識(shí)別與清除3M培訓(xùn)

識(shí)別與清除3M培訓(xùn)2023/2/602023/2/61什么是“3M”起因行動(dòng)1.Muri不自然的操作符合人體工程學(xué)2.Mura不規(guī)則的操作建立標(biāo)準(zhǔn)操作3.Muda浪費(fèi)減少NVAA2023/2/62為什么要開展清除“3M”可以明晰改善思路可以識(shí)別現(xiàn)場(chǎng)問(wèn)題可以提出改善需求可以改善作業(yè)環(huán)境降低員工勞動(dòng)強(qiáng)度

可以穩(wěn)定質(zhì)量與生產(chǎn)可以減少NVAA提升工作效率認(rèn)識(shí)“3M”清除“3M”2023/2/63如何清除“3M”崗位明確“3M”的研究范圍和對(duì)象工序動(dòng)作（步驟或要素）崗位布局問(wèn)題裝配流程問(wèn)題強(qiáng)度與價(jià)值問(wèn)題“3M”的基礎(chǔ)數(shù)據(jù)收集來(lái)源崗位裝配視頻2023/2/64清除“3M”-MURI不合理起因行動(dòng)1.Muri不自然的操作符合人體工程學(xué)2.Mura不規(guī)則的操作建立標(biāo)準(zhǔn)操作3.Muda浪費(fèi)減少NVAA2023/2/65清除“3M”-MURI不合理什么是MURIMURI=人的動(dòng)作或操作導(dǎo)致疲勞在操作需要體力的情況下肌肉會(huì)感到疲勞非自然或困難的操作能使人感到疲勞在操作需要注意力或記憶力集中情況下的心理疲勞在不合理、不愉快的操作情況下情緒疲勞2023/2/66清除“3M”-MURI不合理清除MURI是針對(duì)人體工程學(xué)的問(wèn)題實(shí)施改善，對(duì)人在裝配操作過(guò)程中的動(dòng)作進(jìn)行分類和分析，對(duì)不合理的動(dòng)作進(jìn)行改善。MURI重點(diǎn)關(guān)注的對(duì)象是——人的動(dòng)作崗位工序動(dòng)作（步驟或要素）2023/2/67清除“3M”-MURI不合理清除MURI的目的1、消除操作中的彎腰姿勢(shì)2、消除不自然的操作方式3、操作位置和工具的擺放位置應(yīng)舒適4、物料和貨架貨箱的定置方式易于拿取2023/2/68清除“3M”-MURI不合理如何開展清除MURI標(biāo)準(zhǔn)——9點(diǎn)分析法2023/2/69清除“3M”-MURI不合理如何開展清除MURI現(xiàn)場(chǎng)該觀察什么？2023/2/610清除“3M”-MURI不合理如何開展清除MURI現(xiàn)場(chǎng)該觀察什么？2023/2/611清除“3M”-MURI不合理如何開展清除MURI現(xiàn)場(chǎng)該觀察什么？2023/2/612清除“3M”-MURI不合理如何開展清除MURI現(xiàn)場(chǎng)該觀察什么？2023/2/613清除“3M”-MURI不合理如何開展清除MURI現(xiàn)場(chǎng)該觀察什么？2023/2/614清除“3M”-MURI不合理如何開展清除MURI現(xiàn)場(chǎng)該觀察什么？2023/2/615清除“3M”-MURI不合理如何開展清除MURI工具——視頻+人體工程評(píng)價(jià)矩陣目的——消除紅色等級(jí)的工序2023/2/616清除“3M”-MURI不合理如何開展清除MURI識(shí)別出的人體工程問(wèn)題操作工與物料之間的動(dòng)作操作工與裝配或操作對(duì)象之間的動(dòng)作2023/2/617Step6Makemurimapafter,resultsStatusofmuriafterkaizensStep7Step4Step5Step3Step1TrainingaboutbasicconceptofergonomicsIssuesObservationofmovementsthroughfilmingMakemurimapbeforeOpenthekaizenandattackredmovementsStep2Analysisofmovements清除“3M”-MURI不合理如何開展清除MURI清除MURI的七個(gè)步驟2023/2/618清除“3M”-MURI不合理如何開展清除MURITraining9PointErgonomicsAnalysisSheets(ModelArea)VideoMonitoringonLines2023/2/619清除“3M”-MURI不合理如何開展清除MURIBEFOREBendingwhilepickingbracketBendingwhileAssemblingclutchBendingwhileAssemblingGearboxWristBendingwhiletightenthenutBendingwhilepickingwaterpipeBendingwhileopeningoilcupBendingwhilescrewingfrontbeamfrontbeamweightmorethan10kg2023/2/620100%reductioninredactivitiesFD0108HorizontallyDeployedonFD0109(MA)FD0105(MA)

BC=4BendingwhileTightenliftarmreplacementoftighteningtoolsBeforeAfter清除“3M”-MURI不合理如何開展清除MURI2023/2/621AFTERGravityflowracksimplementedSyntheticDeskImprove20CMSyntheticDeskImprove10CMToolchangeGravityflowracksimplementedSyntheticDeskImprove20CMMakingspecialchairSyntheticDeskImprove20CMBEFOREBendingwhilepickingbracketBendingwhileAssemblingclutchBendingwhileAssemblingGearboxWristBendingwhiletightenthenutBendingwhilepickingwaterpipeBendingwhileopeningoilcupBendingwhilescrewingfrontbeamfrontbeamweightmorethan10kg21MuriKaizensdoneinMA

BC=1.6

BC=3.4

BC=1.5

BC=1.9

BC=2.2

BC=2.2

BC=1.6

BC=3.1

BC=1.7清除“3M”-MURI不合理如何開展清除MURI2023/2/622清除“3M”-MURI不合理如何開展清除MURI2023/2/623清除“3M”-MURA不均衡起因行動(dòng)1.Muri不自然的操作符合人體工程學(xué)2.Mura不規(guī)則的操作建立標(biāo)準(zhǔn)操作3.Muda浪費(fèi)減少NVAA2023/2/624清除“3M”-MURA不均衡什么是MURA記錄和觀察一位操作工重復(fù)完成崗位某個(gè)工序裝配內(nèi)容所消耗的時(shí)間，其每次完成時(shí)間的差異稱為MURA記錄和觀察不同操作工重復(fù)完成崗位某個(gè)工序裝配內(nèi)容所消耗的時(shí)間，其每次完成時(shí)間的差異稱為MURA分析排查崗位每道工序在裝配周期中導(dǎo)致工時(shí)波動(dòng)的變化點(diǎn)，通過(guò)改善消除或縮小完成工序內(nèi)容所消耗工時(shí)的波動(dòng)范圍，目的是使崗位裝配周期和質(zhì)量趨于穩(wěn)定，提升裝配效率。2023/2/625清除“3M”-MURA不均衡MURA重點(diǎn)關(guān)注的對(duì)象是——工序工時(shí)波動(dòng)崗位工序動(dòng)作（步驟或要素）如何通過(guò)分析識(shí)別MURA?2023/2/626清除“3M”-MURA不均衡什么是不易反復(fù)和復(fù)制的操作?1、操作或活動(dòng)的完成的結(jié)果取決與操作者的身體條件2、產(chǎn)品設(shè)計(jì)缺陷或缺少標(biāo)準(zhǔn)工具導(dǎo)致裝配困難（對(duì)準(zhǔn)）3、由于前道的問(wèn)題導(dǎo)致裝配困難4、由于公差配合問(wèn)題導(dǎo)致裝配困難2023/2/627如何開展清除MURA清除“3M”-MURA不均衡Step6Makemuramapafter,resultsMakemuraanalysisafterStep7Step4Step5Step3Step1TrainingaboutbasicconceptsstaticsChoosetheoperationMakemuramapbeforeOpenthekaizenandattackmuraoperationStep2Observationofmuraoperationandmakeanalysisbefore2023/2/628如何開展清除MURA清除“3M”-MURA不均衡BEFOREManualassemblyTwotighteningdevicesusingapipePartsnotsetdisplaySeparationforkhandslapAdjustthecarcarddirectionPickingfromdifflocationsPickingfromdifflocationsPickingfromdifflocations2023/2/629如何開展清除MURA清除“3M”-MURA不均衡TotalNoofObservation20Average

Time

12Min&Max8-17(sec)TotalNoofObservation20Average

Time

3.6Min&Max3–5(sec)ManualassemblyBEFORESpecialToolmadeAFTERNormalDistributionCurveNormalDistributionCurveAveragecycletimeisshortened:-70%Rangeofvariationisshortened:-77.7%

BC=5.02023/2/630TotalNoofObservation20Average

Time

44Min&Max32-58(sec)TotalNoofObservation20Average

Time

11Min&Max8–13(sec)WrenchtotightenBEFOREPneumatictoolstotightenAFTERNormalDistributionCurve(Before)NormalDistributionCurve(After)NormalDistributionCurveAveragecycletimeisshortened:-75%Rangeofvariationisshortened:-80.7%

BC=19.8如何開展清除MURA清除“3M”-MURA不均衡2023/2/631BEFOREManualassemblyTwotighteningdevicesusingapipePartsnotsetdisplaySeparationforkhandslapAdjustthecarcarddirectionPickingfromdifflocationsPickingfromdifflocationsPickingfromdifflocationsAFTERSpecialToolmadeAddatracheaRacksimplementedToolchangeWiththecarcardplacedforassemblyworkersShooterimplementedShooterimplementedImplementationofthesmallboxes

BC=5.0

BC=11

BC=7.8

BC=3.2

BC=13

BC=5.4

BC=6.1

BC=8.2

BC=4.317MuraKaizensdoneinMA如何開展清除MURA清除“3M”-MURA不均衡2023/2/632清除“3M”-MUDA不節(jié)約起因行動(dòng)1.Muri不自然的操作符合人體工程學(xué)2.Mura不規(guī)則的操作建立標(biāo)準(zhǔn)操作3.Muda浪費(fèi)減少NVAA2023/2/633什么是MUDA清除“3M”-MUDA不節(jié)約MUDA=不增值活動(dòng)2023/2/634清除“3M”-MUDA不節(jié)約如何開展清除MUDA2023/2/635清除“3M”-MUDA不節(jié)約如何開展清除MUDA2023/2/636清除“3M”-MUDA不節(jié)約如何開展清除MUDA2023/2/637清除“3M”-MUDA不節(jié)約如何開展清除MUDA2023/2/638清除“3M”-MUDA不節(jié)約如何開展清除MUDADollsystem2023/2/639Step6MakeMudamapafter,resultsMakeMudaAnalysisafterStep7Step4Step5Step3Step1TrainingaboutbasicconceptofMudaMovement

ObservationofmovementsthroughfilmingMakeMudamapbeforeOpenthekaizenwithStep2MakeMudaanalysisbefore清除“3M”-MUDA不節(jié)約如何開展清除MUDA2023/2/640清除“3M”-MUDA不節(jié)約如何開展清除MUDABEFOR2023/2/641在示范區(qū)域設(shè)計(jì)制作裝配小車（Doll-System），并遵循裝配黃金區(qū)域、最佳拾取區(qū)域、一次性拿取原則Inthemodelarea,Tocreatethedoll-systemwehavefollowedthreebasicconceptsasGoldenZone,StrikeZoneandOneMotionPicking。裝配黃金區(qū)域最佳拾取區(qū)域一次性拿取清除“3M”-MUDA不節(jié)約如何開展清除MUDA2023/2/6421、閱讀計(jì)劃；2、取中冷管13、取中