工业工程技术培训01Word文档.docx

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1、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

2、 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&Unlo

3、ad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.）.-Fas

4、tenersneeded（boltszscrews,washers,nuts,clamps,clips,etc.）.* Storage,MaintenanceandInspectionofToolsandFasteners.* GatheringandPreparationofNewToolsandFasteners.TransportofToolsandFastenerstotheProcess.SteP2（Re）DlaCement（更换、装置）* UnfasteningandRemovalofOldTools.* PlacingtheNewTools.* CenteringtheNewTo

5、ols.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-ov

6、er（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.* Newtoolsarebr

7、oughtinaftertheprocesshasbeenstopped.* Neithertoolsnorfastenersareproperlymaintained,checkedorprepared.* Toolsandfastenersarenottidystored.* SeparatedStage（分离阶段）* On-lineandoff-lineoperationsarekeptseparated.* Processisstoppedforon-lineoperationsonly.* Allnecessarypreparationsarecompletedwhilethepro

8、cessisgoingon.* Achecklistisavailableforcarryingoutoff-linework.* Maintenance,inspectionandpreparationoftoolsandfastenersarecarriedoutoff-line.* Acheckismadewhethertoolsandfastenersworkproperly.TransferredStage（移转阶段）* On-lineoperationsaretransferredtooff-lineasmuchaspossible.* Heightofdies,ramsandpr

9、essblocksarestandardized.* Allfastenersandspannersarestandardized.* Standardizedintermediateattachmentsareintroduced.* Adjustmentofmachinesstrokesisavoided.* AdvancedStage（改进阶段）* Bothon-lineandoff-lineoperationsareminimized.* Dimensionsofalltoolsarestandardized.* Handlingofmoulds,jigs,diesandformsis

10、standardized.* Hydraulic,pneumaticormagneticfasteningisintroduced.* Fasteningandadjustmentworkissimplifiedoreliminatedwhereverpossible.*Cassettesareintroduced.FromIntermingledtoSeparatedStage* Makeacleardescriptionofallchange-overoperationstobeexecutedtoday(seeworksheet).* Prepareasummarylistof:-all

11、toolsneeded(jigs,dies,moulds,etc.).-allfastenersneeded(bolts,screws,clips,etc.).*Classifyalloperationsinto:-off-lineactivities.-on-lineactivities.FromSeparatedtoTransferredStage* Transferoperationsfromon-linetooff-lineasmuchaspossible.* Theuseoffunctionalfasteners.* Thepreviousinstallationofintermed

12、iateattachments,bolstersandfasteners.*Introductionoffunctionaldialorpointerreadings.WorksheetNr.:WorkstationNr.:Change-overfromtoOperationTools&FastenersLocationStepstoberemovedtobeplacedPreparation(ReJpIacementAdjustmentCompletionoffonoffonoffonoffonFromTransferredtoAdvancedStage* Improvementofhand

13、ling,transportandstoragemethods.* Theuseofhydraulic,pneumaticormagneticmethodsforplacingand/orfasteningtools.* Theeliminationofcenteringandadjustmentactivitiesbystandardisationof:- dimensionofmoulds.- machinestrokes.- maleandfemalejigs.- centeringandfasteningmethods.* Improvemeasuringandgaugingmetho

14、ds.* Eliminationoftrialruns.（十）IE改善心法WaysoflmprovingtheWorkThroughMotionStudy-EASIERWAY-approachEliminateunnecessarymotionsAvoidmovesrequiringeyedirectionShortenmotiondistanceImprovegetmotionsbypre-positioningEmploysimplefixtures,damps,andguidesReplacehandoperationswithfoot-operateddevicesVhy?Questi

15、oneachoperationAdapttwo-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？(Why

16、sitnecessary?)可否删除？(Canitbeeliminated?)何地完成？为何在那里完成？StoryoftheBedauxSystemI. StorooftheBedailXSyStemIn1911,Mr.CharlesE.Bedauxexperimentedwiththeideaofmeasuringallhumanphysicalworkintermsofacommonunit.TheunitknownastheBedauxUnitofhumanpowermeasurementorBwastoconsistsofacombinationofworkandrest.Thepro

17、portionsbetweenthesetwoitemsweredependentuponthephysicalnatureoftheworkandthesubsequentrestrequiredtocompensateforit.Astasksvaried,theratiooftheworktorestwithintheunitwastovary,buttheunititselfwastoremainconstantatatimevalueofonminute.II. TheBedaUXSyStemOrESyStem(UilitSyStem)The“UnitEisthequantityof

18、workanexperienced,skilledworkercandoperminuteundernormalconditions,takingintoaccounttheinherentallowanceforrest,personalneeds.III. The“MSyStem(UIlitSyStem)TheUnit(M)istheamountofworkthatcanbecarriedoutinoneminutebyatrainedworker,undernormalcircumstance,andatnormalspeed,includingallowancesforinterrup

19、tionsasrestandpersonalcare.TheUnit(M)doesnotrepresenttimeinthesenseofaclocktime,butitisratherameasureofworkquantity“oriaborcontenf,.IV. EXDreSSiOiIWorkQuantityorLaborContent=Work+Rest(Bedauxdefinition)or=Work+TotalAllowance(Philipsdefinition)Example:LaborContent1MTAF-totalallowancefactor:1.14/1.18/1

20、.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,inrelationtowhathasbeendefi

21、nedasnormalperformance.Tempomeanstheintensityofworking.InBedauxtime-studysystem:TempoSpeedofthemovementsSkillofthemovements(i.e.proficiency,usefuleffect,dexterity,efficiency).IX. NOrmalPerfOrmanCeNormalperformanceistheperformanceofanaverageskilledworkerdoingajobundernormalconditionswithoutbeingstimu

22、latedbyanincentivescheme.Itmustbepossibletokeepthisperformancefromdaytodaywithoutexcessivephysicalormentalstrain.Asareferencefornormalperformancecanbetaken,asteadydeliberateandunhurriedaverageperformanceofaperson,whowalksaround4.8Km(3miles)perhourordeals52playing-cardsin30seconds.X. RemarkS- Unit(En

23、glish)- Einheit(German)- Eenheid(Dutch)- 单位(ChilIeSe)- Esystem:forPerformanceorTempo(60E,75E,80E)- Msystem:forLaborContentorWorkQuantity(5Ms,60.5Ms)EffectsofWorkingConditionsondeterminingAllowanceAllowanceValueConstantallowanceC-IPersonalallowance5%C-2Basicfatigueallowance4%VariableallowanceV-IStand

24、ingallowance1%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%40Po

25、unds(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-7NoiselevelContinuous0Inte

26、rmittent-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

27、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：LeftHandODOODVRighlHand1.持

28、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、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

29、(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3384224212929X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

30、1XO=O13=315=51X7=720=O24=822=422=432=636=1833=934=1242=840=O4Xl=44X2=852=1053=155Xl=551=561=662=126Xl=660=O72=147XO=O7XO=O7XO=O82=168XO=O8XO=O8XO=O总计：60总计：56总计：33总计：36AIBHEFGDC总计箱数A1/101/01/10320I1/301/01/101/301/401/301/301/08170B1/201/201/0340H1/40140E1/301/10240F1/202/602/705150G1/102/0310D1/01/2

31、0220C1/101/10220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10=O13=31X4=413=320=O24=824=820=O32=636=183Xl=332=642=840=O4X4=164X1=452=105X3=1554=2052=1061=662=1260=O63=1872=1470=O7XO=O7X1=782=1680=O80=O80=O总计：60总计：56总计：51总计：48健保局作业程序分

32、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K

33、g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）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）