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1、Version A,1,Line Balancing 生產(chǎn)線平衡,,Course Code: SFM-T02,2,,PPP,Purpose目的 Learn the basic concepts and methods of line balancing for production lines 學(xué)習(xí)平衡生產(chǎn)線的基本概念和方法 Process 過(guò)程 Explain the meaning of line balancing and the possible reasons for their occurrence 解釋生產(chǎn)線平衡的含義和可能發(fā)生的原因 Explain the princip

2、les and methods to improve the line balancing 解釋改善生產(chǎn)線平衡的原則和方法 Payoff 回報(bào) Able to avoid line unbalancing problems during planning stage 能夠在規(guī)劃階段就避免線不平衡的問(wèn)題 Able to identify and resolve line balancing problems before production start 能夠于開始生產(chǎn)之前就識(shí)別和解決生產(chǎn)線平衡問(wèn)題,3,Contents 內(nèi)容,1. Introduction 引言 2. Basic Pri

3、nciples 基本原理 3. Shop Floor Monitoring 車間監(jiān)控 4. Line Balance Improvement 生產(chǎn)線平衡的改善,4,1. Introduction 引言,5,Introduction 引言,Line balancing refer to allocate and adjust the work loading of work stations of production line so as to achieve the production output target with minimum human or machine resource

4、s. 生產(chǎn)線平衡是指分配和調(diào)整生產(chǎn)線每個(gè)工作站的工作負(fù)荷，以利用最低人力或機(jī)器資源實(shí)現(xiàn)產(chǎn)量目標(biāo)的。,What is line balancing ? 什么是生產(chǎn)線平衡,6,Before line balancing 生產(chǎn)線平衡以前,Introduction 引言,7,After line balancing 生產(chǎn)線平衡之后,Introduction 引言,8,Line balancing will lead to : 生產(chǎn)線平衡將導(dǎo)致 More effective utilization of labors 更有效地利用勞動(dòng)力 Reduce labor cost 降低勞動(dòng)力成本 Redu

5、ce work in progress 減少在制品 Increase speed of the production line 提高生產(chǎn)線的速度 Uncover inefficiency problems and initiate improvement 發(fā)現(xiàn)低效率的問(wèn)題，并啟動(dòng)改善,Introduction 引言,9,Possible Reasons of unbalanced line : 生產(chǎn)不平衡線的可能原因 Uneven operator workload assignment 工人工作量分配不均衡 Inaccurate operation breakdown and stan

6、dard time 不準(zhǔn)確的工序分拆和標(biāo)準(zhǔn)時(shí)間 (SMV) Bundling effect 捆扎效應(yīng) Learning effect for new style 新樣式的學(xué)習(xí)效應(yīng) New operator effect 新工人的影響 Interruptions due to machine breakdown, operator absence, cut piece shortage, rework, etc. 由于機(jī)器故障，操作員不在時(shí)，切出短缺，返工等等的干擾,Introduction 引言,10,Balance the operator workload assignment 平衡

7、工人工作量的分配,Basic Principles 基本原理,Operator Workload Chart 工人工作負(fù)荷表,11,Enable work sharing 實(shí)現(xiàn)工作分擔(dān) Moving operators 走動(dòng)的工人 Multiple skills training 多能工的培訓(xùn) Proper layout to facilitate moving operators 可促進(jìn)工人走動(dòng)的布局,,14,13,12,11,10,1,2,3,4,8,5,6,,,,,,,,,9,,,,,,,,,Materials 材料,Product 成品,,Basic Principles 基本原理,1

8、2,Limit the WIP level between workstations 限制工作站在制品的水平 Maximum WIP level 最高在制品水平 e.g. 1 bundle扎, 1 pieces件 , 5 pieces件 , etc. The goal is to realize one-piece flow 目標(biāo)是實(shí)現(xiàn)單件流 Work switching rules 工作更換規(guī)則 e.g. switch to another operation when more than 5 pcs before the next operator 例如, 當(dāng) “埋夾”前超過(guò)5件

9、, 轉(zhuǎn)換到“上介英”工作,Basic Principles 基本原理,13,Stabilize operator work 使工人工作穩(wěn)定化 Standardize operation 標(biāo)準(zhǔn)化作業(yè) e.g. workstation, work sequence, traveling path, etc. 例如, 工作站, 工作順序，走動(dòng)路線等 Assign dedicate operators, i.e. water spider, for irregular work 指派專門的工人,即水蜘蛛, 負(fù)責(zé)不規(guī)則的工作 i.e. avoid effect on regular work by

10、 interruptions, such as cut pieces shortage, rework, machine breakdown, etc. 避免正常工作受 ，如裁片短缺，再加工，機(jī)器故障等干擾的影響,Basic Principles 基本原理,14,Shop Floor Monitoring 車間監(jiān)控,15,How to see line imbalance 如何揭視生產(chǎn)線不平衡 ? High WIP level between workstations 工作站之間有大量在制品 Difference between Takt Time (TT) and actual

11、 cycle time 產(chǎn)距時(shí)間（ TT ）和實(shí)際周期時(shí)間之間的差異 Operator waiting 工人等待 Operator slowing down 工人放慢工作 Operator don’t move 工人沒(méi)有走動(dòng),Shop Floor Monitoring 車間監(jiān)控,16,Methods of Monitoring 監(jiān)控方法 Hourly production status report on shop floor 每小時(shí)車間生產(chǎn)狀況報(bào)告 Direct on-spot monitoring and observation 直接現(xiàn)場(chǎng)監(jiān)控和觀察 Identifying bottl

12、eneck workstation 確定瓶頸工作站 Check cycle times in comparison with TT 檢測(cè)周期以及與TT比較 Observe operator behavior and performance 觀察工人行為和表現(xiàn),Shop Floor Monitoring 車間監(jiān)控,17,Hourly Production Status Report,Shop Floor Monitoring 車間監(jiān)控,18,4. Line Balance Improvement 生產(chǎn)線平衡的改善,19,Line Balance Improvement 生產(chǎn)線平衡改善

13、,Check operator workload allocation and make adjustment 檢查工人的工作量分配，并予以調(diào)整 Identify bottleneck workstation and shorten its cycle time by 找出瓶頸工作站，并縮短其周期時(shí)間: Split task and shift sub-task to another workstation 分割工作和轉(zhuǎn)移到另一工作站 Move other operator to support 轉(zhuǎn)移工人支援其他工作站 Replace operator with higher skill

14、 level 更換具有較高的技術(shù)水平工人,20,Line Balance Improvement 生產(chǎn)線平衡改善,Add parallel workstations 增加并行工作站 Improve the efficiency of working method 提高工作方法的效率 e.g. Using principles of motion economy, using work aids, etc. 例如使用動(dòng)作經(jīng)濟(jì)原則，使用輔助工具等 3) Improve process flow and line layout 改進(jìn)工藝流程和線路布局,21,Line Balance Improvement 生產(chǎn)線平衡改善,22,Line balance Improvement 生產(chǎn)線平衡改善,23,END 完,