1、Lean Production Introduction精益生產(chǎn)簡介Prepared by:PIantINOV 20021 What is Lean Production什么是精益生產(chǎn)2. Conveyor Line Vs Lean Production Line傳送帶線與精益生產(chǎn)線對比3. Cell Line ImprovementCell Line 改進(jìn)Q&A1. 川戶為導(dǎo)向（多樣化，拉動式）2. 浪費的減少為導(dǎo)向（七種浪費）3. 精減為手段（JIT, In Line,拉平衡）不良品浪費 過量生產(chǎn)浪費 設(shè)計制程浪費 搬動/處理浪費 庫存浪費 身體移動浪費 不平衡浪費4. 團(tuán)隊I 作

2、為方式（Team Work ）1. NG Waste2. Over Production3. Waste in Process4. Handing5. Inventory6. Waste in Movement7. Unbalance七種浪費（舉例）制造流程浪費Handing Waste七種浪費（舉例）等待時間浪費Un-balance|噢，乖乖，為 什么工作最忙的總 是我卜二 Conveyor Line Vs Lean Production Line1. 傳送帶線與精益生產(chǎn)線對比ItemConveyor LineLean Production Line生產(chǎn)量Volume大批量小批量產(chǎn)品種類Ca

3、tegory單一多祥可變性 FlexibiBly低高轉(zhuǎn)拉損失 Change Over Loss低拉平衡 Line Balancing低髙無數(shù)渤作 Non Value Added多少庫存 Inventory多少反饋 Feedback慢快使用面積Area大水2. Lean Production Line 特點小型機(jī)器及較少的工人完成裝配二 Conveyor Line Vs Lean Production Line二 Conveyor Line Vs Lean Production Line裝配9多功能工人包裝檢杳2. Lean Production Line 特點適應(yīng)產(chǎn)品多樣化,減少轉(zhuǎn)拉損失2.

4、Lean Production Line 特點2. Lean Production Line 特點Cell LineConveyor Line轉(zhuǎn)拉損失2. Lean Production Line 特點RroductionDatePnxiuctiiv)A以產(chǎn)品類型安排Cell 生產(chǎn)量與銷售量同步2. Lean Production Line 特點2. Lean Production Line 特點2. Lean Production Line 特點Conveyor Line生產(chǎn)線布局靈活多變，反饋快Lean Production Line更改布局閑難WWW W W布局議活齊變.距離近満通快&g

5、t; BfitJ任人治瞄有利于提高走品品皆及員 工的丄作熱情減少拉平衡損 工Conveyor Line失，節(jié)省人Lean Production LineS.T>町調(diào)配元素多，拉平衡損失少,從而減少人工2. Lean Production Line 特點Conveyor Line節(jié)省空間Lean Production Line»取消傅送借節(jié)省空間>.縮減位間隙，的省空間A測試臺利用立體空間2. Lean Production Line 特點減少庫存Conveyor LineA/ISMD A/I M/ILean Production Line2. Lean Productio

6、n Line 特點2. Lean Production Line 特點O代表產(chǎn)品在牛產(chǎn)過程中的滯留 搬運在不同的裝配喈段存在童品搬運滯留損失>.咸少制品在綸產(chǎn)過程中的滯留縮短牛產(chǎn)同期 械少眥存2. Lean Production Line 特點2. Lean Production Line 特點2. Lean Production Line 特點暴露問題，快速解決問2. Lean Production Line 特點2. Lean Production Line 特點Push system>Pull system 的轉(zhuǎn) 變，利于減少WIP2. Lean Production Lin

7、e 特點2. Lean Production Line 特點2. Lean Production Line 特點2. Lean Production Line 特點2. Lean Production Line 特點Loss分析 > 便于發(fā)現(xiàn)問題技能損失平衡損失標(biāo)準(zhǔn)時間3. Conveyor Line Vs Lean Production Line 實 例1). AT&T2255Conveyor lineCell lineImprovementTheoretic Output /man. Hour1.18pcs1.41 pcs19.5%Actual Output/man.hour

8、1.031.3228.2%Total Loss12.7%6.4%6.3%-Line balance index63.9%89.6%25.7%FPY81%87.3%6.3%Area (Square meter/unit)3.342.137%Manufacture cost(HK$/unit)10.328.27819.8%(Labor cosUrent cosUdepreclatlonlndlrect material)3. Conveyor Line Vs Lean Production Line 實 例1). AT&T2255Bal anceTnde>GB9r6%24- Apr2

9、). AT&T2230Conveyor lineCell lineImprovementTheoretic Output /man. Hour1.31pcs1.75pcs33.6%-Actual Output/man.hour1.1461.49130.1%Total Loss12.5%14.8%2.3%Line balance index66.6%86.65%20.05%FPY81%84.55%3.55%Area (Square meter/unit)2692.121.9%-Manufacture cost(HK$/unit)9.407.1923.6%(Labor cosUrent c

10、ostiepreciaUon-flndlrect material)3 Conveyor Line Vs Lean Production Line 實 例2). AT&T2230Balance indei:86. 65%May. 0?3. Conveyor Line Vs Lean Production Line 實 例3. Conveyor Line Vs Lean Production Line 實 例3). ATT1455小Cocueyor lineCell line ImprovementTheoretic Output/hour1.69pcs-Actual Output/ho

11、ur1.52-Total Loss10%Line balance index70%FPY83%Area (Square meter/unit)1.11manufacture cost(HK$/unit)10.99(Labor cosUrent cosUdepreclationlndfrect material)2.27pcs1.9215%92%86%0.878.1534%26%5%22%4%22%25.8%3 Conveyor Line Vs Lean Production Line 實 例3) ATT1455ATT1455 (22”)Conveyor Line Balance ChartBa

12、lance Index : 92%3 Conveyor Line Vs Lean Production Line 實 例4) VT9118Conveyor lineCell lineImprovement Theoretic Output / hour1.69pcs2.27pcs34%-Actual Output/hour2.323.4347.8%Total Loss22%5.8%-16.2%Line balance index70%91%21%FPY90.5%93%2.5%Area (Square meter/unit)0.850.6820%manufacture cost(HK$/unit

13、)7.02(Labor cosUrent cosUdepreciatlonlndlrect material)4.9130%3 Conveyor Line Vs Lean Production Line 實 例4). VT91X8Ol 02588”008Ol 02588”008Balance Index:70%ooooooooooO000Q0000O30120020VTS11 S Cell line bnlanoe chart<40.0035.0030.0025.0020.0015.0010.00S.OO0.00TOM- TttM-TOM- YUM COQ- CBQ-TT1TTTTTT

14、TwUTe»«- PQQ- QQ- PQQ-O1 020304O1 0203 HM MM-XM MM- HM- MM- MM- MM- O1 02 OH Q> O1 OS 09Ol 02588”0084. Lean Production Line Fixture Improvement4. Lean Production Line Fixture ImprovementVT9118電話插座及 電源插座固定ATT2255帶電測試 減少對頻時間10 8:54 AM J4. Lean Production Line Fixture Improvement標(biāo)準(zhǔn)工作臺 空間立體

15、應(yīng)用標(biāo)準(zhǔn)工作臺 通用性5. Lean Production Line Labor ReductionModelConveyor LineCell LineLabor reduction qty/shift(Based on same output qty)ReductionPercentLaborQty/ShiftOutput/ShiftLaborQty/ShiftOutput/ShiftATT22551221123“24902621%ATT2230981123V4902728%ATT1455971700336601212%T911867190027.59501218%6. Cost Redu

16、ctionQty impactCost impactWorkers-20%over 1 million / month ( 1500HKS/operator )Technicians+ 30 (3000HKS/Tcch)+ 90000HK$； monthEngineer+ 6 (5()(X)HK$/Eng)+ 3(X)(X)HK$/monthEquipment+ 30%(CID/4421/4402/2201)+ 3 million HK$/ 60 month(50000 HKS/month)Total savingabout 1 million HKS/month三.Cell Line Imp

17、rovementL Short Cycle Time Cell V.S Long Cycle Time CellModelshort cycle time linelong cycle time lineLabor reduction qty/shift(Based on same output qty)ReductionPercentLaborQty/ShiftOutput/ShiftLaborQty/ShiftOutput/ShiftVT9114 A331000261000721%T2420|>186401(、640211%AIM2255|F486004360010%三.Cell L

18、ine Improvement2優(yōu)缺點對比優(yōu)點缺點1減少無效操作時間，生產(chǎn)效率進(jìn)一步提高1 對員工的技能要求高。2.人員少，便于管理2 測試設(shè)備浪費較大。3.能夠滿產(chǎn)品多樣化的需求。3.工具需增加。4轉(zhuǎn)拉速度快，轉(zhuǎn)拉損失更少5.更利于Line平衡提高6 節(jié)省空間2. Standard Cell Line拉倚拉之間距離爲(wèi)05M（如圖A所指）f<V喘4A A只2. Standard Test & Work Table3.標(biāo)準(zhǔn)物料擺放指引3標(biāo)準(zhǔn)物料擺放指引cr測試報表放置于鍵盤7下面并標(biāo)示清楚好m用黃色標(biāo)壞機(jī)用紅色標(biāo)示測試位SAMPLE放 置于最底層并標(biāo)示 清楚 ©3標(biāo)準(zhǔn)物料擺放指引3標(biāo)準(zhǔn)物料擺放指引外觀vs