关于色轮生产系统的精益变革研究

上海交通大学硕士学位论文关于色轮生产系统的精益变革研究姓名：乌国亮申请学位级别：硕士专业：工业工程指导教师：王丽亚;施幸华20051001IIDLPDLP5SJITIEIEIIIABSTRACTLeanProductionisnotonlyamanufacturingmethodtomaximumreducetheresourcesforproductionofthecompanyandthecostsavingonenterprisemanagementandoperation,butalsoatypeofmissionoracultureofthecompany.ManagementiscriticalforLeanproduction,andtowipeoffthewastes,continuouslykeepimprovementisitssoul.Colorwheelisanopticalcomponentassembledbyseveralcolorfilterstogetherwithamotor.ItiswidelyinstalledinDLP(DigitalLightingProcessing)TVandprojections.OriginalColorwheelproductionsystemadoptedthelargequantitiesofproductionmethodandresultedinhugewastes.Forthereasonofcostsaving,itisverynecessarytocarryoutleaningprocessingresearchonColorwheelproductionline.Atthesametime,withtheDLPTVwidelyacceptancebythepeopleandopticalcolorwheelgradualexpansion,iftheresultoftheleanprocessingresearchsuccessfullyapplysincolorwheelproductionline,itwouldbeaverygoodexampletoimplementleanprocessingonthesimilarproductionsystem.Inthispaper,reseachworkiscarriedthroughbothinthorydescriptionandinapplicationorexperiment.Chapter2isintroducedtoresearch,identifyandanalyzetheseventypesofmudaincolorwheelproduction.Inchapter3,“5S”implementationonthespotofcolorwheelproductionisintroduced.Inchapter4,therelatedconceptsofJITproductionsystemanditsresearchandapplicationoncolorwheelproductionaredetaileddiscussed.Thereinto,partoneistointroducethecolorwheelfacilitieslayoutimprovementinto“onepieceflow”productionandtakeuseofrelatedIEtechniquetoanalyze,thengettheresult.ParttwoistodescribetheapplicationofKanbansystemoncolorwheelproductionline.PartthreeistointroducetheimplementationofIEtimestudy&linebalancingoncolorwheelproductionlineandtheresultsareveryusefulforproductionarrangementandmanpowerforecast.Inpartfour,visualmanagementmethodisintroducedincolorwheelproductionline.Inchapter5,asapartofleanthinking,sixsigmatheoryisintroducedandtakeVoiddefectsixsigmaprojectastheexampletoresearchandverifytheimportanceofsixsigmaprojectintheleanprocessingprogramme.Keywords:leanproduction;colorwheel;“onepieceflow”layout;timestudy;linebalancing;Kanbansystem;visualmanagement;2005127I2005127200512711.11.LPIMVPJIT””20602.2•1/2•1/21/3•1/10•1/2•1/4•31.21.1.1DLP(DigitalLightingProcessing)DLPDMDDMD1.1DLPFig.1.1DLPsystemandColorwheel31.2DMDDLP1.2.1RGBRGB1.2.2RGBWRGBW20%WW1.2.3RGBRGBDLPDLP4RGBRGB6180HZ2.199665500DLP200DLP47200440DLP81812000DLPDLP29DLP31887DLPDLP70%300GOLDENDLP51.3125S3JIT••OnePieceFlow•CellProduction••IE•Pull&Kanban•Leadtime456σ6σ62.13(NVA)(NNVA)(VA)7123475672.22.2.11.2.1Fig.2.1ColorwheelprocessflowchartRemoveFromStockScribeCleanGlassSegments(MotorSerializationRingBuildMotorAttachmentTIMAttachBalanceFinalInspection/CleanPackagingtoStockPackagingtoShipSoundTestRightSegmentCleanedSegmentLabeledMotorRightColorRingColorwheelColorWheelwithTIMattachedRightBalancedColorWheelColorWheelaftersoundtestColorWheelafterFinalInspectionPackagedColorWheel82.1(Removematerials)2Scribe3(Cleaning)4RingBuildUVUV5MotorAttachment6TIMAttachment;;7Balance8VibrationAnalysis9FinalInspection10Package2.12.2.21.2.292.2Fig.2.2LayoutbeforetheimprovementFI1Pack-3Pack1Pack2Sound2FI4FI6Sound4AB-12AB-10AB-9AB-11AB-13AB-14FI3FI5Sound3Sound1AB-1AB-3AB-2AB-4MotorAtt-8MotorAtt-7ABAB-16AB-15AB-17BBBB-2AB-18BB-4MotorAtt-7Tim-2MotorAtt-7MotorAtt-7AB-6AB-5AB-7BB-1AB-8BB-3Cleaner-1Cleaner-2Tim-1Tim-3MotorAtt-8MotorAtt-8ABCEDFGHIJKLMNO1ABCEFGHIJKLMNO2ONF3ONDE4ONM102.SAP20046002.3SAPFig.2.3Excessiveproductionordersample2.2113.2.32.312116724.20043%2.45.WIP2.52.513373927786.122.4Fig.2.4Color-wheelbalancestation121432.2.35S5S155S3.15S1.5S5S55S5S5S5S5S5S5S2.5S1234565S161231231235S1745S5S3.25S3.2.15S5SWI5S5SDaily5S5S(05:00-06:00)WeeklyA12VPIToolingCassetteCassetteB.5S1812UVHUBHUBOVENOVENC.WID.WIOVENOVENOVENE.WITIMCW3.15S5S193.15SFig.3.1“5S”requirementsforTIMworkingstationF.3.2WIBALANCEABUVTIMNCM1.OTHERS2.CR3.CR4.CR5.CR6.7.CR8.9.CR10.5S203.25SFig.3.2“5S”requirementsforBalancestationG.3.3WI3.3Fig.3.3ConfigurationsforSoundteststation1.CW2.CW3.CW6.4.5.5S21H3.4WI3.45SFig.3.4“5S”requirementsforFinalinspectionstationJ.WI3.2.25SA3.53.63.11.CW2.CW3.4.5.6.7.5S223.53.6Fig.3.5ToolingcontrolroomFig.3.6Cabinetsfortoolingmanagement3.1NormalBalance(BN13.6)BD402907-01552005-8-272005-10-27NormalBalance(BN20)BD401940-0116162005-8-272005-10-27NormalBalance(BN33)102143607442005-8-272005-10-27NormalBalance(BN13BD402906-01552005-8-272005-10-27NormalBalance(BN20)2005-8-272005-10-27Topconrun-outBD401939-0111102005-8-272005-10-27NormalBalance(BN33)102205913442005-8-272005-10-27NormalBalance(70mm)102132598442005-8-272005-10-27NormalBalance(70mm)102132599442005-8-272005-10-27Motor102233462442005-8-272005-10-27BALANCEBN32BD401742-01222005-8-272005-10-27BALANCEBN32BD401717-01222005-8-272005-10-27SVA102222314222005-8-272005-10-27BN33H102222314222005-8-272005-10-27B3.73.83.73.8Fig.3.7MaterialslayoutFig.3.8Chemicalconfiguration5S23C3.93.103.93.10OQCFig.3.9FinishgoodskeepingareaFig.3.10OQCinspectionarea3.2.35S5S24JIT25JIT4.14.1.1JIT26(a)(b)4.1Fig.4.1Facilityhorizontal&verticalla