精益生产快速换模改善案例（经典作品） .ppt

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1、ManzoniSMEDStamping Workshop,Apr,12th16th 2010,现场改善GK 129,1000T 快速换型,2,Presentations Title,GK129 team 改善团队 奔驰,Team members 团队成员冲压主任 龚小范维修主任张建强模修领班王佑春传播者 王伟操作工 张传有模修王树林维修计划刘景鹏电子工程师 刘伟东860项目组胡智平860项目组高洋巴西专家Silviu巴西专家Evandro Speckhahn巴西模修Renato精益 张春杰,3,Presentations Title,The source of the GK 项目来源,1.VS

2、M 价值流程图,2.860项目组 Capacity Expansion project 8.6 M/y,4,Presentations Title,Objective and Goal 目的与目标降低1000T换型时间=从35分钟至20分钟Decrease the setup model time(1000T)=From 35mins to 20 mins人因工程改善=1项 Ergonomic Improvement=1 Item安全改善=1项 Safety Improvement=1 Item可视化管理=1项 Visual Management=1 Item5S改善=1项 5S Improv

3、ement=1Item,Objectives and Goal 目的 与目标,5,Presentations Title,Benefits of SMED 快速换型的好处,Reduces unproductive time减少非生产时间,Allows to improve the client service(lead time,quantity)有利改善客户服务(交货周期、数量等),Enlarges real capacity of machines扩大机器实际产能,Reduce the investment and production cost减少投资，降低成本,SMED快速换型,All

4、ows to reduce the stocks有利降低库存,Shorter series becomes cheaper(reduce batch size)产品系列更换时间更短、成本更低(缩小批量),6,Presentations Title,Step 1 步骤一,Step 2 步骤二,Step 3 步骤三,Step 4 步骤四,Step 6,Changeover method not rationalised没有理顺换模方法,Study of the actual situation研究实际情况,Separate internal work From external work将内部工作

5、与外部工作分开,Convert internal work in external work将内部工作转化为外部工作,Step 5 步骤五,Reduce of internal work减少内部工作,Absence of method 没有方法,Preparation time with big variations 准备时间变化太大,There is no distinction between external work and internal work 内部和外部工作没有什么区别,Improvement of logistic support改善物流运输,Improvement ser

6、viceability改善可用性,Pre-assembly 预先装配,Pre-adjustments 预先调整,Pre-heating 预热,Previous work before the machine stop 停机前的准备工作,Work to be done with the machine stopped 停机时要做的工作,Work to be done after stopping 停机后要做的工作,Register and classified all the necessary working elements 将所有必要的工作进行登记和分类,Video 视频,Chronogr

7、aph 计时器,The 5 Steps of SMED 快速换型的五个步骤,SMED 快速换型,Eliminate adjustments and settings 消除调整和设定,Simplify fixation and tightening 简化固定和上紧程序,Parallel work 平行作业,Internal Work:Operations which have to happen when the machine is not running外部工作：机器没有运作时要进行的工作,External work:The operations which can take place w

8、hen the machine is running内部工作：机器运作时要进行的工作,Reduce of external work减少外部工作,7,Presentations Title,Step1:Study of the actual situation 步骤一：研究实际情况,Make the list of setup step through film观看录像列出换型步骤(共59步）,8,Presentations Title,Step 2 Separate internal work From external work 步骤二：区分内部工作和外部工作,对59步换型步骤进行内部外部

9、工作的区分,9,Presentations Title,After Kaizen改善后,Before Kaizen改善前,Step 3 Convert internal work to external work 将内部工作转换成外部工作,工具准备 Prepare and Organize tools,Photo,将换型工具按照模型摆放在车上，便于取放。同时增加1个套筒和1个六角扳手Put the tools in the car according the former in order to take easily and at the same time add 1 steel tube

10、 and 1 wrench,工具在车上摆放无序,只有1个套筒和1个六角扳手 The tools were put without order in the car and there was 1 steel tube and 1 wrench,10,Presentations Title,对换型步骤进行排序 Define the better sequence:,统计每个人的工作时间 并确定可以同时做的工作Sichronize activities:,Step 4 Reduce of internal work 减少内部工作,11,Presentations Title,After Kaize

11、n改善后,Before Kaizen改善前,在校平机上安装支架，用于存放手柄同时将手柄加长Make a support beside the machine to lay the handle and lengthen the handle,手柄放在控制台旁边小盒内The handle was in the box of console,(1)制作存放手柄支架 Make a support,Step 4 Reduce of internal work 减少内部工作,12,Presentations Title,Step 4 Reduce of internal work 减少内部工作,Afte

12、r Kaizen改善后,Before Kaizen改善前,(2)拆除校平机护板 Remove the protective net,需将校平机护板拆下，用手柄调整参数Need to remove the protective net,adjust the parameter with handle,将护板更换为有机玻璃并开四个小窗口，直接用手柄调整参数Change the protective net into organic glass and open 4 small windows,Adjust the parameter with handle directly,13,Presenta

13、tions Title,Step 4 Reduce of internal work 减少内部工作,After Kaizen改善后,Before Kaizen改善前,(3)可视化调整参数 Make the parameter visual,操作工在调整参4个调整轮参数时需来回到控制台查看POPThe operator moved to the console to check the POP when he adjusted the parameter,将4个调整轮的调整参数按照顺序贴在校平机上，调整时操作工无需来回走动Put on the parameter card into the gl

14、ass,14,Presentations Title,Step 4 Reduce of internal work 减少内部工作,After Kaizen改善后,Before Kaizen改善前,(4)制作尼龙挡块 Make nylon block,新料料头出校平机后向上弯，与旧料对接不好，操作工必须用撬棍对接The new coil was bent at the exit of machine,and bad connect the end of old coil.The operator must using crowbar to press,在校平机出口安装尼龙挡块Make nylon

15、 block at the exit of machine,15,Step 4 Reduce of internal work 减少内部工作,After Kaizen改善后,Before Kaizen改善前,(5)制作存放字头支架 Make a support to lay stamping punch,字头放在换型车上The stamp punch and the tool were on the setup model car,制作字头存放支架，放在冲床旁，换型时方便取放，减少走动Make a support to lay the stamp punch and the tool besi

16、de the machine,in order to take,16,Step 4 Reduce of internal work 减少内部工作,After Kaizen改善后,Before Kaizen改善前,(6)制作检具支架 Make a support to lay gauge,检具摆放不便于拿取The gauge was put not easy to take,重新制作检具支架Make a new support to lay the gauge,17,结果 Result,History,Result,Goal,以前,目标,结果,分钟,18,Presentations Title,

17、换型时间跟踪 Setup time control,19,Presentations Title,标准化 Standardization,对换型过程进行标准化，编到POP中。明确2名操作工和2名模修的分工Make a standard about the setup model and add this item into POP and define each operator and each toolmakers work,20,Presentations Title,Training 培训,Training record 培训记录,培训三个班的操作工和模修Training the op

18、erators and toolmakers of 3 shift,21,Presentations Title,Safety Improvement 安全改善,After Kaizen改善后,Before Kaizen改善前,安全隐患Accident risk 防护门打开时冲床可以冲活The press is working with the opened gate,只有在防护门关上的情况下才可以冲活,在防护门上开推拉窗便于操作工钩三角废料The press is working with the closed gate only，open a window on the gate easy

19、 to take out the scrap,22,Action 行动计划,共制定17项行动计划，已全部完成 Made 17action plan and finished all,23,Gemba Kaizen Results 改善结果,24,Gemba Kaizen Results 改善结果,25,Presentations Title,Monitoring 改善结果跟踪,Espao(opcional)para concluso 1 mn 13 pts.)Espao(opcional)para concluso 2(fnt mn 13 pts.),实施改善后的一个月内，LPO和精益传播者每周一次对改善项目进行跟踪,26,Presentations Title,Thoughts 感言,减少多余动作同时也降低了风险打破常规，勇于创新只要用心观察，就能找到过程中的不足，并加以精益改善,27,Presentations Title,Q&A问题和解答,GK0129,