基于价值流图的注塑车间精益改善研究

应用价值流图分析L公司注塑车间产品不良率高、换型时间长、现场管理混乱和注塑加工时间长等问题。应用潜在失效模式与后果分析、快速换型、10S管理、ECRS原则和人机作业分析等技术对产品质量、换型时间、生产现场和注塑加工进行精益改善。Valeo连接器交货周期由22 d缩短至8.35 d,平衡率由35.7%提高至50.2%,不良品率由10%降至2%,换型时间由81.5 min缩减至45 min,注塑加工时间由28.5 s缩短至13 s,提高注塑机OEE 15.5%,现场秩序得到改善。

The problems of high defect rate,long changing time,disordered management and long processing time in injection molding workshop of L company were analyzed with value stream mapping(VSM).This paper applies potential failure mode and effects analysis(FMEA),single minute exchange of die(SMED),10S management,ECRS principle and man-machine joint operation analysis to make lean improvement(kaizen)to product quality,mold change time,production site and injection molding process.The delivery cycle of Valeo connector is shortened from 22 days to 8.35 days,the balance rate is increased from 35.7%to 50.2%,the reject rate is reduced from 10%to 2%,the mold change time is reduced from 81.5 min to 45 min,the injection molding processing time is reduced from 28.5 s to 13 s,the injection molding machine OEE 15.5%is improved,and the field order is improved.