Guidance: The goal of lean layout is to minimize waste and overload in the work flow while enhancing visual communication on site. The traditional layout structure does not take into account the closeness of the process route in the manufacturing process and the flow requirements in the production organization process, which seriously restricts the operation of the company’s lean logistics and the establishment of the lean manufacturing model, and brings about the management of the production and manufacturing site of the enterprise. The great difficulty, the chaotic scene, the huge consumption of logistics resources, and the disorderly and unconstrained venues seriously hampered the realization of “one-piece flow” and the entire manufacturing cycle could not be effectively improved due to the traditional layout structure. prototype parts manufacturing
1, what is the lean factory layout:
The lean layout is based on the status quo layout. By eliminating the wastage of people, machines, materials, methods, and rings, the layout of the best combination of the five is achieved, and a systematic method for the effective management of the production system is established.
2, the purpose of lean layout planning:
1, reduce the production cycle time, quickly respond to customers
2, reduce inventory, eliminate handling, effectively reduce waste
3, improve the overall output capacity of equipment
4, improve space utilization
5, reduce the amount of work
6, improve the operating environment
3. Problems in the layout of the enterprise factory without lean layout:
1) Serious waste
According to incomplete statistics, more than 90% of companies consider the lack of expected development strategy and capacity planning during the construction of a new factory, consideration of overall logistics planning, equipment commissioning and installation, turnaround volume, production line layout, and process design. Imperfect, what to put. Because of the unreasonable design, the new plant has a long production distance, insufficient equipment or low utilization rate, and unbalanced processes, etc. after it is put into operation. The company will produce this kind of consumption year after year and day after day. Chronic losses are more alarming than any of the eight major wastes. prototype parts manufacturing
2) The new factory does not have a new look
In the new factory, the designers only paid attention to whether the performance meets the requirements and did not consider and care about the matching and matching of the equipment environment. After the completion, the designers were dark and gloomy and lifeless. The employees did not say that they were full of vigor and vitality, and they were simply suffering from depression. Some factories prefer blue, corporate LOGO is blue, equipment is blue, shelves and tool cabinets are blue, it’s hard to brush a channel, because only the blue paint, also brush into blue! The entire company is in a blue ash, so cold and clear, how can there be a warm and clear atmosphere?
3, old factory copy, no competitive advantage
Many new factories are merely replicas of old factories. They have not considered some unreasonable old plants, and they have adopted new technologies or new equipment to solve problems. Efficiency and efficiency have not improved. prototype parts manufacturing
4. Advantages of lean factory layout planning:
1) Strong adaptability to the transformation of product varieties;
2) As the same kind of equipment is centralized, it is convenient to make full use of production equipment and production area;
3) Reduce the number of repetitive equipment purchases, with lower equipment and maintenance costs;
4) Production will not be interrupted when equipment failures, materials or personnel are insufficient;
5) Facilitate process management, which is conducive to the improvement of employees’ technical level;
6) The processing route of the product can be shortened, saving time and manpower for sending and receiving;
7) It can reduce the in-transit and parking time of products, shorten the production cycle, and reduce the use of work-in-process and liquidity.
5, Steps to carry out factory layout planning
1) Grasping the basic situation: Understand the basic situation of the company’s development and the industry market forecast analysis.
2) Interpretation of corporate culture: Interpretation of corporate culture, access to corporate visual identity documents and other documents.
3) Value Stream Analysis: Performs a factory value stream analysis (information flow, logistics, and process flow).
4) Draw the process resource relationship matrix: identify process and resource matching key points and focus on control.
5) Capacity Planning: Understand the need for production capacity and customer demand, balance equipment and personnel capabilities.
6) Determine the main layout plan.
7) Planning and Design Description: Provide and layout planning and design of the total map, equipment statistics, area, staffing, fixtures and other information, and make an explanation.
8) Simulation and improvement: The use of three-dimensional software or models, sandboxes for logistics, handling tests, and constantly improve the layout planning and design content.
9) Planning and implementation training: The new factory will be relocated, and training and instructions will be implemented according to the plan to ensure the implementation and implementation of the plan.
10) Follow-up after relocation: After the new plant has been successfully put into production, follow-up and return visits are made to the plan to understand imperfections and suggestions for improvement are proposed. prototype parts manufacturing
6, how to system layout design program mode
P (product or material or service)
Refers to the planned production of goods, raw materials, processed parts and finished products or services provided by the project.
Q (Quantity or Output)
Refers to the amount of goods or services that are produced, supplied or used.
The analysis of product output needs to combine the long-term goals of the company’s strategic development and formulate a plant area plan that meets the company’s development goals.
R (production route or process)
This element is the result of the process design and can be represented by equipment tables, process route cards, process diagrams, etc.
S (Auxiliary Services Department)
Refers to public, auxiliary, service departments, including tools, maintenance, power, molds, changing rooms, lounges, canteens, toilets, etc., provided by relevant professionals.
T (time or schedule)
Means when and how long it takes to produce a product, including the operating time of each process and the number of batch changes.
7, logistics design
Whether it is the layout of a new factory or the relocation of an old factory, it is necessary to consider the logistics requirements for the layout. Therefore, it is particularly important to consider how to effectively design the logistics system during the layout process. The logistics system is composed of transportation, storage, loading and unloading handling, packaging, distribution processing, and logistics information. The benefits of logistics are not the result of simple addition of their benefits. They are mutual influence and mutual restraint, and they are part of the unified logistics system chain.
The logistics system refers to the logistics affairs and processes it undertakes as a whole in a certain period of time and space. It uses the systematic viewpoints, system engineering theories and methods for analysis and research to realize the economic benefits of space and time. . prototype parts manufacturing
8, material handling system analysis method (SHA)
Material analysis
When selecting a handling method, the most influential factor is usually the material that needs to be handled. Therefore, it is necessary to clarify the type of material, the main characteristics of the material, and the actual minimum unit or transport unit of the material.
2. Various movement analysis
When analyzing various movements, you need to master materials (material classification), routes (length, starting point and end point) and logistics (flow rate, logistics conditions) and other data.
3. There are two ways to analyze each move:
Ø Process analysis: This method only observes one type of product or material at a time and tracks it along the entire production process. When necessary, the entire process from the raw material warehouse to the finished product warehouse will be tracked and the process chart will be prepared.
Ø Start and end point analysis method: There are two different methods for this method. One is to collect data through observation of the starting point of each movement and analyze one route at a time. Another approach is to observe an area and collect the information. Export all relevant materials in this area and prepare material entry and exit lists. prototype parts manufacturing
4. Charting of various moves
Graphicalization is a method of data processing. It integrates the analysis results of the movements and the layout of the area, and uses some special symbols to make charts. It can clearly show the situation of the need to design a handling system. Therefore, the graphicalization of each move is an important step in the SHA program mode.
The logistics diagram and coordinate indicator drawn on the layout diagram are the two basic diagrams used by SHA to implement each movement.
5. The logistics diagram drawn on the layout
It is drawn on the actual floor plan. The exact location is marked on the map. Therefore, the distance and direction of each route can be shown, which can be used as the basis for selecting the handling method. prototype parts manufacturing