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SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部1/10部门：部品制造部班组：电泳机种：Φ4电泳铁芯SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部2/10一、生产线现状把握SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部3/10单品清洗1.工艺流程图单品烘干热处理喷砂清洗烘干OK品通孔中心孔进料品再生(剥离)组装搬运/吹气上挂电泳吹干烘干拆卸成品清洗烘干检查包装NG品SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部4/10喷砂/清洗/烘干成品清洗/烘干组装包装单品清洗烘干热处理电泳烘干吹气上挂成品检查通孔吹干拆卸2.作业平面图①SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部5/103.现状不良状况统计不良率10.44%9.98%10.01%9.70%9.80%9.90%10.00%10.10%10.20%10.30%10.40%10.50%7月份8月份9月份7月份8月份9月份7、8、9三个月的一次投入平均不良率为：10.14%不良项目产生原因异物1.空气中毛刺及灰尘2.链条运行产生的异物脱落拆卸碰撞及生产过程撞击堆积涂料老化电泳前三项不良SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部6/10电泳部品组人均工数00.020.040.060.080.1①②③④⑤⑥⑦人均工数00.020.040.060.080.1工数节拍工程名工位清洗/烘干/热处理喷砂/清洗/烘干组装搬运/吹气上挂电泳/吹气/烘干拆卸序号①②③④⑤⑥⑦作业工数0.0540.0812.9500.0230.1510.2230.220人员11371233人均工数0.05400.08100.07980.02300.07530.07440.07344.电泳部品组工位及工数电泳日出荷计划：750Kpcs/日，实际完成成品数平均：744Kpcs/日，因不良率平均为10%，因此部品组每日最低投入量：826K+40K(每月保养机器需停线一天需预存料866K÷22天=40K),故部品组每日生产量约为：870Kpcs/日。节拍:0.082S编成率：81.3%(S)SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部7/10电泳成品组人均工数00.020.040.060.080.1⑧⑨⑩⑾人均工数00.020.040.060.080.1工数节拍工程名工位清洗/烘干/搬运检查包装通孔序号⑧⑨⑩⑾作业工数0.0784.770.1670.328人员15224人均工数0.07800.0830.08400.08205.电泳成品组工位及工数节拍:0.086S编成率：97.3%(S)SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部8/106.电泳辅助岗位揭示及人员配布岗位揭示人员配布治具剥离早、夜班共4人弹簧更换治具制作早、夜班共4人压轴治具组装SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部9/10二、目标设定SHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部10/10项目现状目标人员(名)214208生产性(PCS/H.人)331340不良率(%)10.14%8.00%目标设定目标值●人员削减214名208名●每人每小时的生产性2.7%UPSHAJINGSANYOMICROMOTORFACTORYSHJ-部品制造部11/10电泳工数及各岗位人员配布作成：刘福军作成日：06/10/6序号工序名人数工数1工数2工数3工数4工数5平均工数人均工数清洗0.00850.00850.00850.00850.00850.0085烘干0.0110.0110.0110.0110.0110.011热处理0.0340.0340.0340.0340.0340.0342喷砂/清洗/烘干10.0810.0810.0810.0810.0810.0810.0813组装373.022.922.942.952.932.9520.07984搬运/吹气10.0230.0230.0230.0230.0230.0230.0235上挂20.1510.1480.1490.1530.1520.15060.0753电泳0.2030.2030.2030.2030.2030.203吹干/烘干0.020.020.020.020.020.027拆卸30.220.220.220.220.220.220.07348成品清洗/烘干10.0780.0780.0780.0780.0780.0780.0789检查527.564.13.984.074.124.7660.086710包装20.1670.1670.1670.1670.1670.1670.08311铰中心孔41.922.121.921.821.811.9180.0815合计10.4600.706612治具制作413治具剥离/弹簧更换4技术214管理1015大铁芯生产10合计110*2=21424430.07446产量/稼动时间：部品870K/21H（连续烘干炉、喷砂机24H运行）生产节拍：0.082S编程率：81%产量/稼动时间：成品750K/21H生产节拍：0.0862S编程率：95%电泳铁芯工数测定表（现状）110.0535