Line-Balancing-生产线平衡

VersionA1LineBalancing生产线平衡CourseCode:SFM-T022PPPPurpose目的•Learnthebasicconceptsandmethodsoflinebalancingforproductionlines学习平衡生产线的基本概念和方法Process过程•Explainthemeaningoflinebalancingandthepossiblereasonsfortheiroccurrence解释生产线平衡的含义和可能发生的原因•Explaintheprinciplesandmethodstoimprovethelinebalancing解释改善生产线平衡的原则和方法Payoff回报•Abletoavoidlineunbalancingproblemsduringplanningstage能够在规划阶段就避免线不平衡的问题•Abletoidentifyandresolvelinebalancingproblemsbeforeproductionstart能够于开始生产之前就识别和解决生产线平衡问题3Contents内容1.Introduction引言2.BasicPrinciples基本原理3.ShopFloorMonitoring车间监控4.LineBalanceImprovement生产线平衡的改善41.Introduction引言5Introduction引言Linebalancingrefertoallocateandadjusttheworkloadingofworkstationsofproductionlinesoastoachievetheproductionoutputtargetwithminimumhumanormachineresources.生产线平衡是指分配和调整生产线每个工作站的工作负荷，以利用最低人力或机器资源实现产量目标的。Whatislinebalancing?什么是生产线平衡6Beforelinebalancing生产线平衡以前Introduction引言7Afterlinebalancing生产线平衡之后Introduction引言8Linebalancingwillleadto:生产线平衡将导致Moreeffectiveutilizationoflabors更有效地利用劳动力Reducelaborcost降低劳动力成本Reduceworkinprogress减少在制品Increasespeedoftheproductionline提高生产线的速度Uncoverinefficiencyproblemsandinitiateimprovement发现低效率的问题，并启动改善Introduction引言9PossibleReasonsofunbalancedline:生产不平衡线的可能原因Unevenoperatorworkloadassignment工人工作量分配不均衡Inaccurateoperationbreakdownandstandardtime不准确的工序分拆和标准时间(SMV)Bundlingeffect捆扎效应Learningeffectfornewstyle新样式的学习效应Newoperatoreffect新工人的影响Interruptionsduetomachinebreakdown,operatorabsence,cutpieceshortage,rework,etc.由于机器故障，操作员不在时，切出短缺，返工等等的干扰Introduction引言101)Balancetheoperatorworkloadassignment平衡工人工作量的分配BasicPrinciples基本原理OperatorWorkloadChart工人工作负荷表112)Enableworksharing实现工作分担Movingoperators走动的工人Multipleskillstraining多能工的培训Properlayouttofacilitatemovingoperators可促进工人走动的布局141312111012348569Materials材料Product成品BasicPrinciples基本原理123)LimittheWIPlevelbetweenworkstations限制工作站在制品的水平MaximumWIPlevel最高在制品水平e.g.1bundle扎,1pieces件,5pieces件,etc.Thegoalistorealizeone-pieceflow目标是实现单件流Workswitchingrules工作更换规则e.g.switchtoanotheroperationwhenmorethan5pcsbeforethenextoperator例如,当“埋夾”前超过5件,转换到“上介英”工作BasicPrinciples基本原理134)Stabilizeoperatorwork使工人工作稳定化Standardizeoperation标准化作业e.g.workstation,worksequence,travelingpath,etc.例如,工作站,工作顺序，走动路线等Assigndedicateoperators,i.e.waterspider,forirregularwork指派专门的工人,即水蜘蛛,负责不规则的工作i.e.avoideffectonregularworkbyinterruptions,suchascutpiecesshortage,rework,machinebreakdown,etc.避免正常工作受，如裁片短缺，再加工，机器故障等干扰的影响BasicPrinciples基本原理143.ShopFloorMonitoring车间监控15Howtoseelineimbalance如何揭视生产线不平衡?HighWIPlevelbetweenworkstations工作站之间有大量在制品DifferencebetweenTaktTime(TT)andactualcycletime产距时间（TT）和实际周期时间之间的差异Operatorwaiting工人等待Operatorslowingdown工人放慢工作Operatordon’tmove工人没有走动ShopFloorMonitoring车间监控16MethodsofMonitoring监控方法Hourlyproductionstatusreportonshopfloor每小时车间生产状况报告Directon-spotmonitoringandobservation直接现场监控和观察Identifyingbottleneckworkstation确定瓶颈工作站CheckcycletimesincomparisonwithTT检测周期以及与TT比较Observeoperatorbehaviorandperformance观察工人行为和表现ShopFloorMonitoring车间监控17HourlyProductionStatusReportShopFloorMonitoring车间监控184.LineBalanceImprovement生产线平衡的改善19LineBalanceImprovement生产线平衡改善1)Checkoperatorworkloadallocationandmakeadjustment检查工人的工作量分配，并予以调整2)Identifybottleneckworkstationandshortenitscycletimeby找出瓶颈工作站，并缩短其周期时间:•Splittaskandshiftsub-tasktoanotherworkstation分割工作和转移到另一工作站•Moveotheroperatortosupport转移工人支援其他工作站•Replaceoperatorwithhigherskilllevel更换具有较高的技术水平工人20LineBalanceImprovement生产线平衡改善•Addparallelworkstations增加并行工作站•Improvetheefficiencyofworkingmethod提高工作方法的效率e.g.Usingprinciplesofmotioneconomy,usingworkaids,etc.例如使用动作经济原则，使用辅助工具等3)Improveprocessflowandlinelayout改进工艺流程和线路布局21LineBalanceImprovement生产线平衡改善22LinebalanceImprovement生产线平衡改善23END完