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1、Line Status:Line Area:=12M*6.6M-8*1.5 =67.2mm2 2、MAIN LINE & SUB LAYOUT (original)MAIN LINE & SUB LAYOUT (original)12M6.6M8M1.5M第一页，共12页。3. WORK SAMPLING STATISTICS & H/C EVALUATION:3. WORK SAMPLING STATISTICS & H/C EVALUATION:第二页，共12页。4.4.Main Line & Sub Layout (improved)Main Line & Sub Layout (imp
2、roved)Line Status:Line Area:12M*4.5M =54mm12M4.5M第三页，共12页。5. PROCESS FLOW CHART 5. PROCESS FLOW CHART MainFrameBarrow,70m，40EA/time（16EA/BOX）AssemblyBarrow,5m，36EA/time（12EA/BOX）Left FrameAssemblyRight FrameACMGear TrainDuplex AssyBarrow,70m，160EA/time（80EA/BOX）Barrow,10m32EA/time（16EA/BOX）MainFrame
3、AssemblyLeft FrameAssemblyRight FrameACMGear TrainDuplex AssyChange第四页，共12页。6.6.6.BALANCE PRODUCTION LINE6.BALANCE PRODUCTION LINE Eliminate waiting, Neither make anybody too busy, Nor make anybody too free! Only a Fair Environment is able to found high work morale.第五页，共12页。7. DIFFERENCE7. DIFFERENC
4、E差异项目 Difference Item当前实际 Actual改善后 Improved比率 Ratio备注 Remark人员 Human Leader210.50 Now we dont need to transit five sub to main line.Repairer111.00 Mobile OP111.00 Direct OP37280.76 Total41310.76 设备/夹具 FixtureFixture18110.61 Rack200.00 Screw driver21200.95 Screw Supplier661.0 占用面积 Area67mm54mm0.80 L
5、ead Time ( hour )1.42 0.66 0.46 每小时人均产能 Capability PPH2.16 2.86 1.32 第六页，共12页。8-1. DETAIL OF KAIZEN(1) 8-1. DETAIL OF KAIZEN(1) Before ImprovingAfter ImprovingType of Waste Improving ActionTransportation: Ops need transit printer from conveyer belt to workstation. Use roller line, So Ops dont need t
6、o transit printer from conveyer belt to workstation. And every Op will almost reduce a little transportation.第七页，共12页。8-2. DETAIL OF KAIZEN(2) 8-2. DETAIL OF KAIZEN(2) Before ImprovingAfter ImprovingType of Waste Improve ActionMotion: Materials isnt appropriate level of reachPut screw driver on mate
7、rial bracket ,So the distance from screw driver to screw hole is much shorter then before. In line there are many station like this.第八页，共12页。8-3. DETAIL OF KAIZEN(3) 8-3. DETAIL OF KAIZEN(3) Before ImprovingAfter ImprovingType of Waste Improve ActionOver-processing, Transportation , Inventory, Over
8、production, Defect: Pool layout make almost these five types waste in old line.Redesign new “JIT” layout ,Reduce Batch Size to “one piece flow”. (please refer 4.Main Line & Sub 4.Main Line & Sub Layout (improved)Layout (improved)第九页，共12页。8-4. DETAIL OF KAIZEN(4) 8-4. DETAIL OF KAIZEN(4) Before Impro
9、vingAfter ImprovingType of Waste Improve ActionMotion: Switch used with foot press, Op would keep one leg standing, that made them tired.Put switch on collet，Op can press the switch in the same time when move to the relevant position.Switch used with footSwitch used with finger第十页，共12页。8-5. 8-5. OTH
10、ER OTHER KAIZENKAIZEN (1)Before ImprovingAfter ImprovingType of Waste Improve ActionMotion/Cost: The part put one side(A side)to opposite side(B side) from A fixture to B fixture.Improve a little A fixture ,Then the part can be put on one fixture, whenever A side or B side. Total Seven fixture elimi
11、nate in new line.B sideSwitch used with fingerA sideA sideB side第十一页，共12页。8-6. OTHER KAIZEN (2)8-6. OTHER KAIZEN (2)Before ImprovingAfter ImprovingType of Waste Improve ActionCost :The metal claw is expensive (142RMB/set),and they are easy to damaged, We need to replace them termly .Replace The metal claw with rubber claw. That not only can use long time ,but also cost nothing, The rubber ring comes from PC Case Assembly Department.Metal clawRubber claw第十二页，共12页。
