单元生产方式(cell)全面讲解.ppt

,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,Cell,生产方式简介,IE,：王红,日期：,2009/12/10,1,目 录,1.Cell,的基本概念,2.Cell Line,的优点,3.Cell Line,的基本布线规则,4.,单件流,2,1.,每个细胞均具有独立功能,2.,可与其他单元任意组合,3.,自主性,/,灵活性,4.,细胞间活动协调一致,1 Cell,的基本概念,(1),它代表着,创造性与灵活性,!,1.1,C,ell,:“,单元,/,细胞”的意思,3,1.,如同蜜蜂群的组织分工,2.,如同蜜蜂群的团结合作,1 Cell,的基本概念,(2),1.2,C,ell,:“,蜂窝”的意思,它代表着,Team Work,的概念!,4,A,A,A,A,B,B,C,C,C,C,1.,增加产线灵活性,(,型号、产量、布局）,2.,库存降低,3.,可依实际订单决定开几条线,(,弹性,),4.,后工序等待时间减少,5.,可快速换线,(,插入急单,),A,A,A,A,B,B,C,C,C,C,以机器设备为导向,A,A,A,A,B,B,C,C,C,C,B,B,以,生,产,流程,为导向,优点：,2 Cell Line,的优点,2.1,同步化生产,5,1.,换线容易,(,减少延误工时,),2.,减少因线不平衡带来的损失,3.,便于保养,小型,、,低成本,、,低速,、,功能有限,大型高速高效率,2.2,设备小型化,优点：,6,1.,生产,率,提升,2.,工序的前置时间改善,3.,减少生产中的工作量,4.,减少因线不平衡带来的损失,5.,品质提升,6.,人员的减少,多项作业操作,单一作业操作,2.3,多能工的培养,优点：,多能工,7,Before,1.,按需生产,2.,生产排程的灵活性增强,3.,多机种混合生产,4.,换线容易,5.,小批量生产,After,2.4,弹性（灵活）排程,优点：,8,1.,节省取放材料的时间,2.,控制,WIP,A,B,C,D,1.A,工序做完后材料无须送往下一工序,由,B,工序同事来取；,2.,有用到工装的站别，通常该工序员工只负责上工装，做完后由下一站员工,负责下,工装,(,测试站别无人化操作,),。,2.5,拉式生产方式,优点：,从上一工序,拉,(,PULL),而非,传,送下一,工序,(PUSH),9,1.,生产排程的灵活性增强,2.,换线容易,(,减少延误工时,),3.,作业员之间的沟通更容易,、,有效,4.,品质提升,5.,制程的前置时间改善,6.,减少制程中的工作量,7.,减少因线不平衡带来的延误,8.,作业员责任明确,直线观念,（流水线生产系统）,细胞线观念,从左,往右,3 Cell Line,的基本布线规则,3.1,站立、从左往右,优点：,10,3.2,人在内转,时常回顾基本,11,CP,CP,CP,CP,600,/,天,300,/,天,30,0/,天,够小,够精,够活,3.3 cell,越小越好,12,1.,不,落地生根,传统观点认为设备越大效率越高，通常将设备固定在地面而无法移动。设备不能移动，自然缺乏弹性，也就失去了改进布置、应对市场变化的能力。,3.4,架线的三不政策,(1),改采,设备小型化,或,设备可动化。,管线不像常青藤,13,设备“寄居”在固定的管、线及中央式装置之下而无法移动。,3.4,架线的三不政策,(2),2,.,不,寄人篱下,放弃中央式设施,改采用分离式设备如：快速接头、弹性接口。,设备要像快餐车,14,1.,品质提升,2.,WIP,减少,3.,前置时间减少,4.,消除搬运,离线,随,线,工序,2,切勿离线作业,只能以,“,主流,支流,”,的概念进行站别布置,!,3.4,架线的三不政策,(3),3,.,不,离群索居（,IN LINE,）,优点：,工序,1,工序,2,工序,2,工序,1,工序,2,工序,2,工序,2,15,一,笔,画,布,置,3.5,工厂一笔画布置,工厂,/,生产流程在整体上呈,一笔画,布置,16,1,2,3,4,I,O,一致原则,1,2,3,4,空手,走动,浪费,I,nput,O,utput,I,nput,O,utput,生产投入点与完成品取出点尽可能靠近，以避免作业返程造成的时间和体力浪费。,3.6,生产线,U,形化,(1),IO,一致原则同样适用于设备布置，亦可节省空间占用。,17,1.,以,U,字型,布置,方,式,按工艺流程排列生产。,2.,入口和出口,尽量,由同一作业者负责，能够以产距时间按标准数量进行生产及管理，也便于补充生产。,3.,便于作业者相互协作，异常时能停线，及时暴露问题并改善之。,4.,步行最短，可单件流动，人员可增可减,。,1,2,3,4,5,8,1,4,13,12,11,7,10,9,6,成品,材料,3.6,生产线,U,形化,(2),18,各站产出状况,数量,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,平常堆货的生产模式,每站看似都很忙,也能一直保障,3,pcs,的产出,所以看不到线平衡的问题,单件流,(,站,6,只需要,1,pcs),的拉动式生产模式可轻易看到线平衡的问题,我只要,1pcs,4,单件流,19,单件流真的能节约时间吗,?,时间会不会变长,?,单件流到底有什么好处,?,我们可以通过下面动画,看到传统堆货生产,&,单件流的不同,(,某个包含,3,站的产品,),。,面对单件流的疑问,?,20,传统堆货生产,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,21,pcs,产品,21,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A,站,B,站,C,站,21,pcs,产品,传统堆货生产,22,15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A,站,B,站,C,站,21,pcs,产品,1,传统堆货生产,23,15,8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A,站,B,站,C,站,21,pcs,产品,2,传统堆货生产,24,15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,25,15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,6,21,14,7,00:05,A,站,B,站,C,站,21,pcs,产品,4,传统堆货生产,26,15,8,6,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,7,00:06,A,站,B,站,C,站,21,pcs,产品,4,传统堆货生产,27,15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:07,A,站,B,站,C,站,21,pcs,产品,4,传统堆货生产,28,15,8,7,16,9,17,10,3,18,11,2,19,12,1,20,13,5,21,14,6,00:08,A,站,B,站,C,站,21,pcs,产品,4,传统堆货生产,29,15,9,7,16,8,17,10,3,18,11,1,19,12,2,20,13,5,21,14,6,00:09,A,站,B,站,C,站,21,pcs,产品,4,传统堆货生产,30,15,10,7,16,9,17,8,1,18,11,2,19,12,3,20,13,5,21,14,6,00:10,A,站,B,站,C,站,21,pcs,产品,4,传统堆货生产,31,15,11,7,16,9,17,8,2,18,10,3,19,12,4,20,13,5,21,14,6,00:11,A,站,B,站,C,站,21,pcs,产品,1,传统堆货生产,32,15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:12,A,站,B,站,C,站,21,pcs,产品,2,传统堆货生产,33,15,12,7,16,9,17,8,3,18,10,4,19,11,5,20,13,1,21,14,6,00:13,A,站,B,站,C,站,21,pcs,产品,2,传统堆货生产,34,15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:14,A,站,B,站,C,站,21,pcs,产品,2,传统堆货生产,35,15,13,6,16,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:15,A,站,B,站,C,站,21,pcs,产品,2,传统堆货生产,36,16,13,6,15,9,17,8,3,18,10,4,19,11,7,20,12,1,21,14,5,00:16,A,站,B,站,C,站,21,pcs,产品,2,传统堆货生产,37,16,13,6,15,10,17,8,2,18,9,3,19,11,7,20,12,1,21,14,5,00:17,A,站,B,站,C,站,21,pcs,产品,4,传统堆货生产,38,16,13,6,15,11,18,8,2,17,9,4,19,10,7,20,12,1,21,14,5,00:18,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,39,16,13,6,15,12,19,8,2,17,9,5,18,10,7,20,11,1,21,14,4,00:19,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,40,16,12,5,15,13,20,8,2,17,9,6,18,10,7,19,11,1,21,14,4,00:20,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,41,16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:21,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,42,16,12,5,15,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:22,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,43,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:23,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,44,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:24,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,45,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:25,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,46,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:26,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,47,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:27,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,48,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:28,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,49,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:29,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,50,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:30,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,51,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:31,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,52,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:32,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,53,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:33,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,54,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:34,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,55,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:35,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,56,15,12,5,16,14,21,8,2,17,9,7,18,10,6,19,11,1,20,13,4,00:36,A,站,B,站,C,站,21,pcs,产品,3,传统堆货生产,57,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:00,A,站,B,站,C,站,21,pcs,产品,单件流,58,15,8,1,16,9,2,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:01,A,站,B,站,C,站,21,pcs,产品,单件流,59,15,8,2,16,9,17,10,3,18,11,4,19,12,5,20,13,6,21,14,7,00:02,A,站,B,站,C,站,21,pcs,产品,1,单件流,60,15,8,3,16,9,17,10,1,18,11,4,19,12,5,20,13,6,21,14,7,00:03,A,站,B,站,C,站,21,pcs,产品,2,单件流,61,15,8,4,16,9,17,10,2,18,11,1,19,12,5,20,13,6,21,14,7,00:04,A,站,B,站,C,站,21,pcs,产品,3,单件流,62,15,8,5,16,9,17,10,3,18,11,2,19,12,1,20,13,6,21,14,7,00:05,A,站,B,站,C,站,21,pcs,产品,4,单件流,63,15,8,6,16,9,17,10,4,18,11,3,19,12,2,20,13,1,21,14,7,00:06,A,站,B,站,C,站,21,pcs,产品,5,单件流,64,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:07,A,站,B,站,C,站,21,pcs,产品,6,单件流,65,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:08,A,站,B,站,C,站,21,pcs,产品,6,单件流,66,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:09,A,站,B,站,C,站,21,pcs,产品,6,单件流,67,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:10,A,站,B,站,C,站,21,pcs,产品,6,单件流,68,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:11,A,站,B,站,C,站,21,pcs,产品,6,单件流,69,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:12,A,站,B,站,C,站,21,pcs,产品,6,单件流,70,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:13,A,站,B,站,C,站,21,pcs,产品,6,单件流,71,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:14,A,站,B,站,C,站,21,pcs,产品,6,单件流,72,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:15,A,站,B,站,C,站,21,pcs,产品,6,单件流,73,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:16,A,站,B,站,C,站,21,pcs,产品,6,单件流,74,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:17,A,站,B,站,C,站,21,pcs,产品,6,单件流,75,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:18,A,站,B,站,C,站,21,pcs,产品,6,单件流,76,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:19,A,站,B,站,C,站,21,pcs,产品,6,单件流,77,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:20,A,站,B,站,C,站,21,pcs,产品,6,单件流,78,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:21,A,站,B,站,C,站,21,pcs,产品,6,单件流,79,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:22,A,站,B,站,C,站,21,pcs,产品,6,单件流,80,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:23,A,站,B,站,C,站,21,pcs,产品,6,单件流,81,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:24,A,站,B,站,C,站,21,pcs,产品,6,单件流,82,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:25,A,站,B,站,C,站,21,pcs,产品,6,单件流,83,15,8,7,16,9,17,10,5,18,11,4,19,12,3,20,13,1,21,14,2,00:26,A,站,B,站,C,站,21,pcs,产品,6,单件流,84,传统堆货生产,单件流,第一片时间,16,s,6,s,21,片总时间,36,s,26,s,优缺点比较,结果比较,1.,总体时间长，浪费工时,2.,首件产出时间长，难满足客户交期,3.,WIP,多，每个人看起来都很忙,看不到问题在哪,?,4.,WIP,多，急单来却来不及清线,/,盘点,/,换线,5.,WIP,多，出了问题，一重工或报废就是一堆,6.,WIP,多，工作台都是半成品，很难作业,7.,WIP,多，堆积花费时间也较长,1.,总体时间少,节省工时,2.,首件产出时间长，难满足客户交期,3.,WIP,少，容易暴露生产问题，以便加以解决,4.,WIP,少，对外界反应迅速，急单容易插入,转机快,5.,WIP,少，出了问题，受影响程度低,6.,WIP,少，工作台整洁，操作方便,7.,WIP,少，堆积时间少,节省工时,85,The end.,Thanks!,86,