SONY厂房布置(1)

Sony’sImplementationofProductionInnovationEquipmentandManufacturingSystemSolutionsChapter11．Introduction1.1Shiftinproductionneeds1.2Importanceofdemandorientedproduction1.3Productioninnovation’s3maintypesofloss1.4CellproductionmethodShiftinProductionNeedsDiversificationofNeeds・SpecializationSevereEconomicalEnvironment・Worstpost-wareconomicslum・Multi-functionalDrasticMarketChangeFallofProductPricesMassproductionManytypes,smallqtyVarioustypes,variousquantities・DeclineofConsumptionNetworkAge・TelecommunicationRevolut・ElectronicCommerce・Well-soldproductschangequickly・SurplusofinventoryduetothefallofproductpricesProtectionofDemandOrientedProductionGlobalization・NoBorders・GlobalStandardstheEnvironmentDigitalization・LessEnergy・LessResources,Recycling・LSI・Mechanical→SoftwareImportanceofDemandOrientedProductionSellwhatisproducedProduceaccordingtodemandLargemoduletypeproductionlineVariousdemand-orientedcellproductionlines×Linechange-over,modelchangedecfBatch-typeproductionline×Lead-time,Inventory,etc.ba●Productswhichcannotbesold●Change-overloss●WIPloss●Leadtime●HandlinglossTheUltimateProductionSystemCostInvestmentLeadtimeInventorySpaceChange-overlossRejectedproductsBreakdown０ZeroImplementationofProductionInnovationOnlymaketherequiredproductsattherequiredtimeProductionInnovation’s3maintypesofloss1.Handlingloss2.Transportationloss3.StagnationlossMinimizationofnon-valueaddedresourcesProgressbyProductionInnovation(1)■ProductionstyleProductionLargeqtySmallLotProductionTarget:basedonforecastproductionLargeinventoryqtyInnovationZeroInventoryCustomer’sReducedfundsturnoverRequiredproductsReducedspaceRequiredtimeRequiredqtyReducedcontrolcosts■Flow-orientedproduction,informationMixedflow・Individual‘islands’InnovationFlow-orientedIn-lineReductionofWIPReductionofhandlingSimplifiedqualitytrackingProgressbyProductionInnovation(2)■InventoryReductionbyLogisticImprovementsLargeOrder/DeliveryofPartsPushstyleprovisionInputStockPartsInventoryInnovationSmallqtyorder/deliveryDeliveronlywhatisused‘Kanban’DirectReductionofRawmaterials・WIPOutputProvisionProductionline‘Refrigerator’Productionline■ManufacturingequipmentLarge-size・Highspeed・Highperformance・HighpriceSmallsize・Low-mediumspeed・Functional・LowpriceWIPreductionbyproductionlevelingInnovationProgressbyProductionInnovation(3)■Fromsingleoperationtomulti-operationDividedlaborconveyorproductionstyleduetosingleoperationMulti-operationandCellproductionmethodInnovationMulti-operation(Multi-skilledworkers)WIPreductionbyproductionlevelingConveyorlineCell■ControlcomprehensiveforanyoneDatamanagementbycomputer10000pcs.Select&Order・Fixedplace・Fixedqty・FixedmarkingVisualmanagementstorageXXShouldbeinstorage○○?Thereshouldbe○○○○pcs?InnovationMax(XXpcsMin(ＹＹpcs)PartAByseeingtheabnormality,aquickresponseispossibleAbnormal!ExampleofBenefitsofProductionInnovation:ReductionofManpower(Actualfactoryexample)120010008006004002000（persons）94/3995/3996/3997/3998/39ExampleofBenefitsofProductionInnovation:ReductionofSpace(Actualfactoryexample)m21400012000100008000600040002000094/3995/3996/3997/3998/39ExampleofBenefitsofProductionInnovation:ReductionofLeadtime(Actualfactoryexample)(days)35302520151050In-houseproduction94/3995/3996/3997/3998/39ExampleofBenefitsofProductionInnovation:Revenue&Profit(Actualfactoryexample)10080（％）RevenueProductionInnovationActivities6040200-20Profit９２９３９４９５９６９７９８est.Note)Ratio(%)with1992revenueas100FromconveyorlinetovarioustypesofCellProductionConveyorline.....1234n・Change-overlossoccurs・Layoutmodificationisdifficult・Linebalancelossoccurs・HandlinglossoccursSmallmoduleunittypeSpiraltypeOnemancarttypeOneman‘stall’type1decf2banCartChapter22.BenefitsofCellProductionMethod2.1CellProductionMethod2.2BenefitsofCellProductionMethod2.3ExamplesofCellProductionMethodCellProductionMethodTheCellProductionMethodisoneofthebestsolutionsofmanufacturingstylesforsmalllotproduction,inwhichassemblyandworkaredoneinonesingleprocess,byusingsmallmanufacturinginstruments(tools),byoperationofoneorafewworkers.SmallscalelineProductsAssemblyInspectionMulti-functionalworkSmalllotFloworientedPackagingproductionExampleofCellProductionSystemBenefitsofCellProductionMethodFlexibilityUp①Variousitems②Quantityfluctuation③VariouslayoutConveyorlineConveyorlineConveyorlineProductionLossinproductionlinechangeＡＢＣTimeLinemultiplicationisdifficultLayoutmodificationisdifficultCellproductionProductionOperationin3CellsＣＢＡTimeCellproductionBynumberofworkersBunumberofcellsCellproduction●Implementationofvariouscelltypesaccordingtoproductsattributes,levelofoperators,productionquantity;layoutmodificationsarepossibleflexibly●Cellsbyproductiontype●ProductionbysalesspeedBenefitsofCellProductionMethodManpower・Spacereduction①Productivityup→manpowerreduction②SpacereductionConveyorlineBeltconveyorHandlingLossConveyorlineWorktimeLosstimeWorktableProductionqtyChange-overLoss１２３４５ProcessＡＢＣTimeCellproductionCellproduction●Manpowerreductionbyeliminationofconveyorlineloss●Spacereductionbyremovalofconveyor●Eliminationoflossbyreducingin-betweenspacesBenefits