SONY公司厂房布置设计方案.doc

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SONY公司厂房布置设计方案 109 2020年5月29日文档仅供参考 Sony’s Implementation of Production Innovation Equipment and Manufacturing System Solutions Chapter 1 1．Introduction 1.1 Shift in production needs 1.2 Importance of demand oriented production 1.3 Production innovation’s 3 main types of loss 1.4 Cell production method Shift in Production Needs Diversification of Needs ・Specialization Severe Economical Environment ・Worst post-war economic slum ・Multi-functional Drastic Market Change Fall of Product Prices Mass production Many types, small qty Various types, various quantities ・Decline of Consumption Network Age ・Telecommunication Revolut ・Electronic Commerce ・Well-sold products change quickly ・Surplus of inventory due to the fall of product prices Protection of Demand Oriented Production Globalization ・No Borders ・Global Standards the Environment Digitalization ・Less Energy ・Less Resources, Recycling ・LSI ・Mechanical → Software Importance of Demand Oriented Production Sell what is produced Produce according to demand Large module type production line Various demand-oriented cell production lines × Line change-over, model change d e c f Batch-type production line × Lead-time, Inventory, etc. b a ●Products which cannot be sold ●Change-over loss ●WIP loss ●Lead time ●Handling loss The Ultimate Production System Cost Investment Lead time Inventory Space Change-over loss Rejected products Breakdown ０Zero Implementation of Production Innovation Only make the required products at the required time Production Innovation’s 3 main types of loss 1. Handling loss 2. Transportation loss 3. Stagnation loss Minimization of non-value added resources Progress by Production Innovation (1) ■ Production style Production Large qty Small Lot Production Target: based on forecastproduction Large inventory qty Innovation Zero Inventory Customer’s Reduced funds turnover Required products Reduced space Required time Required qty Reduced control costs ■ Flow-oriented production, information Mixed flow・Individual ‘islands’ Innovation Flow-oriented In-line Reduction of WIP Reduction of handling Simplified quality tracking Progress by Production Innovation (2) ■ Inventory Reduction by Logistic Improvements Large Order/Delivery of Parts Push style provision Input Stock Parts Inventory Innovation Small qty order/delivery Deliver only what is used ‘Kanban’ Direct Reduction of Raw materials・WIP Output Provision Production line ‘Refrigerator’ Production line ■ Manufacturing equipment Large-size・High speed・High performance・High price Small size・Low-medium speed・Functional・Low price WIP reduction by production leveling Innovation Progress by Production Innovation (3) ■From single operation to multi-operation Divided labor conveyor production style due to single operation Multi-operation and Cell production method Innovation Multi-operation (Multi-skilled workers) WIP reduction by production leveling Conveyor line Cell ■Control comprehensive for anyone Data management by computer 10000 pcs. Select&Order・Fixed place・Fixed qty・Fixed marking Visual management storage XX Should be in storage ○ ○? There should be ○○○○ pcs? Innovation Max (XXpcs Min (ＹＹpcs) Part A By seeing the abnormality, a quick response is possible Abnormal ! Example of Benefits of Production Innovation: Reduction of Manpower (Actual factory example) 1200 1000 800 600 400 200 0 (persons) 94/3 9 95/3 9 96/3 9 97/3 9 98/3 9 Example of Benefits of Production Innovation: Reduction of Space (Actual factory example) m2 14000 1 10000 8000 6000 4000 0 94/3 9 95/3 9 96/3 9 97/3 9 98/3 9 Example of Benefits of Production Innovation: Reduction of Lead time (Actual factory example) (days) 35 30 25 20 15 10 5 0 In-house production 94/3 9 95/3 9 96/3 9 97/3 9 98/3 9 Example of Benefits of Production Innovation: Revenue&Profit (Actual factory example) 100 80 (％) Revenue Production Innovation Activities 60 40 20 0 -20 Profit ９２９３９４９５９６９７９８ est. Note) Ratio (%) with 1992 revenue as 100 From conveyor line to various types of Cell Production Conveyor line ..... 1 2 3 4 n ・Change-over loss occurs ・Layout modification is difficult ・Line balance loss occurs ・Handling loss occurs Small module unit type Spiral type One man cart type One man ‘stall’ type 1 d e c f 2 b a n Cart Chapter 2 2. Benefits of Cell Production Method 2.1 Cell Production Method 2.2 Benefits of Cell Production Method 2.3 Examples of Cell Production Method Cell Production Method The Cell Production Method is one of the best solutions of manufacturing styles for small lot production, in which assembly and work are done in one single process, by using small manufacturing instruments (tools), by operation of one or a few workers. Small scale line Products Assembly Inspection Multi- functional work Small lot Flow oriented Packaging production Example of Cell Production System Benefits of Cell Production Method Flexibility Up ①Various items ②Quantity fluctuation ③Various layout Conveyor line Conveyor line Conveyor line Producti on Loss in production line change ＡＢＣ Time Line multiplication is difficult Layout modification is difficult Cell production Producti on Operation in 3 Cells ＣＢＡ Time Cell production By number of workers Bu number of cells Cell production ●Implementation of various cell types according to products attributes, level of operators, production quantity; layout modifications are possible flexibly ●Cells by production type ●Production by sales speed Benefits of Cell Production Method Manpower・Space reduction ①Productivity up → manpower reduction ②Space reduction Conveyor line Belt conveyor Handling Loss Conveyor line Work time Loss time Work table Producti on qty Change-over Loss １２３４５ Process ＡＢＣ Time Cell production Cell production ● Manpower reduction by elimination of conveyor line loss ● Space reduction by removal of conveyor ● Elimination of loss by reducing in-between spaces Benefits of Cell Production Method Shortening of production lead time・Inventory reduction・Quality improvement Conveyor Line Cell production Inspec- tion Assembly Assy Work cell As sy Assy As sy Packa- ging Inventory Pack. Insp. Pack. Insp. Stagnation of the products in process Carry × Stagnation, transportation loss between or within processes × Slow feedback of quality information × Unclear responsibility concerning quality ● Reduction of stagnation in processes → Lead time reduction ● Reduction of inventory ● Fast feedback of quality information ● Clear responsibility concerning quality → Quality improvement Higher work morale by individual performance Chapter 3 3. Development of Production Innovation Equipment 3.1 Role of Production Technology 3.2 Codependence of Men and Machines 3.3 Conditions of Production Equipment suitable for Cell Production 3.4 Development of Innovation Equipment Role of Production Technology ”Produce products which have not been produced before” Basic Technology Development which supports Products Excellence ”Further strengthening of Product Creation’s QCD+F” ‘Realization’ Engineering which supports Manufacturing Excellence Codependence of Men and Machines Role of the operator: ”efficiently operate production equipment” ”make improvements to increase capacity” ”make arrangements for next production models” ”design systems” ”make equipment, tools” ”Creation” work Conditions for Production equipment suitable for Cell Production Systems Compact ・ Ability to make the required qty at the required pace (demand synchronized production) ・ Small equipment, not taking much installation space ・ Price suitable to achieve early profit Flexibility QCD ・ Easy reflection of improvement plans for higher efficiency (reflect the feeling Stability on the work floor) ・ Flexibility to adapt to product modifications ・ Simple procedure for product change-over ・ No production of rejected products ・ Minimum required maintenance, easy to carry out ・ Few breakdowns ROBOKIDS Makes Cell-Production Evolution Realized Development Concept: 『Compact』『Minimum Cost』 Tool to Realize ”An Evolution of Cell Production System” Outstanding Features ① Compact : vs. conventional 1/4 ( A4 size ) ② Cost : vs. conventional 1/3 ③ Flexibility : Wide Variety of Applications (Soldering, Dispenser, Screw-Fastening, Circuit Board Splitting) ROBOKIDS ~ Features ~ Conventional Type A4-Size ROBOKIDS ~ Features ~ ROBOKIDS can be utilized from the Day of Installation １００％ RoboKids ８０％６０％ Dedicated Robot Assy System ４０％ SMART SYSTEM ２０％０％ Installation Installation 1 month 2 months 3 months 4 months ROBOKIDS WORLD (Wide Variety) Screw Fastening ROBOKIDS Soldering ROBOKIDS Circuit Board Splitting ROBOKIDS Dispenser ROBOKIDS Actual condition at production factories Flexibility is a main issue in the assembly area , as a starting point of production innovation, however in the surface mounting area … - Very expensive mechanical equipment is lined up - Large qty & high speed processing is a main objective, using identical models of high speed surface mounters - Large scale equipment investment is still needed ”A mounting process, where production innovation is still difficult to introduce” Large lot production Mounting line(A) assy line(a) assy line(b) assy line(d) assy line(e) Mounting line(B) assy line(c) assy line(f) Large qty of WIP, Inventory Objectives of the ”Cellular Mounter” 1) Compatibility of both high precision and flexibility ◆ Building is possible depending on demand variation, variation of production types ◆ Realization of low investment (cost/shot)・ small space 2)Realization of Investment in steps to obtain a high level of investment results ◆ Procure only the required function, at the required time, at the required level Flexible Structure SI-E1000 SI-E Connected machines Parent １ Children １＜Standard type connection＞ One machine is the parent unit and the other three machines are the children units Parent １ Children １＜PCB Mixed flow compatible＞ One machine takes care of type-dependant parts, the other three machines are connected. (type change-over only for the first machine) Flexible Production Capacity = 12,857 ｃｐｈ in 1.2 m = 25,714 ｃｐｈ in 2.4 m Very = 38,571 ｃｐｈ in 3.6m = 51,428 ｃｐｈ in 4.8m Flexible! Comparison of Conventional Mounters and Celluar Mounter ■ 20％ Investment saving and 55％ space saving is possible (per line) Conventional 2m 2m 16m 6m 6m SS-U2 SS-U2 SS-H2F SS-H2F Investment -20% Space -55% 7.2m 1.2m Celluar Mounter SI-E SI-E1000 Chapter 4 4. Manufacturing System Solutions ４ー１ Total Plant Engineering ４ー２ Points of Production Improvement ４ー３ Evolution of Cell Production ４－４ Basic Design of Cell Production Line ４ー５ Horizontal Implementation of P

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