ANDON-暗燈系統(tǒng)課件

1Principle:ContinuousImprovement

原則：不斷改進(jìn)

Element:29AndonConcept

要素：29暗燈概念

GM-GMSOperatingGuideline

全球制造系統(tǒng)操作指引

29.0AndonSystem

29.0暗燈系統(tǒng)23TableofContents

目錄GM-GMSRelationship全球制造體系的內(nèi)部聯(lián)系Definition定義Purpose目的CoreRequirements核心要求Benefits益處AndonEnablers暗燈驅(qū)動因素ProcessOverview:過程概要

AndonComponents暗燈的組成

AndonPullcordandSwitches暗燈的拉繩和開關(guān)

Visual&AudioSignals目視和聲音信息

AndonBoards暗燈板

ConveyorLineLayout傳動鏈布局

SystemOperation系統(tǒng)運(yùn)行

HowtoUsetheAndonSystem如何使用暗燈系統(tǒng)Roles&Responsibilities

角色和責(zé)任Summary總結(jié)Appendix:References

附錄：參考資料Appendix:RevisionLog附錄：審核日志4GM-GMSRelationship全球制造體系的內(nèi)部聯(lián)系TheGM-GMSOperatingGuideline#29.0AndonSystem,supportstheGM-GMSPrincipleofContinuousImprovementincontributingtotheBusinessGoals.GM-GMS#29.0操作指引“暗燈系統(tǒng)”支持GM-GMS“不斷改進(jìn)”原則，有助于制造系統(tǒng)五個目標(biāo)的實(shí)現(xiàn)5Definition定義TheAndonSystemisanoperationalfloorprocesscontrolsystemthatcanbeactivatedmanuallyorautomaticallytocommunicatetheneedforassistancewhenabnormalconditionsoccur,aswellastocommunicateotherrelevantinformation.暗燈系統(tǒng)是流水線操作過程控制系統(tǒng)，當(dāng)出現(xiàn)異常狀況時，通過手動或自動激活系統(tǒng)來尋求幫助以及交流其他相關(guān)的信息。6Purpose目的ThepurposeoftheAndonSystemisto:暗燈系統(tǒng)的目的就是：Empoweroperationstopreventtheoccurrenceorpassingofdefectstothenextprocess.使操作過程能夠防止缺陷產(chǎn)生或流入下一道工序。Callforassistancewhenbehindintheworksequenceoranoutofstandardconditionoccurs.當(dāng)跟不上工作流程或有非標(biāo)準(zhǔn)的狀況產(chǎn)生時，尋求幫助。Initiatetheproblemsolvingprocess.促使解決問題流程的實(shí)施Drivemanagementandsupportgroupsto“GoandSee”theproblemsonthefloorandtakeaction.推動管理層和支持工段“巡視發(fā)現(xiàn)”生產(chǎn)線上的問題并采取行動。Collectdata,identifyingwhereproblemsoccurmostfrequently.搜集數(shù)據(jù)，識別問題發(fā)生最多的地方Communicateoperationalstatusinformation.傳遞操作中的狀態(tài)信息7AndonCoreRequirements暗燈核心要求1TheAndonSystem:暗燈系統(tǒng)a)visuallydisplaysrelevantinformationforanyonetoseeandquicklyrecognizetheproblem.

目視化顯示相關(guān)信息使每個人都看見，并迅速確認(rèn)問題b)Interlockstotooling,equipmentandmanualactivation和加工工具、設(shè)備和手動操作相互關(guān)聯(lián)c)hasthecapabilitytostopthemovinglineprocessattheFPS,exceptinemergencycases

緊急情況下，在固定停止位阻止生產(chǎn)線的移動d)consistsofasinglepullcord/pushbuttonsystem,easilyaccessibletotheoperator

由簡單的拉繩/按鈕系統(tǒng)組成，方便操作者使用e)directsthesupportorganizationto“GoandSee”theproblems

指導(dǎo)支持團(tuán)隊“巡視發(fā)現(xiàn)”問題f)providesfeedbacktothesourcefromqualitychecks,inspectionandrepairstations

把質(zhì)量檢查、審核和返修工位的信息反饋回問題的源頭g)providesinformationtothemaintenanceorganizationtorespond

向維修工段提供信息使其及時響應(yīng)h)signalspeopletoperformstandard/routineactivities提醒員工進(jìn)行標(biāo)準(zhǔn)/常規(guī)的活動i)providesdata(pullsandlinestoptime)byestablishedAndonzonetoproblemsolvebottlenecksandproblemareas

通過暗燈區(qū)域的數(shù)據(jù)(拉動和停線的時間)顯示問題解決的瓶頸以及問題所在區(qū)域j)isflexibleenoughtoincorporateothervisualmanagementneedsastheyarise

有很大的彈性，可以融入其他的目視化管理需求82Apeoplesupport/teamconceptstructuremustexistthathasclearlydefinedrolesandresponsibilitiesasthejobrelatestotheproductionfloor(teamleader,groupleader,productionleadership,maintenance,personnel,engineering,quality,materials,other).

必須有一員工支持/團(tuán)隊概念體系，清楚地定義與生產(chǎn)線相關(guān)的所有工作的角色和責(zé)任(班組長，工段長，生產(chǎn)領(lǐng)導(dǎo)層，維修，人事，工程，質(zhì)量，物料，及其他)3StandardizedWorkisclearlydocumentedandfollowed.

標(biāo)準(zhǔn)化操作明確地整理成文，并予以執(zhí)行4QualityStandardsandProcessControlsaredefinedforeachjob.

每個工位的質(zhì)量標(biāo)準(zhǔn)和過程控制都有定義5TheAndonSystemisusedtoachievetheconceptof“Donotaccept,build,orpassadefect”.

使用暗燈系統(tǒng)來達(dá)到“不接收，制造，或傳遞缺陷”的思想觀念6TheProblemSolvingProcessisusedtoresolverecurringAndoncalls.

使用問題解決流程來消除重復(fù)的暗燈呼叫7Actualtakttime(conveyorspeed)isestablishedtoallowforproperuseoftheAndonSystem.

建立實(shí)際單件工時(傳動鏈的速度)，合理利用暗燈系統(tǒng)8DecouplingexiststoallowfortheproperuseoftheAndonSystem.

退耦(裝置)的存在使得要合理利用暗燈系統(tǒng)9Benefits益處TheAndonSystemsupportscontinuousimprovementinSafety,People,Quality,Responsiveness,andCost.暗燈系統(tǒng)支持在安全、人員、質(zhì)量、響應(yīng)和成本方面的不斷改進(jìn)Andonisusedasaformalcommunicationtooltoalerttheorganizationto“Callsforhelp”andabnormalprocessconditions.AnAndonresponseprocessshouldbeinplacetosupportandrectifysituationsasquicklyaspossible.暗燈作為一種正式的交流工具，警示相關(guān)部門尋求幫助以及有異常的流程狀況發(fā)生。而設(shè)置暗燈響應(yīng)流程為了盡快支持并糾正相關(guān)狀況。Andonboardsforallareasareeasytounderstandandsupport”StatusataGlance”每個區(qū)域的暗燈板都容易理解并“一目了然”Andonareaconfigurationsareestablishedtodirectthesupportorganizationsto“GoandSee”theproblemsonthefloor.暗燈區(qū)的布局可以指導(dǎo)支持工段巡視并發(fā)現(xiàn)流水線上的問題Andonisflexibleinordertoincorporateimprovementsandrequiredchangesastheyarise.為了融入不斷改進(jìn)和所要求的變化，暗燈設(shè)計是柔性的。Andoncollectsdataforproblemsolvingandidentifyingwhereproblemsoccurmostfrequently.暗燈搜集解決問題的數(shù)據(jù)并識別問題發(fā)生最多的區(qū)域Andoncanremindemployeestoperformroutineactivitiesatregularintervals.暗燈可提醒員工定時進(jìn)行常規(guī)活動EmpowersteammemberstoBuildQualityinStation使得員工在每個工位制造質(zhì)量Andonisatooltokeepthelinerunning!暗燈是保持流水線運(yùn)行的工具10AndonEnablers暗燈的驅(qū)動因素BelowaretheenablersthatshouldbeinplacepriortoactivatingtheAndonSystem.以下是在使用暗燈系統(tǒng)前需要合理設(shè)置的驅(qū)動因素ContinuousImprovementCulture不斷改進(jìn)的氛圍ManagementCommitment管理層的義務(wù)Teamwork團(tuán)隊合作EmployeeTraining員工培訓(xùn)DefinedQualityStandards定義過的質(zhì)量標(biāo)準(zhǔn)LevelScheduling同步的計劃FixedPositionStop固定停止位Decoupling/Buffers退耦(裝置)/緩沖StandardizedWork(KeyPoint:avoidoperationinterferenceanddowntimebyreducingoreliminatinglayerbuildsonadjoiningprocesses)標(biāo)準(zhǔn)化操作(關(guān)鍵點(diǎn)：在相鄰的工藝流程減少或消除疊層制造，以避免操作的互相影響以及停線)StandardizedProblemSolving標(biāo)準(zhǔn)化問題解決流程AddressSystem定位系統(tǒng)CapableProcess&Equipment可行的工藝和設(shè)備MutualTrust&Respect互相信任和尊重11AndonComponents暗燈組成WorkstationAddresses工位的位置PullCords,Buttons,andSwitches拉繩，按鈕和開關(guān)Lights亮燈AudioSignalsandSpeakers聲音信號和揚(yáng)聲器AndonBoards暗燈板12Andonboards,workstationlightsandspeakersprovidealertstotheteamleader,groupleader,maintenanceteammember,andmanagementsotheycanrespondquicklyto“Callsforhelp”.暗燈板、工位燈和聲音裝置可以提醒班組長、工段長、維修員工和管理人員對于“尋求援助的需求”迅速響應(yīng)。AndonSystemLayoutforaMovingLine流水線的暗燈系統(tǒng)布局13PullCords,ButtonsandSwitches拉繩、按鈕和開關(guān)TheAndonsystemcanbeactivatedbyanumberofdifferentmethods.Thischartdescribestheproposeanduseofthedifferentpullcords,buttons,andswitchesoftheAndonsystem.有幾種不同的方式激活暗燈系統(tǒng)。圖表描述了暗燈系統(tǒng)不同拉繩、按鈕和開關(guān)的目的及使用。14ActivationDevice激活設(shè)備Purpose目的WhereUsed使用的地方Description描述AndonPullCord暗燈拉繩AndonPushButton暗燈按鈕RunStopSwitch運(yùn)行停止開關(guān)ManipulatorOver-TravelLimitSwitch操作者超程限制開關(guān)TeamMemberHelpCall組員幫助響應(yīng)TeamMemberHelpCall組員幫助響應(yīng)Stoptheprocessorconveyorimmediatelyforsafetyreasons為了安全原因，立即停止流程或傳動鏈Increaselevelofsafetyontheworkstationbystoppingtheconveyorwhenanover-travelconditionoccurs.當(dāng)出現(xiàn)超程情況，停止傳動鏈以提高工位的安全性O(shè)naworkstationinamovingconveyorline移動的傳動鏈上的工位WorkCells,suchasaBodyshoporPressLine,orinaPaintBooth工作間，如車身或沖壓線，或在油漆房Installedalongtheconveyorandonallmajorequipment沿傳動鏈在主要設(shè)備旁安裝Thelimitswitchisinstalledalongthetravelofthemanipulator限制開關(guān)在操作者行進(jìn)路程旁安裝Connectedtoaswitchwithalightandloopedalongthelengthoftheconveyor亮燈和開關(guān)連接，沿傳動鏈形成環(huán)路Switchboxwithapushbuttonislocatedinthemostconvenientlocationoftheworkcell有按鈕的開關(guān)盒處于工作間最方便操作的地方PlacedatregularFixedPositionStopsonalternatingsidesoftheline.(Note:Mustbeinaccordancetoallsafetystandardsandregulations.)在線的兩旁交替放置于固定停止位處(注：必須符合所有的安全標(biāo)準(zhǔn)和規(guī)定)Topreventmanipulators,articulatingarmsandassistdevicesfromdangerousover-travelconditionstoincreasesafetyontheworkstations.避免操作者、連接設(shè)備和輔助儀器發(fā)生危險的超程情況，提高工位的安全性。15PullCords,ButtonsandSwitches拉繩、按鈕和開關(guān)16ActivationDevice激活設(shè)備Purpose目的WhereUsed使用的地方Description描述CriticalCheckCompleteButton&Light關(guān)鍵檢驗(yàn)完成按鈕和亮燈LocalQualityCallButtons區(qū)域質(zhì)量響應(yīng)按鈕

DownstreamQualityCallButtons下道工序質(zhì)量響應(yīng)按鈕

ToindicateCriticalCheckshavebeencompleted表示關(guān)鍵檢查已完成TocallProductionTeamLeadertotheQualityVerificationStation呼叫班組長到質(zhì)檢工位TocalltheProductionGroupLeadertotheQualityVerification呼叫生產(chǎn)工段長到質(zhì)檢工位SwitchesinstalledinZoneareaorasneededtosupporttheprocess開關(guān)安裝在需要的區(qū)域，支持工藝流程QualityVerificationStations質(zhì)量檢驗(yàn)工位QualityVerificationStations質(zhì)量檢驗(yàn)工位Thebuttonlightturnsonindicatingthatacheckmustbedone.Afterthebuttonispressed,thesystemturnsoffthelightbutton,acknowledgingthecheckhasbeencompleted.IftheTeamLeaderdoesnotpressthebuttonbythetimethechecktimeexpires,thebutton-lightflashes.燈亮表示必須檢查。按下按鈕后，系統(tǒng)關(guān)閉亮燈，表示檢查完成。如果班組長在檢查時間結(jié)束時，沒有按下按鈕，亮燈將閃爍。Pushbuttonswitchmountedonapedestal按下裝在支架臺上的開關(guān)按鈕Pushbuttonswitchmountedonapedestal按下裝在支架臺上的開關(guān)按鈕17VisualandAudioSignals目視和聲音信號VisualSignals目視信號Standardcolorshelpdeterminethe“StatusAtAGlance”顏色標(biāo)準(zhǔn)幫助確定狀態(tài)Greensignals“OK”orNormalStatus綠色表示OK或正常狀態(tài)Yellowsignals“HelpRequired”PotentialRiskofLossofProductionorQuality.黃色表示需要幫助，生產(chǎn)或質(zhì)量有潛在損失的風(fēng)險Redsignals“Line,ProcessOrEquipmentIsDown”-ImmediateHelpIsRequired.紅色表示生產(chǎn)線、流程或設(shè)備的停止-需要立即搶修(InsomeapplicationsofAndonitmaybenecessarytouseothercolorstofulfillalltherequirementsofthesystem.)在暗燈的有些使用中，需要應(yīng)用其他顏色來滿足系統(tǒng)的所有要求18AudioSignals聲音信號AudiosignalsconveyauniquemelodyoraudiosignaltoalertthecorrectsupportpersonneltolookupattheAndonBoardortoseetheworkstationlightstodeterminethespecificlocationcallingforhelp.聲音信號發(fā)出獨(dú)特的音樂或聲響來提醒糾正支持人員觀察暗燈板或工位亮燈以確定需要幫助的特定工位。Typicallytwotypesofaudiosignalsareused:使用的兩種典型的聲音信號：

Melodies音樂

Tones音調(diào)UniquemelodiesareusedtodistinguishdifferentAndonevents,Groups,AndonZones,androutinereminders.獨(dú)特的音樂用來區(qū)分不同的暗燈事件、工段、暗燈區(qū)域以及日常的提示TonesareusedforcommonAndonalerts,suchasequipmentfaultsandscheduledstartorstopoftheline.聲調(diào)是用來常規(guī)的暗燈提醒，如設(shè)備故障，生產(chǎn)線的啟動或停止。19AndonLights亮燈ActivationDevice激活設(shè)備Purpose目的WhereUsed使用的地方Description描述WorkstationLight工位燈Runstoplight運(yùn)行停止燈EquipmentFaultlight設(shè)備故障燈

Supportshelpcallfunction尋求幫助功能SupportRunstopfunction運(yùn)行停止功能Supportequipmentfaults顯示設(shè)備故障OneYellowworkstationlightislocatedattheendofeachworkstation.每個工位的末端有一黃色的燈Oneredbeaconlightislocatedattherunstopswitch在運(yùn)行停止開關(guān)處有一紅色的信號燈Oneredbeaconlightislocatedatthecontrolpanelofeachpieceofmajorequipment在每個主要控制設(shè)備的面板上有一紅色的信號燈Turnsonsolidyellowinaresponsetoacallforhelp.Flasheswhenthevehiclereachesthefixedpositionstop.尋求幫助時顯示常黃。當(dāng)車輛達(dá)到固定停止位就閃爍Whenrunstopswitchisactivated,thelightflashes.運(yùn)行停止開關(guān)激活時，亮燈閃爍Whenanequipmentfaultoccurs,itflashes設(shè)備發(fā)生故障，燈就閃爍20AudioSignalsandSpeakers聲音信號和揚(yáng)聲器TheAndonsystemwillplayuniqueaudiosignalssuchas,melodiesandtomesforspecifictypesofhelpcallsandfaults.Itshouldbeuserfriendlyandflexibletoallowforthefollowingfunctions:暗燈系統(tǒng)會發(fā)出獨(dú)特的聲音信號如，求助和發(fā)生故障的特定類型的音樂和聲調(diào)。系統(tǒng)具有以下功能，對使用者友好并具有彈性：

LengthofTimeOn聲音的長短

FastModeofPlay(25%to100%FasterthanOriginal)

播放的快速模式(比開始快25%到100%)Prioritylevelassignmentforeventmelodiesandtones

音樂和聲調(diào)的優(yōu)先級分配

SelectableLocationofMelodyPlay(Zone,Boardorboth)

可供選擇的播放音樂(區(qū)域，顯示板)CapableofsupportingallAndonCallsandFaultswithaspecificMelodyorTone

用一特定的音樂和聲調(diào)支持所有的暗燈求助或故障情況

Adjustablespeakervolume可調(diào)節(jié)的聲響21SpeakersareplacedtoensureTeamLeadersandGroupLeadersandallotherrespondershearthemelodies.Speakerplacementisespeciallycrucialforlouderfacilities.放置揚(yáng)聲器是確保班組長，工段長以及其他所有響應(yīng)者聽到音樂。揚(yáng)聲器的放置對于有噪聲的設(shè)備十分重要。22AndonBoards暗燈板DifferentTypesofAndonBoards(allboardsmaynotberequiredtofulfillthecorerequirementsofAndon)不同類型的暗燈板(所有的暗燈板不一定都要滿足暗燈的核心要求)GroupBoards工段板Supportsaspecificgroupofoperationsorproductionarea,usuallyonegroupleader’sarea支持一特定工段的操作或生產(chǎn)區(qū)域，通常是工段長區(qū)域ShopStatusBoard車間狀態(tài)板Supportstheorganizationandprovidesreal-timestatusandperformanceinformationofthecurrentshift.提供當(dāng)前班次的實(shí)時狀態(tài)和績效信息23PerformanceBoard績效板SupportstheProductionteamleadersandgroupleadersbyprovidingreal-timepullcountanddowntimeinformationbyZoneforthecurrentshift.提供當(dāng)前班次各個區(qū)域的拉燈次數(shù)及停線信息，支持生產(chǎn)班組長和工段長FinalProcessBoard最終工藝板SupportstheProductionandQualityOrganizationsbyprovidingqualityandthroughputinformationandinformsthemwherehelpisrequested支持生產(chǎn)部門和質(zhì)量部門，提供質(zhì)量和產(chǎn)量信息并告知需要幫助的地方MaintenanceBoard維修板SupportstheMaintenanceorganizationbyprovidinginformationrelatedtoabnormalitieswithequipmentandinformsthemwherehelpisrequested.提供設(shè)備異常的相關(guān)信息，支持維修部門并告知需要支援的地方24GroupBoard工段板TheGroupBoardsupportsaspecificgroupofoperations,conveyorlengthorproductionarea,usuallyonegroupleader’sarea.Theappropriatelightisturnedonandmelodyisplayedtoalertsupportpersonnelwhenhelpisrequestedorafaultoccurs.工段板是對一個特定工段的操作，傳動鏈或生產(chǎn)區(qū)域，通常是工段長區(qū)域的支持。當(dāng)需要幫助或發(fā)生故障時，相關(guān)的燈亮，音樂響起提醒支持人員。Becauseofdifferentprocessrequirements,groupsizes,andboardlocationsforeachdepartment,theboardsmayvaryslightlyfromdepartmenttodepartment.由于不同的工藝需要、工段大小和位置，每個工段的暗燈板略有區(qū)別Smallersizeboardscanbeusedwhereteammembersareworkinginisolatedworkcellsaslongastheyretainthecommonfunctionalityrequirements.員工在單獨(dú)的工作間里操作時，可使用較小尺寸的暗燈板，只要符合通常的功能要求。ItshouldalsoberecognizedthatinotherworkcellapplicationsoftheAndonsystemsuchasastampingprocess,thegroupboardsmaylookdifferentfromwhatwewouldseeinatypicalmovinglineoperation.Theseboardswouldbemorefocusedoncellcallsandequipmentfaults,buttheintentofthesystemmuststaytruetothecorerequirementsofAndon.必須指出，在其他工作間使用的暗燈系統(tǒng)，如沖壓流程，工段板和運(yùn)行的流水線操作的工段板是不同的。這些板更注重于工作間的求助及設(shè)備故障，當(dāng)然系統(tǒng)的內(nèi)容必須符合暗燈的核心要求。2526ShopStatusBoard車間狀態(tài)板Supportstheorganizationandprovidesreal-timestatusandperformanceinformationforthecurrentshift.提供當(dāng)前班的實(shí)時狀態(tài)和績效信息Thelocationoftheboardistypicallyattheendofashop,orattheVisualManagementCenterwhereallteammemberscanobtainstatusinformationquickly.板的位置通常在車間的末端，或在目視化管理中心，所有的員工可以迅速得到狀態(tài)信息。27Line生產(chǎn)線Condition情況ShopStatus車間狀態(tài)AreaorLineStatus區(qū)域或生產(chǎn)線狀態(tài)Starved/Blocked短缺/堵塞TotalDowntimeArea/Line總的停線時間KeyProductionInformation&Counts關(guān)鍵生產(chǎn)信息及數(shù)量Green-OK-Lineisrunning綠色-生產(chǎn)線運(yùn)行正常Red-NotOK.Lineisnotrunning.紅色-生產(chǎn)線沒有運(yùn)行FA：FloatAlarm:YellowSolidLevel2AlarmYellowFlashingLevel3Alarm緩沖警示：黃燈常亮2級警示，黃燈閃爍3級警示Green-OK-Lineisrunning綠色-生產(chǎn)線在運(yùn)行Red-LineisdownforAndonCallorEquipment

紅色-由于暗燈或設(shè)備的原因停線Green-OK綠色-OKStarved/Blocked-Red紅色-短缺/堵塞TotalAreaorLinedowntime總的區(qū)域或生產(chǎn)線停線時間CurrentShiftProductionInformation-Goal,Actual,Trend,Quality,Float,Shipped當(dāng)前班生產(chǎn)信息-目標(biāo)，實(shí)際，趨勢，質(zhì)量，緩沖，裝運(yùn)PainttoGABufferCount油漆到總裝的緩沖數(shù)28PerformanceBoard績效板ThePerformanceboardsupportsaspecificgroupofoperationsorproductionarea,usuallyonegroupleader’sarea.績效板支持一特定工段的操作或生產(chǎn)區(qū)域，通常是工段長區(qū)域。29Display顯示Description描述AndonDowntimeClock暗燈停線時間計時鐘EquipmentDowntimeClock設(shè)備停線時間計時鐘VerificationStationDowntimeClock質(zhì)檢工位停線時間計時鐘ZoneDowntimeClock區(qū)域停線時間計時鐘ResetButtons重置按鈕DisplaysthetotallinedowntimerelatedtoAndoncalls顯示與暗燈相關(guān)的總停線時間DisplaythetotallinedowntimeduetoEquipmentfaults顯示由于設(shè)備故障的總停線時間Displaysthetotallinedowntimeduetoqualitycallsandrepairsintheverificationstations顯示由于質(zhì)檢工位的質(zhì)量問題或返修而造成的停線時間Displaysthetotallinedowntimeforeachspecificzone顯示每個特定區(qū)域的總的停線時間Resetbuttonsareusedtoreseteachdowntimeclockandpullcountdisplayafterinformationisrecorded.在記錄數(shù)據(jù)后，用重置按鈕重新設(shè)置每個停線計時鐘和拉動次數(shù)30FinalProcessBoard終線流程板TheFinalProcessBoardsupportsthefinalprocessandproductionrepairorganizationsbyalertingthemwhenhelpisneeded.Italsoprovidesqualityandthroughputinformation.終線流程板支持最終工藝以及生產(chǎn)返修部門，提醒他們何時需要援助。同時提供了質(zhì)量和產(chǎn)量信息。31QualityOKRates:質(zhì)量通過率DisplayedistheActualOKratesfortheQualityVerificationstations顯示質(zhì)檢工位的實(shí)際通過率ThroughputPerformance產(chǎn)量績效DisplayedareActualnumberofvehiclesoffEOL顯示離開終線的實(shí)際車輛數(shù)量OnholddisplaysthenumberofvehiclesOnholdHold表示滯留的車輛OK-Status:Normalfloatlevel,allrepairareasunderthepredeterminedfloatlevels.正常的浮動車輛標(biāo)準(zhǔn)，所有的返修區(qū)域在設(shè)定的浮動標(biāo)準(zhǔn)范圍內(nèi)Level1Alarm,forFinalProcessonly,Systemturnsonlevel1alarmconditionatapredeterminedpercentageoffloatlevelcapacity.只對終線工藝而言，系統(tǒng)在預(yù)置的流動容量百分比上顯示一級警示狀態(tài)Level2Alarm:SystemturnsonLevel2Alarmconditionatapredeterminedpercentageoffloatlevelcapacity,priortoreachingmaximumcapacity.Groupleadersinvolvedinproblemsolving.二級警示：在達(dá)到最大容量之前，系統(tǒng)在預(yù)置的流動容量百分比上顯示二級警示狀態(tài)。工段長參與問題解決。Level3Alarm:Systemturnsonatthemaximumallowablefloatlevelcapacity.Areamanagerandplantmanagementinvolvedinproblemsolving.三級警示：系統(tǒng)達(dá)到最大允許流動容量時的級別。區(qū)域經(jīng)理和生產(chǎn)基地領(lǐng)導(dǎo)班組參與問題解決。

32MaintenanceBoard維修板TheMaintenanceBoardsupportstheMaintenanceorganizationbyprovidinginformationrelatedtoabnormalitieswithequipmentandtoolsandlocationwherehelpisrequested.提供設(shè)備異常的相關(guān)信息，支持維修部門并告知需要支援的地方TheMaintenanceBoarddisplayswillvarydependingonthemaintenancedeploymentstrategyimplemented.Insomecases,extramarqueesmaybeaddedasnecessarytosupporttheeffectivenessofthemaintenancefunction.Shownbelowareexamplesofdepartmentalmaintenanceboards.依據(jù)實(shí)施的維修分布策略，維修板的顯示有所不同。有時，必須增加附加的車輛以支持維修的效率。以下是部門維修板的樣例。33Line生產(chǎn)線Condition情況AreaorConveyorStatus區(qū)域或傳動鏈狀態(tài)EquipmentStatus設(shè)備狀態(tài)EquipmentUptimeActual設(shè)備實(shí)際工作時間BufferCount緩沖數(shù)BufferCount緩沖數(shù)Green-OK;Equipmentandconveyorsrunning.綠色-設(shè)備和流水線運(yùn)行正常Red-Linenotrunning.Conveyororequipmentnotrunning紅色-流水線或設(shè)備停止運(yùn)行Green-OK綠色-OKRed-Equipmentfault紅色-設(shè)備故障DisplayedistheActualuptimeoftheequipmentineachrespectivearea.顯示的是每個區(qū)域設(shè)備的實(shí)際工作時間PainttoGAbuffercount油漆到總裝的緩沖數(shù)Trim4toChassis1buffercount內(nèi)飾四到底盤一的緩沖數(shù)34AndonboardLayoutPlanning暗燈板規(guī)劃布局WhenplanningAndonboardlayoutsandboardconfigurationsinadepartment,therearemanythingsthatneedtobeconsidered.Suchas:當(dāng)在一部門進(jìn)行暗燈板的規(guī)劃和版面設(shè)置時，需要考慮很多事。如：WhataretheTeam/Groupsizesandlocations?班組/工段的大小和位置Canthegroup,includingtheverificationstation,betiedintooneboard?工段，包括質(zhì)檢工位，可否聯(lián)成一塊板？Isthereaclearlineofsightforteammembers?班組成員是否能清楚看見Whatistheclearanceheightneededunderneaththeboardstoallowforareaactivity?考慮區(qū)域活動的進(jìn)行，板下的高度是多少？Whatisthemaintenancedeploymentstrategyforequipmentfaults?對于設(shè)備故障的維修分布策略是怎樣的？Aretherecentralorsatellitemaintenanceworkshops?是否有維修中心車間？Aretherescheduledcontrolledstopsandstarts?是否有計劃的控制停線和啟動？Areproceduresinplaceforroutinereminderssuchascriticalchecksormaterialpullcardpick-up?是否有程序作為日常行動的提醒，如關(guān)鍵檢查或物料拉動卡的搜集？Isthereflexibilityinthesystemforfutureneeds?對于系統(tǒng)將來的需求是否有可塑性？Isthereanervecenterorcentralmeetingarea?是否有控制中心或會議區(qū)域？35ConveyorLineLayout流水線的布局KeyPoints關(guān)鍵點(diǎn)GroupAndonboardssupportAndonzones.Typicallyazonerepresentsoneteam(4-6teammembers).Azonecanbeleftorrightoperationsand2-5workstations.Oneworkstationequalsthedistancebetweenthefixedpositionstopmarkings.Insomecasesduetoisolatedteamlocations,individuallinesegments,andautomation,Andonboardsmayneedtosupportthestationandteamlevel.工段的暗燈板支持暗燈區(qū)域。通常一個區(qū)域表式一個班組(4-6個組員)。一個區(qū)域包含左邊或右邊的操作，2-5個工位。每個工位在固定停止位標(biāo)記間的距離是相同的。有些情況，由于獨(dú)立的班組位置，單獨(dú)的分裝線，暗燈板需要支持這個工位和班組。Andoncordsareinstalledinaclotheslinefashiononmovinglinesorascallbuttonsinworkcellsandpaintbooths.Workstationlightsarelocatedattheendoftheworkstation.Runstopswitchesarelocatedasrequiredinthearea.Speakersareplacedineachzone.暗燈線在移動的生產(chǎn)線上的安裝采用曬衣繩的樣式，而在工作間和油漆房內(nèi)采用按鈕形式。工位的末端設(shè)置亮燈。運(yùn)行停止開關(guān)在需要的區(qū)域放置。每個區(qū)域都有揚(yáng)聲器。36暗燈板位于生產(chǎn)線或區(qū)域的中央37SystemOperation系統(tǒng)運(yùn)行InformationonthefollowingpagesdescribestheSystemhelpcallsandFaultconditionsoftheAndonsystem.Describedindetailarethecorrespondingvisualandaudioalertsforeachtypeofhelpcallandfaulteventlistedbelow:以下幾頁的信息描述了暗燈系統(tǒng)的系統(tǒng)求助信號和故障狀態(tài)。對以下羅列的每一種求助信號和故障的目視和聲音提示進(jìn)行了詳細(xì)的描述。

TeamMemberhelpcall組員幫助需求

ElectronicErrorProofinghelpcall電子防錯幫助需求

FloatAlarm緩沖警報

LocalQualityverificationstationhelpcall

局部質(zhì)量檢驗(yàn)工位需求

Downstreamqualityverificationstationhelpcall

后道工序質(zhì)檢工位需求

Criticalcheckreminder關(guān)鍵檢查提示

Runstop運(yùn)行停止38Manipulatorout-of-positionandover-travel操作者越位和超程EquipmentandConveyorFaults設(shè)備和傳動鏈故障EntranceandExitConveyorFaults傳動鏈入口和出口故障StarvedandBlocked短缺和堵塞StatusofOtherLines其他線的狀態(tài)ScheduledStartorStop計劃啟動或停線ProductionStatusInformation生產(chǎn)狀態(tài)信息Goal目標(biāo)Sub-Assembly分裝線Actual實(shí)際ExitConveyorCount流出傳動鏈車輛數(shù)Trend趨勢BodiesfromPreviousProcess前道工藝的車身Quality質(zhì)量FloatorBuffer懸浮或緩沖車輛Downtime停線時間39TeamMemberactivatesanAndoncall:組員激活暗燈需求：

Andonboardzone,station,orworkcellnumberturnsonflashingYellow.

暗燈板上相關(guān)區(qū)域，工位或工作間的數(shù)字閃爍黃色

Uniquezoneaudiosignalisplayed發(fā)出特定的區(qū)域聲音信號

Yellowworkstationlightgoesonsolid工位黃色燈不動

FixedPositionStopisactivated,exceptinworkcellsandPaintbooths.

固定停止位發(fā)生作用，工作間和油漆房除外SystemOperation系統(tǒng)運(yùn)行40IfFixedPositionStopisreachedbeforetheAndonisreset:在暗燈重置之前到達(dá)了固定停止位：

ConveyorstopsandDowntimeclockstarts.

傳動鏈停止，停線計時鐘啟動

GreenLineStatusLight(Trim3)turnstoflashingRed

生產(chǎn)線狀態(tài)燈綠色變成紅色閃爍

FlashingYellowzonenumberremainsontheAndonBoard

暗燈板上依舊是閃動的黃色區(qū)域數(shù)字

UniqueAudioSignalforthezoneplaysfastmode.

獨(dú)特的區(qū)域聲音信號加快

YellowworkstationLightbeginstoflash工位的黃色燈開始閃爍SecondPullorreleasingthecallbutton,resetsthecalleventandthelineresumesnormaloperation.暗燈線第二次拉動或釋放按鈕，流水線恢復(fù)正常運(yùn)行

Conveyorrestarts.傳動鏈重新啟動

Alllightsreturntonormaloperation.所有燈回復(fù)正常狀態(tài)41SystemOperation系統(tǒng)運(yùn)行WhentheerrorproofingOKsignalisnotreceivedandthepredefinedProgrammableWarningPointisreached,theerrorproofingsystemactivatesanAndonhelpcall.當(dāng)防錯的OK信號沒有被接收，而達(dá)到預(yù)先審定的可編程警告點(diǎn)時，防錯系統(tǒng)激活暗燈求助需求。

AndonboardzonenumberturnsonflashingYellow暗燈板上相關(guān)區(qū)域的數(shù)字閃爍黃色

Uniquezoneaudiosignalisplayed發(fā)出特定的區(qū)域聲音信號

YellowworkstationlightturnsonSold工位黃色燈不動42IftheAndonsystemdoesn’treceiveanOK,Release,orBy-passsignal,theconveyorwillstopatthefixedpositionstopwhenreached.如果暗燈系統(tǒng)沒有接收OK、釋放或通過信號，當(dāng)傳動鏈到達(dá)固定停止位時就停線了。

ConveyorstopsandDowntimeclockstarts.

傳動鏈停止，停線計時鐘啟動

GreenLineStatusLight(Trim3)turnstoflashingRed

生產(chǎn)線狀態(tài)燈(內(nèi)飾三)綠色變成紅色閃爍

FlashingYellowzonenumberremainsontheAndonBoard

暗燈板上依舊是閃動的黃色區(qū)域數(shù)字

UniqueAudioSignalforthezoneplaysfastmode.獨(dú)特的區(qū)域聲音信號加快

YellowworkstationLightbeginstoflash工位的黃色燈開始閃爍WhentheerrorproofingreceivesanOK,Release,orBy-passsignal,thelineresumesnormaloperation.當(dāng)防錯系統(tǒng)接收了OK，釋放或通過信號，生產(chǎn)線恢復(fù)正常運(yùn)行

Conveyorrestarts.傳動鏈重新啟動

Alllightsreturntonormaloperation.所有燈回復(fù)正常狀態(tài)43SystemOperation系統(tǒng)運(yùn)行OKstatus:Normalfloatlevel,allrepairareaunderthepredeterminedfloatlevels.OK狀態(tài)：正常的流通車輛水平，所有的返修區(qū)域在設(shè)定的流通水平范圍內(nèi)

FinalprocessAndonboardfloatalarmstacklightisGreen.終線工藝暗燈板流動警示燈是綠色的Level1Alarm,forFinalProcessonly,Systemturnsonlevel1alarmconditionatapredeterminedpercentageoffloatlevelcapacity.一級警示，只對終線工藝而言，系統(tǒng)在預(yù)置的流動容量百分比上顯示一級警示狀態(tài)。

Floatalarmmelodyisplayed(onFinalProcessBoardonly)發(fā)出流動警示音樂(只在終線板上)FinalProcessAndonBoardFloatAlarmStackLightturnsonsolidBlue

終線工藝暗燈板流動警示燈變?yōu)槌Ｋ{(lán)色44Level2Alarm:SystemturnsonLevel2Alarmconditionatapredeterminedpercentageoffloatlevelcapacity,priortoreachingmaximumcapacity.二級警示：在達(dá)到最大容量之前，系統(tǒng)在預(yù)置的流動標(biāo)準(zhǔn)容量百分比上顯示二級警示狀態(tài)。

FloatAlarm“FA”turnsonsolidYellow(allandonboards)

流動警示“FA”變?yōu)槌｜S色(所有的暗燈板)FloatAlarmmelodyisplayed(allareas)發(fā)出流動警示音樂(所有區(qū)域)FinalProcessBoardFloatAlarmStackLightturnsonsolidYellow.

終線工藝暗燈板流動警示燈變?yōu)槌｜S色Level3Alarm:Systemturnsonatthemaximumallowablefloatlevelcapacity.三級警示：系統(tǒng)達(dá)到最大允許流動容量時的級別

FloatAlarm“FA”turnsonflashingYellow流動警示“FA”變?yōu)殚W爍的黃色

FloatAlarmmelodyisplayed(fastmodeallareas)

發(fā)出流動警示音樂(所有區(qū)域節(jié)奏變快)FinalProcessboardfloatalarmstacklightturnsonsolidRed.

終線工藝暗燈板流動警示燈變?yōu)槌＜t色45SystemOperation系統(tǒng)運(yùn)行Qualityteammembercallsforhelpbypressingtheappropriatequalityzonebutton.質(zhì)檢人員按下相應(yīng)的區(qū)域質(zhì)量按鈕尋求幫助

QualityzonenumberbeginstoflashYellow.質(zhì)量的區(qū)域數(shù)字變?yōu)殚W爍的黃色

Uniquezonemelodyisplayed.播放獨(dú)特的區(qū)域音樂TeamLeaderrespondstothequalityverificationstationandpressestheappropriatequalityzonebuttontoresettheevent.班組長響應(yīng)質(zhì)量檢驗(yàn)工位，再次按下相應(yīng)的區(qū)域質(zhì)量按鈕

Qualityzonenumberturnsgreen質(zhì)量的區(qū)域數(shù)字變?yōu)榫G色

Uniquezonemelodystopsplaying.獨(dú)特的區(qū)域音樂停止46SystemOperation系統(tǒng)運(yùn)行Qualityteammembercallsforhelpbypressingtheappropriateareaqualitybutton.質(zhì)檢人員按下相應(yīng)的區(qū)域質(zhì)量按鈕尋求幫助

VerificationstationnumberisdisplayedflashingYellow表示質(zhì)檢工位的數(shù)字顯示閃爍的黃色

Quality/FloatAlarmmelodyisplayedfor5seconds質(zhì)量/流動警示音樂播放5秒種GroupLeaderrespondstothecallandtheappropriateareaqualitybuttonispressedtoresettheevent.工段長響應(yīng)，重新設(shè)置相關(guān)的區(qū)域質(zhì)量按鈕

VerificationStationnumberisturnedoffandthedisplaychangesbacktonormaloperation.

質(zhì)檢工位的數(shù)字變?yōu)檎５牟僮鳡顟B(tài)47SystemOperation系統(tǒng)運(yùn)行SystemautomaticallyturnsonCriticalchecklights系統(tǒng)自動亮起關(guān)鍵檢查燈

Criticalcheck“C”turnsonsolidYellow“C”關(guān)鍵檢查的C

變?yōu)槌｜S色的CCriticalcheckmelodyisplayedfor5seconds關(guān)鍵檢查音樂播放5秒種

CriticalcheckcompletebuttonturnonsolidBluefortheappropriatezones

相關(guān)區(qū)域的關(guān)鍵檢查完成按鈕變?yōu)槌Ｋ{(lán)色48TeamLeaderspresstheirCriticalcheckcompletebuttonsoncetheyhavecompletedrecordingalltheirchecks.ThesystemwillturnofftheCriticalCheckCompleteButtonLightsastheyarepushed.只要班組長記錄了檢查的數(shù)據(jù)，就按下關(guān)鍵檢查完成按鈕。系統(tǒng)會關(guān)閉關(guān)鍵檢查燈。OnceallteamleadershavepushedtheirCriticalCheckCompletebuttons,thesystemwill:一旦所有的班組長按下關(guān)鍵檢查完成按鈕，系統(tǒng)將

TurnthesolidY