基于整流化的生产线精益改善方法研究

Lean Improvement Method Research Based on Streamlining of Production Line

针对某数字相控阵雷达的核心部件数字阵列模块生产线存在的产能不足、物流路径混乱、生产线不平衡、操作人员疲劳强度高等问题,提出了基于整流化理论的精益改善方案。通过秒表测时、工序内作业拆分、生产线布局调整、瓶颈工序改善、节拍确定和全工序流动等方法实现了在减人缩时的情况下产能提升了50%、日增值工作时间比率从73.9%提高到87.9%。生产线平衡率由原来的55.8%提高到90.3%、在制品数量从76件降低到16件。并应用元单位量份配送方式进行生产线各工位的消耗物料补充,通过带有标签的空盒回收实现对线下准备区作业的看板拉动。

Production line for Digital Array Module（DAM）which is a key component of phased array radar cannot meet customer needs in quantity. Besides, problems of logistics route chaos, low line balancing ration and higher level of labor fatigue are seriously needed to solve. As a result, one improvement method based on streamlining for production line was proposed to work out the above problems. Finally, through the application of time measurement,iob decomposition within working procedure, adjustment of production line layout, improvement of bottleneck,Takt Time confirmation and whole procedure flow with less labor and time consumption, the throughput of DAM line is increased by 50 % and the value added time is improved form 73. 9 % to 87. 9%. The line balancing ratio is improved from 55.8% to 90. 3%. Besides, cell parts supply method for consuming materials and parts was applied to ensure the normally flow of the line. And the recycle of empty material cases were used as manufacturing Kanban to deliver production message to preparanon zone.