快速换型在SMT生产线的应用及改善研究_工业工程.rar

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摘要:由于当前多品种、小批量的生产特点,生产制造型企业在生产过程中需要频繁进行不同模具和工具的切换,造成机器因换型产生闲置,产能下降。换型过程不稳定,还会造成产品质量下降。因此,提高换型效率,稳定换型过程,可有效缩短停机时间,增加生产计划柔性,减少浪费,提高运行能力的同时还可以提高产品质量。

   本文在说明快速换型的重要性的基础之上,分析快速换型对实现精益生产的作用。以某公司SMT生产线为研究对象,通过导入SMED快速换型中心,起到辅助内外部作业的作用,保障换型过程流畅;实现换型过程标准化,包括流程标准化和动作标准化;推行TPM,保持良好的设备状态,为快速换型作保障;实行目视化管理,以5S、看板、按灯系统等手段,保证快速响应。最终,使得平均换型时间由8.42min降低到6.03min,大大提高了设备利用率。

   通过总结快速换型优化措施,得出结论:快速换型与精益生产之间是相互影响的,实现快速换型有利于精益生产的推广,精益生产的工具又为快速换型提供保障;快速换型是一项系统性工程,需要全体人员在管理和技术上的支持,以及持续性的改善。

关键词:快速换型;SMT;精益生产;生产力;工业工程

 

ABSTRACT:In the condition of multi variety and small batch market, manufacturing enterprises must switch moulds and tools frequently in production process, which cause machine down and capacity loss. The quality of product will deteriorate with unstable machine. Improve the efficiency of changeover can shorten down time and make production plan more flexible. That will reduce loss and improve KPI, even product quality.

   Based on the analysis of interrelation of Single Minute Exchange of Die and Lean production as well as the importance of SMED, this paper makes one company’s SMT lines as study object. By means of setting SMED center, which can support on line and off line work, make change over smoothly; standardizing changeover process, including changeover flow and behavior; carry over TPM, keep machine on good condition; push visual management, such as 5S, Andon, Kanban. Applying these solution lead change over time from 8.42min to 6.03min; reduce internal and external change over time simultaneity, greatly improved overall equipment effectiveness.

   Summary above improvement, we can make following conclusion: quick change over and lean production is influence each other, the former can accelerate the latter and the latter can support the former. Quick change over is a systemic engineering, which need management and technology support from all personnel.

Keywords: SMED; SMT; Lean production; productivity; Industrial Engineering

 

  本文主要采用调查法、观察法及案例研究法。通过在实施精益化比较成熟的B企业的实地调查,利用公司15条SMT生产线的换型次数统计结果,得出实现快速换型的必要性,结合目前企业在SMT生产线上所采取的快速换型措施,指出其中的可取之处,同时指出不足。

  在运用所学习的理论知识和国内外学者的研究成果的基础之上,分析快速换型的重要性,不仅可以节约产品切换时间,而且有利于减少在制品数量,便于均衡化的实现。总结分析快速换型与精益生产之间的关系,提出优化的换型措施,包括设立SMED换型中心;优化换型流程;注重换型过程中的5M1E;强调换型过程的目视化管理。并将以上措施在生产线上做尝试性的改进,分析比较结果,得出这些措施的可行性。最终得出结论,实现快速换型不仅有利于精益生产的实现,同时也需要与精益生产的其他工具相配合,是一项系统化工程。

 

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