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非标自动化设备的使用更加助于企业推行精益生产

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  精益生产方式的改革对于企业有着至关重要的意义,精益生产管理思想就是围绕减少浪费,提高效能来进行生产组织的一种现代化生产管理思想。非标自动化设备就是结合不同行业不同产品其非标特性加以分析制定出切实可行的办法。
  The reform of lean production mode is of great significance to enterprises. The idea of lean production management is a kind of modern production management thought which focuses on reducing waste and improving efficiency. Non standard automation equipment is to combine the non-standard characteristics of different products in different industries to analyze and formulate practical methods.
  大多数情况下一个公司产品虽然结构形式和尺寸规格千变万化,但作业工序相对比较标准。实际上单件流水式加工就是作业工序的流水化,仍然符合基本的流水作业思想,所以大多数产品可以通过非标产品的标准化作业来实现单件流水式加工生产。
  In most cases, although the structure and size of a company's products are changeable, the operation process is relatively standard. In fact, single piece flow process is the flow process of operation, which is still in line with the basic flow process idea. Therefore, most products can realize single piece flow processing through the standardization of non-standard products.
  如何实现单件流水式加工生产是非标自动化设备完成的首要目的。
  How to realize single piece flow processing production is the primary purpose of non-standard automation equipment.
非标自动化设备精益生产
  1、非标特性分析
  Non standard characteristic analysis
  在实施之前应该将公司产品按产品的属性和使用范围进行分类,实际上是进行一类产品的标准化设计(不可能让冰箱和汽车在一条生产线上完成)。
  Before implementation, the company's products should be classified according to the product properties and scope of use. In fact, it is a standardized design of a class of products (it is impossible to make refrigerators and cars in one production line).
  设计师在进行非标产品设计时大多依据企业已有的标准化产品作为原型加以改进设计。故作为设计原型的标准产品是进行非标产品的非标特性分析的基础。
  When designers design non-standard products, most of them use the standardized products as prototypes to improve the design. Therefore, the standard product as a design prototype is the basis for the analysis of non-standard characteristics of non-standard products.
  工艺人员必须认真对产品进行工艺研究和分析,特别关注非标部分的工艺设计,必须切实考虑现有生产线的设备、工装、工具,甚至是工位器具以及作业空间,尽可能的在现有工艺水平下完成非标产品的工艺设计。
  Technical personnel must seriously study and analyze the process of products, pay special attention to the process design of non-standard parts, and must consider the existing production line equipment, tooling, tools, and even the working space, and complete the process design of non-standard products as far as possible under the existing process level.
  同时,如果在进行工艺分析过程中发现设计结构不利于在现有条件下的生产有必要和设计师进行工艺沟通,在不改变客户需求的条件下统一到现有的生产制造平台上来。
  At the same time, if it is found that the design structure is not conducive to the production under the existing conditions in the process analysis, it is necessary to communicate with the designer on the existing production and manufacturing platform without changing the customer requirements.
  最后工艺人员必须在工艺分析卡上对特殊的工艺处理进行明确说明。
  Finally, the process personnel must clearly explain the special process treatment on the process analysis card.
  2. 非标产品的标准化工序设计
  Standard chemical process design of non-standard products
  工艺分析的基础上完成工序设计,为了有清晰的制作主线,新的工艺路线必须建立在原有的标准产品的生产工艺路线基础上。
  In order to have a clear production main line, the new process route must be established on the basis of the original standard product production process route.
  在工序设计上采用主干线加支线的办法,标准作业工序作为主干线,非标部分以支线的方式与主干线搭接,这样我们只要设计好了非标部分的工序节奏就能以原有标准作业的方式组织好生产,使得整个的生产规划和生产控制变得简单,而且减少了非标定制产品制作过程中的不确定性。
  In the process design, the method of trunk line plus branch line is adopted. The standard operation process is taken as the main line, and the non-standard part is overlapped with the main line in the way of branch line. So long as we design the process rhythm of non-standard part, we can organize the production in the original standard operation way, make the whole production planning and production control simple, and reduce the production of non-standard customized products Uncertainty in the process.
  3. 事先进行非标作业规划
  Planning non-standard operation in advance
  包括作业过程中的物流规划,确保非标作业动作的标准化。进行场地规划,将各个工序所需要的材料就近放置便于生产作业人员不离线就近取材保证持续生产,减少领料的时间浪费。
  Including the logistics planning in the operation process to ensure the standardization of non-standard operation. Site planning is carried out to place the materials required by each process nearby, so that the production personnel can obtain materials nearby without off-line, so as to ensure continuous production and reduce the waste of picking time.
  在工序转运间设置可移动工装以减少搬运浪费,等等。
  Set up movable tooling in process transfer room to reduce handling waste, etc.
  对各种标准作业动作进行规范,制定规范表形成作业标准。
  Standardize all kinds of standard operation actions, formulate the standard table and form the operation standard.
  4.用科学方法对标准作业动作进行工时测算和动作分析
  Using scientific method to measure and analyze the working hours of standard operation
  在标准作业的基础上为了避免因为产品非标性带来的效率低下,仍然需要对实际工作进行监控,通过过程监控发现一些不必要的浪费活动予以纠正。
  On the basis of standard operation, in order to avoid the inefficiency caused by non-standard products, it is still necessary to monitor the actual work and correct some unnecessary waste activities through process monitoring.
  同时参照原来的标准作业工序用“非标系数”予以调节,这样确保了非标作业产品的作业工时的上限得到限制,也有利于生产计划的安排和多品种作业调度。
  At the same time, referring to the original standard operation process, the "non-standard coefficient" is used to adjust, so as to ensure that the upper limit of working hours of non-standard operation products is limited, and it is also conducive to the arrangement of production plan and multi variety operation scheduling.
  通过科学的工时测定来平衡生产线的产能和混流产品的范围(以确保最佳的经济性)。
  Balance the production line capacity and the range of mixed model products through scientific man hour measurement (to ensure the best economy).
  在实际生产管理中采用摄像监测的办法是必要的,通过摄像监测来观察员工的整个作业过程,通过对摄像过程的分析来找出值得改善的地方(包括工装的完善,物料的存放位置等)。
  In the actual production management, it is necessary to use camera monitoring to observe the whole operation process of employees. Through the analysis of the camera process, it is necessary to find out the places worthy of improvement (including the improvement of tooling, the storage position of materials, etc.).
  5.运用统计工具制作满足宽使用范围(满足80%)的标准工装,以提高速度和质量
  Use statistical tools to make standard tooling with wide application range (80%) to improve speed and quality
  结合产品的不同特点,在前面工艺分析,工序布置和动作研究的基础上,可以研究制作适合大多数产品的作业工装。
  Combined with the different characteristics of the products, based on the previous process analysis, process layout and action research, we can research and manufacture the operation tooling suitable for most products.
  这样可以将一些看似非标的产品用标准化的方法来完成生产(比如,相对于标准产品仅是尺寸发生变化等)自然提高了质量保证能力,同时降低了生产准备时间提高了作业效率。
  In this way, some seemingly non-standard products can be produced in a standardized way (for example, only the size changes compared with the standard products), which naturally improves the quality assurance ability, reduces the production preparation time and improves the operation efficiency.
  6.质量监控点的设置
  Setting of quality monitoring points
  为了实现一个流的生产,质量检测就必须作为生产的一道工序纳入生产线规划中,设置检验工序确保产品质量。同时强化“质量是制造出来的不是检验出来的”意识,加强工序自检和互检。
  In order to achieve a flow of production, quality inspection must be included in the production line planning as a production process, and inspection procedures should be set to ensure product quality. At the same time, we should strengthen the awareness of "quality is produced by manufacturing, not by inspection", and strengthen self inspection and mutual inspection of working procedures.
  为了满足尽量宽泛的产品进行混流生产,切实推行看板管理,各种产品用看板进行身份标示,各工序按看板要求进行组织生产。
  In order to meet the mixed model production of products as wide as possible and implement Kanban management practically, various products are identified by Kanban, and each process is organized according to Kanban requirements.
  7.软环境的建设
  Construction of soft environment
  必须配套建立起各种软性的制度。生产线物料补给制度、停线制度、代岗制度等等,并切实加以执行。
  All kinds of soft systems must be set up. Production line material supply system, stop line system, on behalf of the post system and so on, and effectively implement.