SixSigma项目提高装配计划内完成率课件.pptx

滨特特尔 1MAICDDefine滨特特尔 2PCPPCP生产部装配车间生产部装配车间手动阀组在清洗、备料、装配、试压、油漆和报缴等各工序间有较多的异常因素，导手动阀组在清洗、备料、装配、试压、油漆和报缴等各工序间有较多的异常因素，导致每日计划内致每日计划内完成率较为完成率较为低下以以33月份月份为例为例，手动阀组当月，手动阀组当月日平均日平均计划内完成率计划内完成率仅为仅为 50.48%50.48%50.48%50.48%，对产品交，对产品交货周期及工厂运营都有不利影响因此，有必要成立项目，提升手动阀组每日计划内完成率货周期及工厂运营都有不利影响因此，有必要成立项目，提升手动阀组每日计划内完成率MAICD日期本日计划完成当量计划内实际完成当量和计划内完成率日期本日计划完成当量计划内实际完成当量和计划内完成率3-5128.48111.4199.21%3-20135.5442.3046.44%3-6177.28125.5571.22%3-21112.7514.1312.53%3-7124.9673.2359.08%3-22169.27119.4370.56%3-8106.35106.35100.00%3-231822.1981.054.46%3-1240.2812.9932.25%3-261822.1997.485.36%3-1368.6243.4963.38%3-271339.30172.3615.67%3-14437.30162.9537.26%3-281522.36275.0321.38%3-15562.01371.6066.12%3-291513.56359.5426.46%3-16439.94439.94100.00%3-301351.91211.5827.82%3-19245.20245.21100.00%Problem Statement滨特特尔 Y Y：每天计划内完成率：每天计划内完成率Y DefinitionY DefinitionY=Y=计划内实际完成当量（计划完成当量-缺料当量）备注：计划内实际完成当量=报缴入库当量+待检验当量+待报缴当量+待油漆当量Including valve assembly,Including valve assembly,testing,and nameplate testing,and nameplate marking marking,excluding lapping.excluding lapping.Project ScopeProject ScopeBaseline50.48%Target70%MAICDBig Y滨特特尔 Dept.MembersResponsibilityMBB:Bao DanielData collectionLeader:Wang XingLiangProductionLi XiuJunBao JianXiongWu JianAdjust assembly line FrequencyEvery DayChampion:Liu JianProductionYuan JunCommunicationWhen we needYuan BoMRPEvery DayPlanning arrangementMAICDTeam Members滨特特尔 DefineDefineDefineDefineMeasureMeasureMeasureMeasureAnalyzeAnalyzeAnalyzeAnalyzeImproveImproveImproveImproveControlControlControlControlMonthMonth May June July August SeptemberMay June July August SeptemberPlanned Project ScheduleMAICD滨特特尔 MeasureDMAIC滨特特尔 清洗機清洗機棧板組棧板組裝台裝台組裝桌待上線區金屬鋼球金屬鋼球研磨區研磨區待組裝區待測試區待測試區待測試區棧板棧板位置位置棧板棧板位置位置棧板棧板位置位置棧板棧板位置位置鎖鎖固固機機組裝桌組裝桌組裝桌組裝桌測單邊測單邊組裝桌組裝桌組裝桌組裝桌鎖鎖固固機機鎖固鎖固機機鎖固鎖固機機棧板棧板位置位置棧板棧板位置位置待組裝區待組裝區棧板棧板2 2#试试压压机机1 1#试压试压机机3 3#试试压压机机4 4#试试压压机机5 5#试试压压机机6 6#试压试压机机内内件件标标件件摆摆放区放区阀阀体体左体左体摆摆放区放区WashingAssemblyTESTINGMarkingDMAIC滨特特尔 SupplierInputProcessOutputCustomerWashingTestingAssemblyMarkingPaintingOperatorsMaterialsTestingmachinesMRPDeliveryQualifiedFGCompletionratewithintheplanFGwarehouseWarehouseFixturesWashingmachinesAssemblyplansSIPOCDMAIC滨特特尔 Fromthechartabovewecanseethattheprocessisstable.Process stability analysisDMAIC滨特特尔 DatasnormalCpkisonly-0.66,processisfarlessofcapability.Process capability analysisDMAIC滨特特尔 AnalyzeMADIC滨特特尔 ConvenienceoffetchingtoolsHeightofwashingmachineComponentsqualityErgonomicofassemblydesks*Components matching rateDistanceofcraneneedtomoveTestingefficiencyCraneusagefrequencyJobidentity*reasonableness of assembly line layout*Reasonableness of planningOperatorcapabilityLow completion rateMethodEnvironmentMaterialManMachine*Too much WIP*rework ratePotential key factors:Potential key factors:X1:Reasonableness of planning X2:Reasonableness of assembly line layout X1:Reasonableness of planning X2:Reasonableness of assembly line layout X3:Components matching rate X4:Reasonableness of operators arrangementX3:Components matching rate X4:Reasonableness of operators arrangementX5:Rework rateX5:Rework rate X6X6：WIP rateWIP rate*Reasonableness of operators arrangementFishboneMADIC滨特特尔 XsX3:PartsmatchingrateX4:OperatorsarrangementX5:ReworkrateX6:WIPrateContinuousAttributeContinuousContinuousYsCompletionrateRegressionANOVARegressionRegressionContinuousForX1&X2,theresnodataforanalysis,sowehadabrainstormtoapplyQUICKWINandthenfollowtheeffect.Analysis plansMADIC滨特特尔 MRP made monthly and weekly plans according to SO delivery time.Production would check with MRP about the completion situation.Every weekend for weekly completion and every month end for monthly completion.MRP made monthly,weekly as well as daily plans according to SO delivery time.Production will feedback the completion situation to MRP every noon,to forecast the completion,and to review with MRP the completion every day at 16:00.Same as before,production would check with MRP about the completion situation.Every weekend for weekly completion and every month end for monthly completion.BeforeAfterQuick win for X1MADIC滨特特尔 Fromthechartabovewecanseethatreasonableplancaneffectivelyimprovethedailycompletionrate.Effect verification for X1 quick winMADIC滨特特尔 清洗机清洗机内内件件标标件件摆摆放区放区阀阀体体左体左体摆摆放区放区2 2#试试压压机机1 1#试压试压机机3 3#试试压压机机4 4#试试压压机机5 5#试试压压机机6 6#试压试压机机装配桌装配桌栈栈板板位置位置锁锁固台固台栈栈板板位置位置锁锁固固机机装配桌装配桌装配桌装配桌鎖鎖固固機機装配桌装配桌装配桌装配桌栈栈板板位置位置栈栈板板位置位置栈栈板板位置位置測單邊測單邊栈栈板板位置位置栈栈板板位置位置金屬鋼金屬鋼球球研磨研磨區區Quick win for X2-BeforeMADIC滨特特尔 清洗機清洗機棧板棧板組裝組裝台台組裝桌待上線區金屬鋼球金屬鋼球研磨區研磨區待組裝區待測試區待測試區待測試區棧板棧板位置位置棧板棧板位置位置棧板棧板位置位置棧板棧板位置位置鎖鎖固固機機組裝桌組裝桌組裝桌組裝桌測單邊測單邊組裝桌組裝桌組裝桌組裝桌鎖鎖固固機機鎖固鎖固機機鎖固鎖固機機棧板棧板位置位置棧板棧板位置位置待組裝區待組裝區棧板棧板2 2#试试压压机机1 1#试压试压机机3 3#试试压压机机4 4#试试压压机机5 5#试试压压机机6 6#试压试压机机内内件件标标件件摆摆放区放区阀阀体体左体左体摆摆放区放区Quick win for X2-ImprovingMADIC滨特特尔 清洗机清洗机零件区零件区铸铸件区件区2 2号号机机1 1号号机机3 3号号机机4 4号号机机组组装桌装桌（2及以下金属密及以下金属密封、无油、高温）封、无油、高温）金属球金属球研磨研磨区区栈栈板板栈栈板板栈栈板板栈栈板板5 5号号机机测单边测单边6 6号号机机锁锁固固机机栈栈板板栈栈板板栈栈板板栈栈板板栈栈板板组装桌（1/2-2软密封）组装台（8”以上装配区）返修返修桌桌（非无油）（非无油）中中转小小车停放区停放区组装桌（1/2-2软密封）栈栈板板栈栈板板返修返修桌桌（无油，待采（无油，待采购）超音波超音波清洗清洗机机R700锁。