production)
通过以上改善及後续将要描述的其它有效改善活动，我们得到了一个十分明显的产量提升比较值，诚如丰田改善专家大野耐一先生所言，‘改善的目标祗只有一个,路却有许多条’。(表1为季度比较产量统计表)
Through the improvement of above and following will be described effective activities of improvements, we have a very significant yield increase compared to the last quarter. (Table 1-quarter comparison output tables)
表1:季度产量统计表(Table 1: Seasons output report) July七月 Aug八月 Sep九月
10’11季
476,008
500,412
810,230
09’10季
332,734
384,650
651,941
1.3 Packing包
10’11’季的改善方向定义为在人员数量不增加的情况下，产能提升15%。为此，包装部在流程改善，推行自动化，工种混合使用方面做了相应的改善行动。
孙子云：‘水无常形，因地而制流’。於流程改善方面，包装部主要是因应客人的查货要求，客供物资的供应状态及包装类型设立包装集中作业，在线包装作业两种生产模式。减少客观原因造成的产能损失，发挥生产调配作用， 使包装产能最大化。
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在包装作业中，套胶袋作业及封胶袋作业占用了平均1/3的生产作业时间，而此作业时间通过IE技术之动作研究及自动设备之选用是可以得到缩减的。为此，我们设计了套胶袋支架用于套胶袋作业，使工人双手同时动作，减少调整时间。此支架之使用使套胶袋作业时间平均减少达1/4以上。(图3为套胶袋作业支架使用效果图)
10’11’ quarter improvement direction of packing is defined as increase 15% productivity with same manpower as 09’10’. Hence, carry out improve action in process improvement, automation and operator’s multiple job arrangement. The packaging Department was mainly to guests ' requirements, material delivery status and packing method to decide adoption of online packaging or centralize packing which helps us reduce production capacity losses, make packing capacity optimization.
In packaging operations, the job of set plastic bags and sealed plastic bag takes up 1/3 of the average pacing time, this time can be reduced throughout IE maneuver study and adoption of automatic device. We have designed a set of plastic bags bracket which is used to simplify operation of set plastic bags, the workers two hands movement replace single hand movement. This bracket helps to reduce setup time of wrapping and make cycle time reduced ? in averages. (Figure 3 shows bracket used in plastic bags wrap)
图3:套胶袋作业支架使用对比效果图 (Figure: Hang packing)
人手撕胶带封胶袋口是一项比较繁琐的作业，并且它是一项无附加价值之作业，为此，我们与采购部合作，开发了自动剪切胶带设备，此设备使人手撕胶带这一无价值作业被完全取消。(图4为自动剪切胶带设备，此设备可以将封胶袋所用的胶带自动剪切备用)
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Hands tear tape and sealing plastic bag is a cumbersome job, it’s also a kind of none added ononononvalues’ job. For this reason, we cooperate with purchasing department for developed an automatic adhesive tape cutter, this device helps us completely cancelled worthless job of manual tear tape. (Figure 4 shows the device)
图4:自动剪切胶带设备 (Figure 4:Tape auto-cutter)
1.4 Training培训学校
为使产能得到提升，员工操作技能之培训强化必不可少。为提高培训效率，多出人才，快出人才，我们将培训分为三个层次。
对於全生手，培训课程由最基本的脚踏手推开始，逐渐提高难度，使生手於4-6周的较短时间内掌握基本车缝技术。此培训分部位于印花部二楼。
由SG工厂IE拍摄教学短片，於车缝学校反复放映，培育新员工之行业兴趣，推行最佳动作方案，强化标准作业。(图5为IE车缝教学短片放映现场效果图)
To improve productivity, employee skills strengthen by effective training is essential. We divided training course into three levels for the purpose of raise efficiency of training, train more operators in fast pace.
For beginners, training lesson initiate from the most basic operations such as pedal stamp and hand push. Then increase degree gradually. We hope to make the beginner become qualified operators with relatively short period about 4-6 weeks. This training division is located in second floor of the printing mill.
We use teaching video which produced by SG IE department. The repeatedly show of videos helps cultivate new staff interesting about swimwear industry, implement optimized operations, strengthen standards operations. (Figure 5 shows site of operation video training)
图5: IE车缝教学短片放映现场效果图 (Figure 5: Training with IE video)
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对于半熟手，培训课程由泳衣车缝技术开始，通过实际生产作业，强化泳衣车缝技能。此培训分部位于B3、B4大楼。
对于熟手工人的培训主要是推行标准化作业，简化执手，提升效率。为此，IE部开发了车缝数据库系统，用于培训，强化，推行标准化作业。(图6为标准动作数据库电脑截图)
For half proficient, training courses initiate by swimwear sewing technology. Through actual production exercises, the half proficient strengthened skill of swimwear sewing. These training division are located in B3, B4 building.
For proficient workers, training course mainly concentrated by standardized work implement, simplifying the job of handle carrying, enhance efficiency. To this end, IE Department developed a sewing data bank for training, strengthen, and implement standardized operations. (Figure 6 a glance of PC system of sewing data bank)
图6:标准动作数据库电脑截图(Figure 6: Data bank of SOP)
通过对现有车缝员工的培训强化，我们的目标是使效率90%以上的A级员及效率80-90%的B级员工的总比例达到60%，比上季度的54%增加11%。会三种车缝工序以上的全能工比例由上季度的10%增加至15%。
Through the intensive training for existing sewing operators, our goal is to make A-level operators whose efficiency over 90% plus B-level operations whose efficiency in 80-90% achieve 60% in total number of sewing operators, which increase 11% compare with last quarter of 54%. The Utility operators who conduct more than 3 operations increase in ratio from 10% to 15%.
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２． Efficiency improvement效率改善
2.1 IE工业工程部
IE部的效率提升计划主要集中在标准动作的设定、推广及运用上。而车缝数据库的建立使得这些改善要素得以实现系统化。如此同时，新设备、新装置的开发使用使得生产效能得到直接提升(如自动胶带剪切设备)或使产质量量得到保证(如胶浆模拟缩水机的设计运用)。(图7为IE标准动作视像研究现场)
IE Department efficiency enhancement program mainly focused on the standard operations setting, promotion and application. And sewing operation data bank allows these elements to be systematized and improvement in practices. At the same time new equipment, new device development and adoption make production efficiency be promoted directly (such as automated tape cutter) or help in production quality assurance (e.g. rubber printing shrinkage tester). (Figure 7 shows video analyze of sewing operations)
图7:IE标准动作研究 (Figure 7: Motion study)
IE部之其它改善项目见附录一。
Appendix 1 listed some examples of IE improvement items.
2.2 PPC生产计划部
生产计划部的效率改善活动主要体现於对整个部门的架构重组方面。由於本厂物资依期率长期处于较低水平且长期得不到改善，使得生产计划部门疲于计划更正及物资追踪。为此，PMC小组之设立实乃所需。此PMC小组之工作职责为确保各项生产物资依计划交付生产部门，当物资交期发生改变时，会同PC组及时调整生产计划。实践证明此种做法极大地减少了因物料延迟交付而造成的产能流失。
The efficiency improvement activities of Production Planning Department primarily embodied in department organization re-organize. Because the material on time delivery rate keep in consistently lower levels and to improve the long term, which causing production planning departments struggle to plan revise and material tracking. To this end, establishment of PMC team is necessary. The responsibility of PMC team is to ensure material delivered according to the plan of PPC and, when material delivery changes, take action in conjunction with PC group, give production promptly adjustment.
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2.3 GEM装备部 |
发表于 2012-2-22 12:07:24
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