过下面动画,看到传统堆货生产&单件流的不同(某个包含3站的产品)。,面对单件流的疑问?,传统堆货生产,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:00,A站,B站,C站,21pcs产品,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A站,B站,C站,21pcs产品,传统堆货生产,15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A站,B站,C站,21pcs产品,1,传统堆货生产,15,8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A站,B站,C站,21pcs产品,2,传统堆货生产,15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A站,B站,C站,21pcs产品,3,传统堆货生产,15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,6,21,14,7,00:05,A站,B站,C站,21pcs产品,4,传统堆货生产,15,8,6,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,7,00:06,A站,B站,C站,21pcs产品,4,传统堆货生产,15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:07,A站,B站,C站,21pcs产品,4,传统堆货生产,15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:08,A站,B站,C站,21pcs产品,4,传统堆货生产,15,9,7,16,8,17,10,3,18,11,1,19,12,2,20,13,5,21,14,6,00:09,A站,B站,C站,21pcs产品,4,传统堆货生产,15,10,7,16,9,17,8,1,18,11,2,19,12,3,20,13,5,21,14,6,00:10,A站,B站,C站,21pcs产品,4,传统堆货生产,15,11,7,16,9,17,8,2,18,10,3,19,12,4,20,13,5,21,14,6,00:11,A站,B站,C站,21pcs产品,1,传统堆货生产,15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:12,A站,B站,C站,21pcs产品,2,传统堆货生产,15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:13,A站,B站,C站,21pcs产品,2,传统堆货生产,15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:14,A站,B站,C站,21pcs产品,2,传统堆货生产,15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:15,A站,B站,C站,21pcs产品,2,传统堆货生产,16,13,6,15,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:16,A站,B站,C站,21pcs产品,2,传统堆货生产,16,13,6,15,10,17,8,2,18,9,3,19,11,7,20,12,1,21,14,5,00:17,A站,B站,C站,21pcs产品,4,传统堆货生产,16,13,6,15,11,18,8,2,17,9,4,19,10,7,20,12,1,21,14,5,00:18,A站,B站,C站,21pcs产品,3,传统堆货生产,16,13,6,15,12,19,8,2,17,9,5,18,10,7,20,11,1,21,14,4,00:19,A站,B站,C站,21pcs产品,3,传统堆货生产,16,12,5,15,13,20,8,2,17,9,6,18,10,7,19,11,1,21,14,4,00:20,A站,B站,C站,21pcs产品,3,传统堆货生产,16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:21,A站,B站,C站,21pcs产品,3,传统堆货生产,16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:22,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:23,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:24,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:25,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:26,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:27,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:28,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:29,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:30,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:31,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:32,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:33,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:34,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:35,A站,B站,C站,21pcs产品,3,传统堆货生产,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:36,A站,B站,C站,21pcs产品,3,传统堆货生产,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:00,A站,B站,C站,21pcs产品,单件流,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A站,B站,C站,21pcs产品,单件流,15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A站,B站,C站,21pcs产品,1,单件流,15,8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A站,B站,C站,21pcs产品,2,单件流,15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A站,B站,C站,21pcs产品,3,单件流,15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,6,21,14,7,00:05,A站,B站,C站,21pcs产品,4,单件流,15,8,6,16,9,17,10,4,18,11,3,19,12,2,20,13,1,21,14,7,00:06,A站,B站,C站,21pcs产品,5,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:07,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:08,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:09,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:10,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:11,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:12,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:13,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:14,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:15,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:16,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:17,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:18,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:19,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:20,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:21,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:22,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:23,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:24,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:25,A站,B站,C站,21pcs产品,6,单件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:26,A站,B站,C站,21pcs产品,6,单件流,优缺点比较,结果比较,1.总体时间长，浪费工时2.首件产出时间长，难满足客户交期3.WIP多，每个人看起来都很忙,看不到问题在哪?4.WIP多，急单来却来不及清线/盘点/换线5.WIP多，出了问题，一重工或报废就是一堆6.WIP多，工作台都是半成品，很难作业 7.WIP多，堆积花费时间也较长,1.总体时间少,节省工时2.首件产出时间长，难满足客户交期3.WIP少，容易暴露生产问题，以便加以解决4.WIP少，对外界反应迅速，急单容易插入,转机快5.WIP少，出了问题，受影响程度低6.WIP少，工作台整洁，操作方便 7.WIP少，堆积时间少,节省工时,The end.,Thanks!,
