IE线平衡改善.pptx

*,按一下以編輯母片標題樣式,按一下以編輯母片,第二層,第三層,第四層,第五層,When are you going to finish your job?,I have been waiting so long!,你到底要在什麼時間才能做完,我要等到什麼時候?,My cycle time is too quick for me!,我來不及做了！,Operation Training-,線平衡改善,Line Balancing,方法:去除壓膠布的制程,要求作業員在空白膠外使用T26膠,Unbalance Lines Problems 線上不平衡造成的主要問題,Constant flow and distance between each product.,Constant flow and distance between each product.,Soldering have to pickup work from Fixture one by one after process 焊錫站需要從線上一個一個拿取,10月-2210月-22Wednesday,October 26,2022,Line Balance efficiency線平衡率 =Total time/(Bottle neck cycle time*O/P No.,Operators can fully concentrate on their jobs,they do not have to care about others ability to finish their work on time or not.,工作從線頭流到線尾將會有較好的線平衡.,15、最具挑战性的挑战莫过于提升自我。,20小時=4800 sec produced 860 pcs.,Operators lack concentration Waste time to wait for the coming product or pull the product from the line instead of completing the product in hand.,Unbalance Lines Problems 線上不平衡造成的主要問題,17、一个人即使已登上顶峰，也仍要自强不息。,Use very few space for production line because there are no need space for store and Wip movement.,(Productivity Performance 生產力狀況),Cycle Time=6 second,Line Balance=,(4+5+3+3+4+6+5+4+4+3+3+6+2)/(6X13),=66.66%,Line Balance Concept,Cycle Time=6 second,Line Balance=,(4+5+6+4+6+5+4+4+3+3+6+2)/(6X12),=72.20%,Line Balance Concept,Cycle Time=6 second,Line Balance=,(4+5+6+4+6+5+4+4+6+6+2)/(6X11),=78.80%,Line Balance Concept,Cycle Time=5 second,Line Balance=,(5+5+5+5+5+5+4+5+5+5+3)/(5X11),=94.50%,Line Balance Concept,Cycle Time=4 second,Line Balance=,(4+4+4+4+4+4+4+4+4+4+4)/(4X13),=100%,Line Balance Concept,Possible?,Conveyor speed is too much faster than operators ability.,如果傳送帶的速度遠遠快於作業員的作業能力,1.,Too much WIP at the bottle neck station.,在瓶頸站將堆積過多的,WIP,2.Operators lack concentration Waste time to wait for the coming product or pull the product from the line instead of completing the product in hand.,作業員無法專心作業。等待材料及從正在作業的產品中分心以拿取線上流過的材料。,Unbalance Lines Problems,線上不平衡造成的主要問題,3.Quality Problem,品質問題,3.1 Incomplete Process,制程不完善,-Insufficient parts,作業不全,-Parts not properly inserted,材料未適當裝插,-Wrong part being inserted,插件錯件,-Wrong side is being inserted,插件反向,-Not all required points are inspected,檢查不完備,-Did not correctly choose the Select Switch,按錯測試鍵,-Did not put all Labels or wrongly placed.,未全面貼放標籤或錯貼,-etc.,Unbalance Lines Problems,線上不平衡造成的主要問題,3.2 Defects,不良,-Damage and dirty,破損及污漬,-Scratches,刮傷,-Label,scratches,標籤不良等,etc.,4.Inspectors need to repair the defects,thus causing additional time.,作業員修復不良品將花費多餘工時,Unbalance Lines Problems,線上不平衡造成的主要問題,5.Line leaders and other supporting people have to waste their time in assisting and solving the WIP problem at the bottle neck station.,組長及其他線外支援人員不得不耗費時間以解決瓶頸站的,WIP,6.The space available in the line are already very limited,it will become even smaller.,線上空間本來有限，還需佔據空間,7.Un-forecastable and uncontrollable output,造,成無法預計和控制的產出,8.Decreased Productivity,生產力降低,Unbalance Lines Problems,線上不平衡造成的主要問題,When the conveyor speed is slower than the operators ability.,當傳送帶之速度遠慢於作業員的操作能力,1.Lost time without output,無產出的異常工時,2.Lower output than expected,低於計劃的產能,3.Operators are not active enough,becomes dull,作業員無法積極作業，變得懶散,Unbalance Lines Problems,線上不平衡造成的主要問題,4.Must take more time to recover the lost output,需要安排額外的工作時間以彌補未達成的產能,5.Unit cost becomes higher,單位產品的成本增加,6.Decreased Productivity,生產力降低,7.Cannot control or forecast the output systematically,無法系統的控制和預估產能,Unbalance Lines Problems,線上不平衡造成的主要問題,Step of line balancing,線平衡步驟,LINE BALANCE is the method used to set up working time of operators in one line as the same as possible.,線平衡是盡可能把線上作業員的作業時間安排一致的方法。,Line Balancing,線上觀察,分 析,討 論,設定標準,標準工時及,O/I,檢討,起草作業指導書並檢討,執 行,跟蹤情況,正式發行,O/I,跟蹤及不斷的改善,動 作,制 程,布 局,治 具,方便,快捷,安全,價廉,保障,合併,去除,改善,(重排、調適),簡化,Line Balance Concept,Production Design,(R&D),Process Design,Flow Chart,Lay Out,Operation Instruction,Motion&Time Study,Seriously continuous,follow up,產品設計,(,工程),制程規劃,流程圖,布局安排,作業指導書,功效研究,認真持續的跟蹤情況,Line Balance Concept,Observation,觀察,Analyze,分析,Set Norm,設定標準,Man load,安排人力,Implement,執行,Follow up,跟蹤,(Before&After),(Max,Min,Avg.,最大值,最小值,平均數,),(Observation sheet,時間觀測表,),-Combine,合併,-Eliminate,去除,-Improve,改進,-Simple,簡化,(Productivity Performance,生產力狀況,),(Std.Time,標準工時,),Step of line balance,Step 1.Observation:,Observe and timing from the start to end of each process as sample.,第一步.,觀察,:,如下所示,按制程從第一站到最後一站觀查並測量時間,.,Step of line balance,Step 2.Analyze:,Analyze time from observation to define minimum,Maximum and Average.,第二步.,分析,:,從觀察得出的數據中分析得到最小值，最大值及平均值,.,Step of line balance,Step 3.Set norm(standard time):,Select the time to be used as the standard time at each step.Normally will be the average time.,第三步.,設定標準,(,標準時間):,定訂每一站的標準時間,.,通常使用平均值,.,Step of line balance,Step 4.Manload:,Calculate manpower to be used to produce.These number will be the most effective and balance the production line as much as possible.(Compare before&After),第四步.,人力安排,:,計算生產所需的人力.這個數據最有效並能最好的達到線平衡,.(,比較,before&After),Step of line balance,Step of line balance,Step 5.Implement:,Use all data to compare as the Before and After Report.Set up line balance by using the following concept.,第五步.,執行,:,用所有的數據比較,before&after,用以下的觀念平衡生產線.,-Combine,合併,-Eliminate,去除,-Improve,Re-arrange,改進,重排,-Simplify,簡化,Step 6.Follow Up:,Follow up all the implementation continuingly at least 2 weeks.,第六步.,跟蹤,:,持續的跟蹤執行情況至少兩星期,.,Line Balancing Benefits,Line Balancing Benefits,線平衡的優點,1.Systematic production output control,系統的產能控制,2.Constant flow and distance between each product.,持續的流水作業,3.Reduce operators chance for defect and carelessness.,降低作業員不良及忽略的錯誤,4.Loss time reduction and control.,降低並控制異常工時,.,Line Balancing Benefits,線平衡的優點,5.Prevention of WIP in the production lines.,防範線上,WIP.,6.Ease and clear identification of the problems.,清楚的問題分析,7.When defects are found and separate from the line,it can be very clearly identified,.,不良品的明確標識，以便明確的區分.,Line Balancing Benefits,線平衡的優點,8.Operators do not have to be worried about the next coming material when his/her present one is not complete yet.,在作業員進行當前作業時，無需擔心下一個材料.,9.Operators can fully concentrate on their jobs,they do not have to care about others ability to finish their work on time or not.,作業員全心投入工作,無需擔心其他組員的作業狀況.,10.The constant distance between products can prevent damages from direct hits.,產品之間的間隔可避免直接碰撞產生的損害,就制程和產品改善方面與相關的部門合作，如：產品品質、降低成本、產能提升等等。,Output increased much more than Input,Step of line balance,防範線上WIP.,第六步.,16、业余生活要有意义，不要越轨。,Before&After at station soldering,Line Balance Concept,time per piece will decrease and line balance efficiency will be higher,Make New fixture which can release all work in the same time 作新制具以便同時作業,Line Balance Example線平衡範例,Line Balancing Benefits 線平衡的優點,17、做前，能够环视四周；,IE Function,THE END,Line Balance Example,線平衡範例,Cycle Time(Bottle neck,瓶頸,)=,9.85 second,Line Balance efficiency =,Total time/(Bottle neck cycle time*O/P No.),線平衡率 =總工作時間,/(,瓶頸站,cycletime*,作業員人數.),=67.45%,-Before Improvement,改善前,PROCESS,SEC,Improvement:Improve process of producing such as Bottle neck,改善:改善生產制程如瓶頸站,Cycle Time(Bottle neck,瓶頸,)=,7.47 second(Avg of winding),Line Balance efficiency,線平衡率,=,Total time/(Bottle neck cycle time*O/P No.),總工作時間,/(,瓶頸站,cycle time*,作業員人數.),=83.80%,PROCESS,SEC,Before Improvement,改善前,After Improvement,改善後,Solder pressed wire before Solder trimming Press,焊理線站後焊壓線,Separate pressing wire activity for each process,壓線部份獨立出來,Eliminate:Decrease Loss or unnecessary process,去除:去除不必要及造成延誤的制程,Method:eliminate pressing Margin Tape process by asking operator to use Tape T26 over Margin Tape,方法:去除壓膠布的制程,要求作業員在空白膠外使用,T26,膠,Cycle Time(Bottle neck,瓶頸,)=,7.35 second,Line Balance efficiency,線平衡率,=,Total time/(Bottle neck cycle time*O/P No.),總工作時間,/(,瓶頸站,cycle time*,作業員人數.),=84.58%,SEC,PROCESS,Before&after,station winding wrap margin tape,Combine:combine process by using motion and time study,合併:根據功效學合併制程,Cycle Time(Bottle neck,瓶頸,)=,7.35 second,Line Balance efficiency,線平衡率,=,Total time/(Bottle neck cycle time*O/P No.),總工作時間,/(,瓶頸站,cycle time*,作業員人數.),=92.14%,Method:combine encasing Core(station 4)and input Clip(station 5)together.,方法:合併包鐵芯,(,第4站)和上耳夾(第,5,站),.,PROCESS,SEC,Simple:Using fixture to help operator.,簡化:使用制具幫助作業員,.,Cycle Time(Bottle neck,瓶頸,)=,7.10 second,Line Balance efficiency,線平衡率,=,Total time/(Bottle neck cycle time*O/P No.),總工作時間,/(,瓶頸站,cycle time*,作業員人數.),=94.65%,SEC,PROCESS,Before Improvement,改善前,After Improvement,改善後,Soldering have to pickup work from Fixture one by one after process,焊錫站需要從線上一個一個拿取,Make New fixture which can release all work in the same time,作新制具以便同時作業,Before&After at station soldering,Comparing Improvement,比較改善前後,In the case of improve,Bottle neck,and,decrease operator,改善,瓶頸站,並,減少作業員,In case of stable input hour and improve,Bottle neck,如果投入不變而改善,瓶頸站,Remark,Std.time per piece will decrease and line balance efficiency will be higher,說明:,單位產品所需的標準工時將減少，線平衡率將提升,Comparing Improvement,比較改善前後,Adjust line balance incase of produce lower than Plan,調整線平衡,Daily Variance Report,每日差異報表,As follow up from variance Report,the first hour has variance of 100 pieces lower than plan.If production line wants to produce cover variance,The conveyer is need to be adjusted as follow:(Cycle time 5 sec),從每日差異報表的跟蹤情況可知,第一個小時較計劃有100個差異,.,如果生產線希望趕上計劃,傳送帶需做如下調整,:(Cycle time 5 sec),In case of produce less than plan,Example,范例,(Cycle time 5 sec),8.25 Hours for one day,一天8.25 小時,=31500 sec target 6300 pcs.,First 1.20 hour,第,1.20小時,=4800 sec produced 860 pcs.,Work have to be produce,必須完成,=6300-860,=5440 Pcs,=31500-4800,=26700/5440,=,4.94,sec,Then the conveyer have to be adjust to,4.94,sec in order to cover Variance (,In case of operators could do,),為了去除差距傳送帶速度需調整為,4.94,(,假設作業員能做到,),Method of increasing Productivity,生產力提升之方法,Output Stable,產量不變,Input Decrease,投入減少,Output increase,產量增加,Input Stable,投入不變,Output increase,產量增加,Input Decrease,投入減少,Output increased much more than Input,產量的增加速度遠遠超出投入的增加速度,Output Decreased much more than Input,產量的減少速度遠遠超出投入的減少速度,Benefit of Using Conveyer,Reduce the expense of transportation or product movement.,降低運輸費用及產品的搬運.,Reduce time to move or store work in process(Wip).,降低在制品移動及儲存的時間.,Reduce expense of tool or pallet to keep Work in process.,減少制具及盤子費用以便工作在線上作業,.,Use very few space for production line because there are no need space for store and Wip movement.,生產線使用少量的空間因沒有必要為線上儲存材料而佔據空間,.,If has a good line balancing,work will be flown through from start to stop.,工作從線頭流到線尾將會有較好的線平衡.,Lower Work in Process in production line,Each station will have only piece to produce.,減少線上在制品,每一站只有一個產品生產,.,If the process has been balanced effectively the production line will be fast and effective,如果生產線得到有效的平衡，生產線會更快捷,If plan to produce only one model,the quality of work will be better because of the process of checking,如果只生產一個機種,品質和產量會更好。,Easy to control quantity and quality if the process of producing are stable.,如果生產制程穩定，產品品質和產量都會更易控制.,Easy to track the NG product,the line can be stop and correct.,更容易對不良品進行跟蹤,可以把線停下並糾正,.,Build up team building in between operators,If some station is slower than others the performance of all line will be low.,在作業員中建立團隊合作意識,如果一些站別較慢，整條線都會受影響,.,Make line leader more active,If some error or mistake occur in the line,the work will be NG for all the line also.,組長會更加積極,如果線上某站出問題整條線都會被影響,.,Benefit of Using Conveyer,P,Q,C,D,S,M,P,=,Productivity,Q,=,Quality,C,=,Cost,D,=,Delivery,S,=,Safety,M,=,Morale,5-S,Process Flow Design,制程規劃,Design Work Flow,流程規劃,Line Layout,線上布局規劃,Establish Standard Time and Man-load,設定標準工時及人力需求,Line Balancing,線的平衡,Issue Operation Instruction for Lines,發行作業指導書,Observe Motion,Time Study and Measurement,就動作的功效進行衡量及研判,IE Function,Follow-up and Continuous Improvement,跟蹤情況並不斷改善,Daily corrective and preventive supports on Production problems,每日就生產線問題進行更正及防范支援,Cost Analysis,成本分析,Co-operate with other concerned departments for improving and developing the process and product,i.e.quality,cost reduction,capacity upgrade etc.,就制程和產品改善方面與相關的部門合作，如：產品品質、降低成本、產能提升等等。,Other jobs as assigned,其他交辦事項,IE Function,9,、静夜四无邻，荒居旧业贫。,10月-26,10月-26,Monday,October 5,2026,10,、雨中黄叶树，灯下白头人。,01:01:16,01:01:16,01:01,10/5/2026 1:01:16 AM,11,、以我独沈久，愧君相见频。,10月-26,01:01:16,01:01,Oct-26,05-Oct-26,12,、故人江海别，几度隔山川。,01:01:16,01:01:16,01:01,Monday,October 5,2026,13,、乍见翻疑梦，相悲各问年。,10月-26,10月-26,01:01:16,01:01:16,October 5,2026,14,、他乡生白发，旧国见青山。,05 十月 2026,1:01:16 上午,01:01:16,10月-26,15,、比不了得就不比，得不到的就不要。,。,十月 26,1:01 上午,10月-26,01:01,October 5,2026,16,、行动出成果，工作出财富。,2026/10/5 1:01:16,01:01:16,05 October 2026,17,、做前，能够环视四周；做时，你只能或者最好沿着以脚为起点的射线向前。,1:01:16 上午,1:01 上午,01:01:16,10月-26,9,、没有失败，只有暂时停止成功！。,10月-26,10月-26,Monday,October 5,2026,10,、很多事情努力了未必有结果，但是不努力却什么改变也没有。,01:01:16,01:01:16,01:01,10/5/2026 1:01:16 AM,11,、成功就是日复一日那一点点小小努力的积累。,10月-26,01:01:16,01:01,Oct-26,05-Oct-26,12,、世间成事，不求其绝对圆满，留一份不足，可得无限完美。,01:01:16,01:01:16,01:01,Monday,October 5,2026,13,、不知香积寺，数里入云峰。,10月-26,10月-26,01:01:16,01:01:16,October 5,2026,14,、意志坚强的人能把世界放在手中像泥块一样任意揉捏。,05 十月 2026,1:01:16 上午,01:01:16,10月-26,15,、楚塞三湘接，荆门九派通。,。,十月 26,1:01 上午,10月-26,01:01,October 5,2026,16,、少年十五二十时，步行夺得胡马骑。,2026/10/5 1:01:16,01:01:16,05 October 2026,17,、空山新雨后，天气晚来秋。,1:01:16 上午,1:01 上午,01:01:16,10月-26,9,、杨柳散和风，青山澹吾虑。,10月-26,10月-26,Monday,October 5,2026,10,、阅读一切好书如同和过去最杰出的人谈话。,01:01:16,01:01:16,01:01,10/5/2026 1:01:16 AM,11,、越是没有本领的就越加自命不凡。,10月-26,01:01:16,01:01,Oct-26,05-Oct-26,12,、越是无能的人，越喜欢挑剔别人的错儿。,01:01:16,01:01:16,01:01,Monday,October 5,2026,13,、知人者智，自知者明。胜人者有力，自胜者强。,10月-26,10月-26,01:01:16,01:01:16,October 5,2026,14,、意志坚强的人能把世界放在手中像泥块一样任意揉捏。,05 十月 2026,1:01:16 上午,01:01:16,10月-26,15,、最具挑战性的挑战莫过于提升自我。,十月 26,1:01 上午,10月-26,01:01,October 5,2026,16,、业余生活要有意义，不要越轨。,2026/10/5 1:01:16,01:01:16,05 October 2026,17,、一个人即使已登上顶峰，也仍要自强不息。,1:01:16 上午,1:01 上午,01:01:16,10月-26,MOMODA POWERPOINT,Lorem ipsum dolor sit amet,consectetur adipiscing elit.Fusce id urna blandit,eleifend nulla ac,fringilla purus.Nulla iaculis tempor felis ut cursus.,感谢您的下载观看,专家告诉,