制造设备的精益设计课程(PDF 73页）

1. INTRODUCTION1
1.1. Purpose. 1
1.1.1. Relationship of Equipment Design and PDP .. 1
1.2. Review of System/Cell Design  3
1.2.1. Process Requirements . 4
1.2.2. System/Cell Design Goals. 4
1.3. Review of Manufacturing System Design (MSD) Methodology ..... 5
1.3.1. Determine Module Size..... 5
1.3.2. Calculate TAKT Time. 5
1.3.3. Construct a Block Diagram..... 5
1.3.4. Prepare a Machine Balance Chart . 5
1.3.5. Lay Out the System ..... 6
1.3.6. Prepare an Operator Balance Chart ..... 6
1.3.7. Determine Buffer Sizes, Lot Sizes and Lead Time..... 6
1.3.8. Determine Containerization and Packaging Requirements..... 6
1.3.9. Error-Proof the System 6
1.4. System Simulation and Mockup .. 7
2. EQUIPMENT DESIGN GUIDELINES ....9
2.1. Supports the Operator .... 10
2.1.1. Safety and Ergonomics.... 10
2.1.1.1. Proper Lockout Placement ... 10
2.1.1.2. Simple But Effective Guarding.. 10
2.1.1.3. Equipment Addresses All Ergonomic Issues ..... 11
2.1.2. Select Proper Cycle Initiation ..... 12
2.1.3. Reduce Machine Noise.... 13
2.1.4. Simple Part Presentation Devices ..... 13
2.1.5. Provide Necessary Visual or Audio Controls ..... 14
2.1.6. Workplace Organization . 15
2.1.7. Pacing Mechanism .... 15
2.1.8. Distance Between Machines . 15
2.2. Simplified . 17
2.2.1. Proper Use of Automation..... 17
2.2.1.1. Levels of Automation..... 18
2.2.1.2. Manual Loading . 19
2.2.1.3. Manual Unload vs. Auto-Eject... 19
2.2.2. Use “Off-the-Shelf” Machines .... 20
2.2.3. Right Size Electrical/Mechanical Components... 21
2.2.4. Minimize Use Of Conveyance .... 22
2.2.5. Eliminate Waste in Equipment.... 23
General Motors Corporation, Delphi Automotive Confidential iii
2.2.6. Minimize Machined Surfaces 24
2.2.7. Simplify Gaging .. 24
2.3. Supports One-Piece Flow 25
2.3.1. Narrow Effective Width Machines ... 25
2.3.2. Machine is Open on the Sides ..... 26
2.3.3. Avoid Large Batch Type Off-Line Equipment ... 26
2.3.4. Review Multiple Operation Equipment .. 27
2.3.5. Manual Backup ... 27
2.4. Portable and Flexible  28
2.4.1. Design Equipment to be Self Contained . 28
2.4.2. Provide for Flat floor Mounting .. 29
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