通用匈教材牙利工厂精益生产实践.pptVIP

Lean Implementation 2004-2007 Extend the flow to milling operation Old teething machine Step 1 Lift in the 9 E Stg 2 fixture into the machine (10min) Step 2 Positioning and Fastening the fixture on the machine (12min) Insert new driver curve (15min) Step 3 Step 4 Step 5 Find the right size gauge for end switch setup (8 min) Setup the end switches on both side two places (15min) 1,5 hours changeover time Teeth Assy machine DS20 2m VTL DS20 2m VTL Bulard 2m VTL FAREL 2m VTL Thunder Milling Thunder Milling Cincinatti Milling Thunder Milling OSP milling M I L L N G T U R N I N G Fixture loading for next turning job Diaphragm process - The diaphragm parts came from 5 different milling centers - The setup time is 1.5 hrs Using 3P to design new machine 9EStg 2 teething 6B Stg 2 prepared on the fixture table Changing the machine teething diameter to a predefined value : one minute Step 1 Step 2 Step 3 Predefined values Before Kaizen After Kaizen “U” shape arrangement Teeth Kanban Nozzle stg23 Single Piece Flow Standard work combination sheet for manual operations Products on the Bay 3 production area: 9Est2, 9Est3, 9FAst2, 6Bst2, 6Bst3 Calculated Takt Time: 0.8 hours/segment 9E stg2 cycles Cycle time vs. T/T Kaizen ideas to design flow Before Kaizen After Kaizen Operation Nozzle assembly Problem Discription NO special screwdriver for air-box screw Action Taken Special screwdriver made by operators Result Shorter cycle Safety tool Kaizen activity Kaizen activity Before Kaizen After Kaizen Operation Problem Actions Taken Results Assembly No flow Rearrange the layout Parallel flow assembly arial LOCATOR Before Kaizen After Kaizen Operation Problem Actions Taken Results Assembly Less waiting time The nozzles wait for the last piece to start assembly Small tables implemented to make 3 piece assembly SET BOOK Before Kaizen After Kaizen Operation Problem Actions Taken Results Set book for milling No