Team1加工單元（剪-沖-折-焊）加工線布局調(diào)整RedefineManufacture

cell(shear-punch-bend-spotweld)Product

LineBEINGTHEBESTATWHATWE

DOTeamNo.項目名稱 項目負責人Task

Name principal助手Assistant小組成員Members組1Team1鈑金加工線布局調(diào) 劉維整；斯海明王國榮、許華良、李曉軍、王國海、嚴紅建圍壁/（廳門）按一件流組織生產(chǎn)小組成員Team

MemberBEINGTHEBESTATWHATWE

DO改善區(qū)域

Improve

ZoneBEINGTHEBESTATWHATWE

DO1312141091167834512EDCBA點焊機SHS6*310剪扳機SHEAR改進前Before

change數(shù)控剪板機LVD-SHEARLVD

PPEB-5

320/40折彎機BRAKE

PRESSM5000

多工位沖床PUNCH

M5000C3000

激光沖床TP+LASERPHS110折彎機110t-PressPHS160折彎機160t-Press110t-Press等離子切割機液壓擺式剪板機SHEARQ12Y-16-3200PLASMAPHS110折彎機SHS6*310剪扳機SHEARRESISTANCESPOT

WELDING點焊機LVD激光切割機80t折彎機LVD80

PRESS135t折彎機LVD135PRESSLASERCUTTING

MACHINERESISTANCESPOT

WELDING改善區(qū)域

Improve

ZoneBEINGTHEBESTATWHATWE

DO目標：廳門、轎壁加工單元實行一件流BEINGTHEBESTATWHATWE

DOTarget:LandingDoor、CarPanelProcessImpleteOnepiece

flow機器名稱Machine

Name剪（1）沖（1）折（1）班次Shift2322機器名稱Machine

Name剪（2）沖（2）折（2）點焊（2）231班次Shift點焊（1）2設(shè)備-班次現(xiàn)狀theActualStatusof

Equipment-ShiftBEINGTHEBESTATWHATWE

DO目標：1.C3000&M5000沖工序由3班減為2班BEINGTHEBESTATWHATWE

DO2.縮短Cycle

Time行動ActionBEINGTHEBESTATWHATWE

DO修改及優(yōu)化數(shù)控加工程序—沖床減少機床加工作業(yè)時間結(jié)果：節(jié)約11s減少作業(yè)時間-M5000沖ReduceAutotime-M5000

PunchBeforeAfter-BettermenttheNC

programBEINGTHEBESTATWHATWE

DO減少作業(yè)時間-M5000沖

ReduceAutotime-M5000

Punch 改進實例：轎底板 XAA347XTBEINGTHEBESTATWHATWE

DO該產(chǎn)品的數(shù)量：140塊/天每天節(jié)約時間：140*11=1540s=25.6min改進前Before目標Target改進后After實際Actual節(jié)約Save77s-766s-11s11/77*100%=14.3%Kaizen

報告Kaizen

NewspaperBEINGTHEBESTATWHATWE

DO小組編號：01Team

Number:01 工作地名稱：加工單元Area:Manufacture

cell 今天

Today

2003/04/25今晚

Tonight明天

Tomorrow編號

待解決的問題Item Problemtobe

Resolved必要的措施Action

Needed負責人Responsibility完成日期 效果date Results1修改程序工藝人員協(xié)助參與許華良5月31日沖床C/T時間降10%2設(shè)備布局調(diào)整李曉軍5月8日減少工件移動距離79MRESISTANCESPOT

WELDINGLASERCUTTING

MACHINE135t折彎機LVD135

PRESS80t折彎機LVD80

PRESSLVD激光切割機點焊機RESISTANCESPOT

WELDINGPHS110折彎機PLASMA等離子切割機110t-PressSHS6*310剪扳機SHEAR液壓擺式剪板機SHEARQ12Y-16-3200160t-PressPHS160折彎機110t-PressPHS110折彎機C3000

激光沖床TP+LASERPUNCH

M5000M5000

多工位沖床LVD

PPEB-5

320/40折彎機BRAKE

PRESS數(shù)控剪板機LVD-SHEARSHS6*310剪扳機SHEAR點焊機5487611910141213PHS160折彎機160t-Press改善區(qū)域及流程--改后BEINGTHEBESTATWHATWE

DOTeam

2轎（廳）門裝配裝箱線再改進RechangeofCar(Landing)DoorAss’y&Packing

LineBEINGTHEBESTATWHATWE

DO小組成員

Team

MembersTeamNo.項目名稱Task

Name項目負責人principal助手Assistant小組成員Members組2Team2轎（廳）門裝配裝箱線再改進Rechangeof

Car(Landing)DoorAss’y&Packing

Line謝國華劉維丁璐珞、余利平、盛良生、徐為明BEINGTHEBESTATWHATWE

DO改善區(qū)域

Improve

ZoneBEINGTHEBESTATWHATWE

DO改進目標BEINGTHEBESTATWHATWE

DO項目現(xiàn)狀目標產(chǎn)量/天19臺/天23臺/天節(jié)拍時間23.6min19min循環(huán)時間30.5min19min改進后

After

ImprovementBEINGTHEBESTATWHATWE

DO結(jié)果:循環(huán)時間由30.5分降為26分,降低4.5分,即降低14.7%.項目改進前目標改進后產(chǎn)量/天15臺/天23臺/天19臺/天節(jié)拍時間30min19min23.6min循環(huán)時間30.5min<19min26minKaizen

報告Kaizen

NewspaperBEINGTHEBESTATWHATWE

DO小組編號：03Team

Number:01工作地名稱：裝箱單元今天

Today

2003/04/25今晚

Tonight明天

Tomorrow編號Item待解決的問題Problemtobe

Resolved必要的措施Action

Needed負責人Responsibility完成日期date效果Results1木箱板放置位置.工藝人員協(xié)助參與丁璐珞5月20日23臺/天2工具放置位置.丁璐珞5月8日23臺/天

TEAM3

電控單元（控制柜裝配）流程改進

ControllerAss’y

LineBEINGTHEBESTATWHATWE

DO電控車間控制柜裝配區(qū)布局圖BEINGTHEBESTATWHATWE

DO領(lǐng)導(dǎo)王順法助手陳翔組員周建友、王征、楊占強BEINGTHEBESTATWHATWE

DO作業(yè)者人數(shù)11人現(xiàn)在生產(chǎn)18臺/日改進目標30臺/日目標第三小組情況改善組成員現(xiàn)狀（Actuality

Layout）Ass’yConnectCableline

oneConnectCableline

twoROADBEINGTHEBESTATWHATWE

DOROADModelCycle

Time(min)Ass’yconnectStarcon86270Star75180Ministra75200Hy2175170BEINGTHEBESTATWHATWE

DO單位：分當前產(chǎn)品時間（Product

Cycle

time）1根據(jù)計劃分配產(chǎn)品。2改進控制柜裝配方式。BEINGTHEBESTATWHATWE

DO行動Action控制柜產(chǎn)品分配生產(chǎn)線改進BeforeStarcon=7Star=5Starcon=10AfterStar+Starcon=5+3=8BEINGTHEBESTATWHATWE

DOTheCycletimeofStarcon270

minTheCycletime

of

Star 180

minOneTwoWorkingtimeofoneline427.5minWorkingtimeofTwoline472.5

minEffect:DecreasetheWaitingtime20

min/day控制柜接線方式改進Improvethe Lineconnection

MethodBeforeBEINGTHEBESTATWHATWE

DOAfter控制柜上線時間表424548404545454510020304050601234beforeafterDecreasethecycletime

：180-175=5

minBEINGTHEBESTATWHATWE

DO時間監(jiān)測Time

observationFinalKaizen

PaperBEINGTHEBESTATWHATWE

DO編號Item解決的問題Problemtobe

Resolved必要的措施Action

Needed負責人Resp