The index which shows the productivity of the assembly, the manufacture
line (the line of the mechanical neck process) by the automation facilities
has [the facility overall efficiency] and [the yield in 1 man-hour].
It put the productivity of the assembly, the manufacture line by these
automation facilities below about the aim and the improvement technique
of the improving improvement in order.
The aim of the productivity improvemen
１）The improvement of the yield
In case of expansion of the production request quantity.The improvement
that the required personnel are constant and that they give a 1-hour yield
to secure a productive capacity
２）The cutbacks in personnel
The improvement which reduces personnel without changing a production
cycle time when the request quantity of the production is constant. Or,
it is the improvement which reduces personnel when the request quantity
of the production decreases and still increases production per work member
more.
It makes above aim clear and it grapples by the following improvement procedure.
The procedure and the improvement means of the line
improvement
| The procedure | The improvement content explanation | The improvement The means example |
| 1 step | ・ It grasps linear facility
overall efficiency.Then, it makes the efficiency obstruction loss of the
line clear and it improves the obstruction loss of the time operating rate. It does the individual improvement which reduces "setup and adjustment" and "the tool exchange" time of the obstruction loss of the time operating rate. （The "setup and adjustment" time abridgment improvement means clicks this place.。) It investigates the looseness of the yield for every the time.The yield for every the time extremely improves among these the loss to be making fall to. Moreover, it grasps to do the bad of the process and the actual state of the modification and it grapples from the worst bad phenomenon. As for losing a breakdown by the facilities and the mold, it develops "the autonomy maintenance activity" and "the schedule maintenance activity". （The details of "the autonomy maintenance activity" and "the schedule maintenance activity" click this place.） |
･ It standardizes a way of operating facilities ･ It grasps facility overall efficiency. ･ It improves a way of grasping production's progress and a yield for every the time. ･ It improves setup and adjustment exchange time abridgment. ･ It makes setup and adjustment exchange work a procedure and it trains in the work. ･ It improves a production lot size. ･ It improves a way of the production indication. ･ It improves a quality defects and rework. ･ The facility autonomy maintenance activity spread ･ It does the analysis of the facility breakdown and a recurrence prevention measure. |
| ２ step | ・ It improves the obstruction
loss of the performance rate in the facility overall efficiency. It improves "the minor stoppage, the idling losses"and "the part supply forwarding". The improvement means of "the minor stoppage" clicks this place. Next, it improves "the cycle time abridgment". (The attention : Don't do before improving a minor stoppage) The improvement means of "the cycle time abridgment" clicks this place.。 |
･ It improves in the abridgment of the work make-ready time in the
morning. ･ It improves management's record work. ･ It improves facility minor stoppage and idling individually. ･ It improves a way of the inspection measurement. ･ It improves part supply forwarding container on replacement to make a one touch. ･ It improves in the individual M/C cycle time abridgment. |
| ３ step | ・ It improves to the continuation
unattended operation (manned) and the noon recess or the automated system
operation during the shift. It realizes 3 zeros (zero piece of quality defects, zero breakdown, zero minor stoppage) and it challenges the extension of the continuation unattended operation time. (It does the supply forwarding of the material, the manned doing of the quality confirmation by it but the facilities are in the condition which doesn't stop). The continuation unattended operation improves the obstruction work of the perfect automated system operation implementation in the noon recess next if achieving for equal to or more than 1 hour. (Unattended-ization of the supply forwarding of the material, the quality confirmation by it) After noon recess automated system operation, it challenges an automated system operation during the shift. But, when there is not request production, there is not necessity of the automated system operation. However, if the ability of the automated system operation is confirmed, the increase of the number of the lines to operate in the working at one of the automation lines in the following manned operating time becomes possible. |
･ It measures a No touch MTBF. ･ It improves a way of the part supply forwarding. ･ It improves to the built-in check equipment. ･ It improves an automatic tool exchange. ･ It improves at the equipment of the unattended abnormal stop protection against disasters. |
| ４ step | ・ The improvement of the work
organization of the change of the request production When request production's changes are few, it becomes the adjustment of the operating time.However, when production is mainly decreased, the required personnel must be reduced of course. Then, it sets "the personnel arrangement" and "the facility laying-out" and "the production method" not to make the productivity of the automation line decline. The intermission stop of the line occurs by one worker's working at a lot of lines and producing them (The intermittently occurring plan stop). Also, the loss of the facility overall efficiency occurs because it does working facility tool exchange and setup and adjustment work alone.However, the yield of one worker for every the time improves. About the case with request production to have been mainly increased The automation line is the cycle time of the facilities and a productive capacity is limited.Therefore, production's correspondence isn't made in the increase in personnel of the worker.In this case, it is necessary that the number of the operation days increases.Then, the machine cycle time must be improved in the abridgment. One is "the intermission production method" to produce at the cycle time which adjusted a line to the request production.Another is "the visitor production method" which wanders a line, producing constant quantity in the gathering but there is it. It examines well and it decides which production method is efficient.Seemingly, "the visitor production method" can be efficiently seen but has been formed into a great deal of stock during the following process.Then, it causes the loss of the container, the carriage, the stock. As for "the intermission production method", the overall efficiency of the facilities declines. However, to produce request production minutely, being raw, the stock during the following process is the least. Then, there is not loss of the container, the carriage, the stock. In the request production, as for the non-mass production, it should choose "the visitor production method" and in above the quantity production should choose "the intermission production method". Incidentally, make the production lot of the taking of "the visitor production" the inside of the range with the quantity of the forwarding cycle.Then, it begins at the 1 division production in the forwarding cycle and moreover it should improve for the 2 division production. There is the following risk in the 1 division production. When the facility breakdown and so on occur while producing, it is because it becomes to the forwarding back. The minimum forwarding becomes of the production above the 2 division production possible. |
･ The improvement of the work personnel combination and the arrangement
in case of the request quantity change ･ The selection of the optimal production method ･ The improvement of the division production method to the forwarding cycle ･ The improvement of the process laying-out ･ The combination with the other line and the collection(Parallel laying-out of a line) ･ The combination of the non-mass production line and the improvement of the generalizing |
| ５ step | ・ The improvement of the flow,
the materials handling method of the product with the back and forth processAnd,
it is the improvement of the production indication method. It does the improvement of the way of the movement of the product from the pre-process and the improvement of the way of the movement of the product to the rear process. (Production lot size, the style of packing, SNP, the way of carrying, the carriage cycle time) It improves production methods such as the stock, the setup and adjustment lot stock, the complete stock, the materials handling method during the back and forth process. |
･ The synchronization of the production cycle time ･ The unification of the container, SNP ･ The improvement of the way of carrying ･ Doing a back and forth process the linear becoming of the direct connection ･ It makes the management which can be seen by the eyes of the production indication, the forwarding indication. |
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