การเพิ่มผลผลิตด้วยระบบอัตโนมัติแบบลีน (LEAN Automation) Part 1

ry board

าหรับการวางแผนและการทําลีน

ใสขอ มูล
ภาพ

Full version

คต สงิ่ ทต่ี อ งการจะทาํ ตวั ชวี้ ดั ประสิทธิภาพ และแผนการดาํ เนินงาน

ของทกุ ระดบั เขา ใจเปาหมายและสงิ่ ทต่ี อ งทาํ ตรงกนั ไดง า ย 167

mprovements By Don Tapping, Tom Luyster and Tom Shuker

ท่มี ารปู : Value Stream Management: Eight Steps to Planning, Mapping, and Sustaining Lean Im

Methodology

168

mprovements By Don Tapping, Tom Luyster and Tom Shuker

Step4: Map the

e current state

169

ท่มี ารปู : Value Stream Management: Eight Steps to Planning, Mapping, and Sustaining Lean Im

mprovements By Don Tapping, Tom Luyster and Tom Shuker 170

Production con

ABC Production super
Weekly

I=2,500

Machining Deburring Crimping

1 FIFO 1
CT = 45 sec. CT = 40 sec.
C/O = 60 min. 3,360#4 CT = 5 sec. 3,500 C/O = 5 min. 2
Avail = 27,600 1,680#6 C/O = 0 min. Avail = 27,600 4
Uptime = 87% Uptime = 99%
5 days Avail = 27,600
Uptime = 100%
45 sec.
10 days 7 days

5 sec. 40 sec.

ntrol 1 Shift/day-8.5 hours
30 min unpaid lunch

Breaks = 20 min.
Net Avail Time = 460 min.

rvisor Cord, Inc. Perday
10,080/mo
336
6,720#4 168
3,360#6
504
21 cont.

Daily
Ship

Testing Marking 2,000

2,000 1 2,000 1
CT = 30 sec. CT = 50 sec.
C/O = 5 min. C/O = 5 min.
Avail = 27,600 Avail = 27,600
Uptime = 99% Uptime = 99%

4 days 4 days 4 days LT = 34 Days
TCT= 170 sec.
30 sec. 50 sec.

175

Step6: Map the

e future state

178

ท่มี ารปู : Value Stream Management: Eight Steps to Planning, Mapping, and Sustaining Lean Im

mprovements By Don Tapping, Tom Luyster and Tom Shuker 179

Product

ABC Pitch =22
S
VW

Weekly

S VW
5S Clamp
Machining
AM 5S Std. 2
QCO work CT = 10
1 C/O = <
TPM CT = 45 sec. Avail = 2
Uptime
C/O = 30 min. Takt = 5
Avail = 27,600
Uptime = 93%

5 days 2 days

45 sec.

tion control

Cord, Inc.

504 units per day
24 units per container

W SB Daily
SB Ship
P SB
ping/Testing/Marking QCO 5S

05 sec. 1 ddays LT = 8 Days 204
<1 min. TCT= 150 sec.
27,600
e = 100%
55 sec.

105 sec.



205

Source: http://clipart-library.com/

206

Process desig

(How to Analyze Process)

gn & Kaizen

(How to Improve Process)

1/58

Process Des
Manual Ass

手組ラインの

sign for
sembly Line
の工程設計

2/58

กรณีศกึ ษา โรงงานประกอบรถขอ

มรี ถ 2 ประเภทในโรงงาน

องเล่น

น

3/58

Content

1 Bill of Process

工程系統図とは

2 Bill of Material

部品表とは

3 Process Design for M
(Practice) 手組ラインの工程

4 Points to keep in mind

工程設計時の留意点

Manual Assembly line

程設計 (実習)

d (Process Design)

4/58

Bill of P

工程系統図

Process

図とは

1 Bill of Process 工程系統

◆Bill of Process 工程

The process flow in
by the symbol like a
and the kind of proc

ラインにおける工程の流れ
工程の順番、工程の種類

統図
程系統図

the line is indicated
as the order of steps
cess etc.

れを図示記号で示し、
類を表したもの

6/58

1 Bill of Process 工程系統

(Ex.) Symbol

記号

Part A Part B

Part C Part A assembly
Part C assembly
Part C welding Pr
Visually check In
Product

統図

Parts Meaning

部品 意味

rocessing Material, raw material,
raw material, semi-finished
加工 product, finished part

材料、原料、素材、半加工品、完成品

Process of changing the
shape and property of part
(Ex.) Assembling, welding,

Heat treatment etc.

部品の形状や性質に変化を与える工程
(例) 組立、溶接、熱処理 など

nspection Process mainly for
inspection
検査 such as appearance,
dimensional.

外観検査、寸法検査、性能検査など
検査を主とする工程

7/58

1 Bill of Process 工程系統

Outline of Manual Assembly

LASIショーケース手組

Industry : Automobile manuf

業種: 自動車製造
Product : 2 Types 2タイプ

EV 0001 (Electronic Vehicle

電気自動車

統図 (Practice)

y Line for LASI Showcase

組ラインの概要

facture

e) Pick-up 0002

ピックアップ

8/58

1 Bill of Process 工程系統

◆Bill of Process 工程系統図

Rear Base R

Tire 01 Rear Assembly

02 Tire Assembly

03 Tire Press Fitting
(Auto Machine)

Frame 04 Visually Check
(Incorrect parts, Missing p

Front 05 Frame Assembly

06 Front Assembly

統図

Roof Parts △
部品

Assembly ○
組付工程

07 Roof Assembly Inspectio

n◇

08 Visually Check 検査工程

(Incorrect parts , Missing parts)

parts) 09 Performance Engine Check
(Auto Machine)

10 Tire Press Fitting Dimension Check
(Manual Gauge)

11 Frame Fitting Dimension Check
(Manual Gauge)

12 Appearance Check
(Visually Check)

13 Packing (EV, Pickup)

9/58

部品表とは



2 Bill of Materials 部品
Parts 部品
<Common

Base 0101 Front 0501 F
＜Individua

(EV)

Roof 0601 Rear 0201

品表とは
n> 共通部品

Frame 0401 Tire 0301

al＞ 個別部品 (Pick up)

Roof 0602 Rear 0202

11/58

2 Bill of Materials 部品
◆Bill of materials 部品

List of parts names,
and numbers supplie

各工程で供給される部品名, 種類（品番）

(Ex.)

No. Process Parts Pa

工程 部品名 部

① Part A assembly Part A 0
部品A組立 Part B 0
0
② Part C assembly Part C
部品C組立 0

③ Part C welding -
部品C溶接
-
④ Visually check
目視検査

(Ref.: P.11/58)

品表とは

品表

types (part numbers)
ed in each step

）, 数を一覧に表したもの

arts No. No. of Parts 部品数

部品品番 Prod. A 製品A Prod. B 製品B
22
0101 1-
0201 -1
0202
44
0301

- --

- --

12/58

2 Bill of Materials 部品

◆Bill of materials 部

No. Process

① Rear Assembly

② Tire Assembly
③ Visual Check
④ Tire Press Fitting (Auto Machine)
⑤ Frame Assembly
⑥ Front Assembly

⑦ Roof Assembly

⑧ Visual Check
⑨ Performance Check (Auto Machine)
⑩ Tire Press Fitting Dimension Check
⑪ Frame Fitting Dimension Check
⑫ Visual Check (Appearance Check)
⑬ Packing (EV , Pickup)

品表とは

部品表

Parts Parts No. No. of Parts
EV Pickup
Base 0101
0201 11
Rear 0202 1-
0301 -1
Tire 44
- - --
- - --
0401 22
Frame 0501 11
Front 0601 1-
0602 -1
Roof - --
- --
- - --
- - --
- - --
- - --
-
- 13/58

Process Desig
for Manual

gn
Assembly Line

Steps of Process Desig

3-1. Planning condit

1 Planning Condition
2 P-Q analysis Table
3 Takt time

3-2. Analyze current

1 Net Time (1 Cycle
2 Compare Manpow
3 Compare C.T,T.T

3-3. Considering Kaiz

1 Time Analysis for
2 Making Graph Yam

gn for Manual Line

tion

n
e

condition

e Analysis)
wer

zen Point

1 cycle work
mazumi Chart

15/58

3-1. Planning conditio

1 Planning condition
① Production Quantity
② Monthly working days
③ Daily Production Quant
④ Working Shift

Regular operational tim

Q : Production Quantity per Shift.

3,380 Pcs/Day

＝

2 Shift/Day

⑤ No of Operator : 3 Per