Cell生產(chǎn)方式簡介(PPT 86頁).ppt

1、Cell生產(chǎn)方式簡介,IE：王紅 日期：2009/12/10,目 錄,1.Cell的基本概念,2.Cell Line的優(yōu)點,3.Cell Line的基本布線規(guī)則,4.單件流,1.每個細胞均具有獨立功能2.可與其他單元任意組合3.自主性/靈活性4.細胞間活動協(xié)調(diào)一致,1 Cell的基本概念(1),它代表著創(chuàng)造性與靈活性!,1.1 Cell:“單元/細胞”的意思,1.如同蜜蜂群的組織分工2.如同蜜蜂群的團結(jié)合作,1 Cell的基本概念(2),1.2 Cell:“蜂窩”的意思,它代表著Team Work的概念!,1.增加產(chǎn)線靈活性(型號、產(chǎn)量、布局） 2.庫存降低 3.可依實際訂單決定開幾條線(彈性

2、) 4.后工序等待時間減少 5.可快速換線(插入急單),優(yōu)點：,2 Cell Line的優(yōu)點,2.1 同步化生產(chǎn),1.換線容易(減少延誤工時) 2.減少因線不平衡帶來的損失 3.便于保養(yǎng),2.2 設備小型化,優(yōu)點：,1.生產(chǎn)率提升 2.工序的前置時間改善 3.減少生產(chǎn)中的工作量 4.減少因線不平衡帶來的損失 5.品質(zhì)提升 6.人員的減少,2.3 多能工的培養(yǎng),優(yōu)點：,多能工,Before,1.按需生產(chǎn) 2.生產(chǎn)排程的靈活性增強 3.多機種混合生產(chǎn) 4.換線容易 5.小批量生產(chǎn),After,2.4 彈性（靈活）排程,優(yōu)點：,1.節(jié)省取放材料的時間 2.控制WIP,1.A工序做完后材料無須送往下一

3、工序,由B工序同事來取； 2.有用到工裝的站別，通常該工序員工只負責上工裝，做完后由下一站員工負責下工裝,(測試站別無人化操作)。,2.5 拉式生產(chǎn)方式,優(yōu)點：,從上一工序拉(PULL)而非傳送下一工序(PUSH),1.生產(chǎn)排程的靈活性增強 2.換線容易(減少延誤工時) 3.作業(yè)員之間的溝通更容易、有效 4.品質(zhì)提升 5.制程的前置時間改善 6.減少制程中的工作量 7.減少因線不平衡帶來的延誤 8.作業(yè)員責任明確,從左 往右,3 Cell Line的基本布線規(guī)則,3.1 站立、從左往右,優(yōu)點：,3.2 人在內(nèi)轉(zhuǎn),600/天,300/天,300/天,夠小,夠精,夠活,3.3 cell越小越好,1

4、.不落地生根,傳統(tǒng)觀點認為設備越大效率越高，通常將設備固定在地面而無法移動。設備不能移動，自然缺乏彈性，也就失去了改進布置、應對市場變化的能力。,3.4 架線的三不政策(1),改采設備小型化或設備可動化。,管線不像常青藤,設備“寄居”在固定的管、線及中央式裝置之下而無法移動。,3.4 架線的三不政策(2),2.不寄人籬下,放棄中央式設施,改采用分離式設備如：快速接頭、彈性接口。,1.品質(zhì)提升 2.WIP減少 3.前置時間減少 4.消除搬運,離線,隨線,工序2,切勿離線作業(yè),只能以“主流,支流”的概念進行站別布置!,3.4 架線的三不政策(3),3.不離群索居（IN LINE）,優(yōu)點：,工序1,

5、工序2,工序2,工序1,工序2,工序2,工序2,一 筆 畫 布 置,3.5 工廠一筆畫布置,工廠/生產(chǎn)流程在整體上呈一筆畫布置,1,2,3,4,IO一致原則,1,2,3,4,空手走動浪費,Input,Output,Input,Output,生產(chǎn)投入點與完成品取出點盡可能靠近，以避免作業(yè)返程造成的時間和體力浪費。,3.6 生產(chǎn)線U形化(1),IO一致原則同樣適用于設備布置，亦可節(jié)省空間占用。,1.以U字型布置方式按工藝流程排列生產(chǎn)。 2.入口和出口盡量由同一作業(yè)者負責，能夠以產(chǎn)距時間按標準數(shù)量進行生產(chǎn)及管理，也便于補充生產(chǎn)。 3.便于作業(yè)者相互協(xié)作，異常時能停線，及時暴露問題并改善之。 4.步行

6、最短，可單件流動，人員可增可減。,1,2,3,4,5,8,14,13,12,11,7,10,9,6,成品,材料,3.6 生產(chǎn)線U形化(2),各站產(chǎn)出狀況,數(shù)量,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,1,站1,站2,站3,站4,站5,站6,平常堆貨的生產(chǎn)模式,每站看似都很忙,也能一直保障3pcs的產(chǎn)出,所以看不到線平衡的問題,單件流(站6只需要1pcs)的拉動式生產(chǎn)模式可輕易看到線平衡的問題,我只要 1pcs,4 單件流,單件流真的能節(jié)約時間嗎?時間會不會變長? 單件流到底有什么好處? 我們可以

7、通過下面動畫,看到傳統(tǒng)堆貨生產(chǎn)&單件流的不同(某個包含3站的產(chǎn)品)。,面對單件流的疑問?,傳統(tǒng)堆貨生產(chǎn),15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:00,A站,B站,C站,21pcs產(chǎn)品,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A站,B站,C站,21pcs產(chǎn)品,傳統(tǒng)堆貨生產(chǎn),15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A站,B站,C站,21pcs產(chǎn)品,1,傳統(tǒng)堆貨生產(chǎn),15,

8、8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A站,B站,C站,21pcs產(chǎn)品,2,傳統(tǒng)堆貨生產(chǎn),15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,6,21,14,7,00:05,A站,B站,C站,21pcs產(chǎn)品,4,傳統(tǒng)堆貨生產(chǎn),15,8,6,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,7

9、,00:06,A站,B站,C站,21pcs產(chǎn)品,4,傳統(tǒng)堆貨生產(chǎn),15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:07,A站,B站,C站,21pcs產(chǎn)品,4,傳統(tǒng)堆貨生產(chǎn),15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:08,A站,B站,C站,21pcs產(chǎn)品,4,傳統(tǒng)堆貨生產(chǎn),15,9,7,16,8,17,10,3,18,11,1,19,12,2,20,13,5,21,14,6,00:09,A站,B站,C站,21pcs產(chǎn)品,4,傳統(tǒng)堆貨生產(chǎn),15,10,7,16,9,17

10、,8,1,18,11,2,19,12,3,20,13,5,21,14,6,00:10,A站,B站,C站,21pcs產(chǎn)品,4,傳統(tǒng)堆貨生產(chǎn),15,11,7,16,9,17,8,2,18,10,3,19,12,4,20,13,5,21,14,6,00:11,A站,B站,C站,21pcs產(chǎn)品,1,傳統(tǒng)堆貨生產(chǎn),15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:12,A站,B站,C站,21pcs產(chǎn)品,2,傳統(tǒng)堆貨生產(chǎn),15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:13,A站,B站

11、,C站,21pcs產(chǎn)品,2,傳統(tǒng)堆貨生產(chǎn),15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:14,A站,B站,C站,21pcs產(chǎn)品,2,傳統(tǒng)堆貨生產(chǎn),15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:15,A站,B站,C站,21pcs產(chǎn)品,2,傳統(tǒng)堆貨生產(chǎn),16,13,6,15,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:16,A站,B站,C站,21pcs產(chǎn)品,2,傳統(tǒng)堆貨生產(chǎn),16,13,6,15,10,17,8,2,18,9,3

12、,19,11,7,20,12,1,21,14,5,00:17,A站,B站,C站,21pcs產(chǎn)品,4,傳統(tǒng)堆貨生產(chǎn),16,13,6,15,11,18,8,2,17,9,4,19,10,7,20,12,1,21,14,5,00:18,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),16,13,6,15,12,19,8,2,17,9,5,18,10,7,20,11,1,21,14,4,00:19,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),16,12,5,15,13,20,8,2,17,9,6,18,10,7,19,11,1,21,14,4,00:20,A站,B站,C站,21pcs產(chǎn)品,

13、3,傳統(tǒng)堆貨生產(chǎn),16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:21,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:22,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:23,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,

14、11,1,20,13,4,00:24,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:25,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:26,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:27,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,

15、12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:28,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:29,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:30,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4

16、,00:31,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:32,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:33,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:34,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,2

17、1,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:35,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:36,A站,B站,C站,21pcs產(chǎn)品,3,傳統(tǒng)堆貨生產(chǎn),15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:00,A站,B站,C站,21pcs產(chǎn)品,單件流,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A站,B站,

18、C站,21pcs產(chǎn)品,單件流,15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A站,B站,C站,21pcs產(chǎn)品,1,單件流,15,8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A站,B站,C站,21pcs產(chǎn)品,2,單件流,15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A站,B站,C站,21pcs產(chǎn)品,3,單件流,15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,

19、6,21,14,7,00:05,A站,B站,C站,21pcs產(chǎn)品,4,單件流,15,8,6,16,9,17,10,4,18,11,3,19,12,2,20,13,1,21,14,7,00:06,A站,B站,C站,21pcs產(chǎn)品,5,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:07,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:08,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,

20、5,18,11,4,19,12,3,20,13,1,21,14,2,00:09,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:10,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:11,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:12,A站,B站,C站,21pcs產(chǎn)品,

21、6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:13,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:14,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:15,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2

22、,00:16,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:17,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:18,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:19,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:20,A站,B站,C站,21pcs產(chǎn)品,6,單件流,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,