非標自動化設備的使用更加助于企業推行精益生產
發布時間：
2023-02-10 11:26
精益生產方式的改革對于企業有著至關重要的意義，精益生產管理思想就是圍繞減少浪費，提高效能來進行生產組織的一種現代化生產管理思想。非標自動化設備就是結合不同行業不同產品其非標特性加以分析制定出切實可行的辦法。
The reform of lean production mode is of great significance to enterprises. The idea of lean production management is a kind of modern production management thought which focuses on reducing waste and improving efficiency. Non standard automation equipment is to combine the non-standard characteristics of different products in different industries to analyze and formulate practical methods.
大多數情況下一個公司產品雖然結構形式和尺寸規格千變萬化，但作業工序相對比較標準。實際上單件流水式加工就是作業工序的流水化，仍然符合基本的流水作業思想，所以大多數產品可以通過非標產品的標準化作業來實現單件流水式加工生產。
In most cases, although the structure and size of a company's products are changeable, the operation process is relatively standard. In fact, single piece flow process is the flow process of operation, which is still in line with the basic flow process idea. Therefore, most products can realize single piece flow processing through the standardization of non-standard products.
如何實現單件流水式加工生產是非標自動化設備完成的首要目的。
How to realize single piece flow processing production is the primary purpose of non-standard automation equipment.
1、非標特性分析
Non standard characteristic analysis
在實施之前應該將公司產品按產品的屬性和使用范圍進行分類，實際上是進行一類產品的標準化設計（不可能讓冰箱和汽車在一條生產線上完成）。
Before implementation, the company's products should be classified according to the product properties and scope of use. In fact, it is a standardized design of a class of products (it is impossible to make refrigerators and cars in one production line).
設計師在進行非標產品設計時大多依據企業已有的標準化產品作為原型加以改進設計。故作為設計原型的標準產品是進行非標產品的非標特性分析的基礎。
When designers design non-standard products, most of them use the standardized products as prototypes to improve the design. Therefore, the standard product as a design prototype is the basis for the analysis of non-standard characteristics of non-standard products.
工藝人員必須認真對產品進行工藝研究和分析，特別關注非標部分的工藝設計，必須切實考慮現有生產線的設備、工裝、工具，甚至是工位器具以及作業空間，盡可能的在現有工藝水平下完成非標產品的工藝設計。
Technical personnel must seriously study and analyze the process of products, pay special attention to the process design of non-standard parts, and must consider the existing production line equipment, tooling, tools, and even the working space, and complete the process design of non-standard products as far as possible under the existing process level.
同時，如果在進行工藝分析過程中發現設計結構不利于在現有條件下的生產有必要和設計師進行工藝溝通，在不改變客戶需求的條件下統一到現有的生產制造平臺上來。
At the same time, if it is found that the design structure is not conducive to the production under the existing conditions in the process analysis, it is necessary to communicate with the designer on the existing production and manufacturing platform without changing the customer requirements.
最后工藝人員必須在工藝分析卡上對特殊的工藝處理進行明確說明。
Finally, the process personnel must clearly explain the special process treatment on the process analysis card.
2. 非標產品的標準化工序設計
Standard chemical process design of non-standard products
工藝分析的基礎上完成工序設計，為了有清晰的制作主線，新的工藝路線必須建立在原有的標準產品的生產工藝路線基礎上。
In order to have a clear production main line, the new process route must be established on the basis of the original standard product production process route.
在工序設計上采用主干線加支線的辦法，標準作業工序作為主干線，非標部分以支線的方式與主干線搭接，這樣我們只要設計好了非標部分的工序節奏就能以原有標準作業的方式組織好生產，使得整個的生產規劃和生產控制變得簡單，而且減少了非標定制產品制作過程中的不確定性。
In the process design, the method of trunk line plus branch line is adopted. The standard operation process is taken as the main line, and the non-standard part is overlapped with the main line in the way of branch line. So long as we design the process rhythm of non-standard part, we can organize the production in the original standard operation way, make the whole production planning and production control simple, and reduce the production of non-standard customized products Uncertainty in the process.
3. 事先進行非標作業規劃
Planning non-standard operation in advance
包括作業過程中的物流規劃，確保非標作業動作的標準化。進行場地規劃，將各個工序所需要的材料就近放置便于生產作業人員不離線就近取材保證持續生產，減少領料的時間浪費。
Including the logistics planning in the operation process to ensure the standardization of non-standard operation. Site planning is carried out to place the materials required by each process nearby, so that the production personnel can obtain materials nearby without off-line, so as to ensure continuous production and reduce the waste of picking time.
在工序轉運間設置可移動工裝以減少搬運浪費，等等。
Set up movable tooling in process transfer room to reduce handling waste, etc.
對各種標準作業動作進行規范，制定規范表形成作業標準。
Standardize all kinds of standard operation actions, formulate the standard table and form the operation standard.
4.用科學方法對標準作業動作進行工時測算和動作分析
Using scientific method to measure and analyze the working hours of standard operation
在標準作業的基礎上為了避免因為產品非標性帶來的效率低下，仍然需要對實際工作進行監控，通過過程監控發現一些不必要的浪費活動予以糾正。
On the basis of standard operation, in order to avoid the inefficiency caused by non-standard products, it is still necessary to monitor the actual work and correct some unnecessary waste activities through process monitoring.
同時參照原來的標準作業工序用“非標系數”予以調節，這樣確保了非標作業產品的作業工時的上限得到限制，也有利于生產計劃的安排和多品種作業調度。
At the same time, referring to the original standard operation process, the "non-standard coefficient" is used to adjust, so as to ensure that the upper limit of working hours of non-standard operation products is limited, and it is also conducive to the arrangement of production plan and multi variety operation scheduling.
通過科學的工時測定來平衡生產線的產能和混流產品的范圍（以確保最佳的經濟性）。
Balance the production line capacity and the range of mixed model products through scientific man hour measurement (to ensure the best economy).
在實際生產管理中采用攝像監測的辦法是必要的，通過攝像監測來觀察員工的整個作業過程，通過對攝像過程的分析來找出值得改善的地方（包括工裝的完善，物料的存放位置等）。
In the actual production management, it is necessary to use camera monitoring to observe the whole operation process of employees. Through the analysis of the camera process, it is necessary to find out the places worthy of improvement (including the improvement of tooling, the storage position of materials, etc.).
5.運用統計工具制作滿足寬使用范圍（滿足80%）的標準工裝，以提高速度和質量
Use statistical tools to make standard tooling with wide application range (80%) to improve speed and quality
結合產品的不同特點，在前面工藝分析，工序布置和動作研究的基礎上，可以研究制作適合大多數產品的作業工裝。
Combined with the different characteristics of the products, based on the previous process analysis, process layout and action research, we can research and manufacture the operation tooling suitable for most products.
這樣可以將一些看似非標的產品用標準化的方法來完成生產（比如，相對于標準產品僅是尺寸發生變化等）自然提高了質量保證能力，同時降低了生產準備時間提高了作業效率。
In this way, some seemingly non-standard products can be produced in a standardized way (for example, only the size changes compared with the standard products), which naturally improves the quality assurance ability, reduces the production preparation time and improves the operation efficiency.
6.質量監控點的設置
Setting of quality monitoring points
為了實現一個流的生產，質量檢測就必須作為生產的一道工序納入生產線規劃中，設置檢驗工序確保產品質量。同時強化“質量是制造出來的不是檢驗出來的”意識，加強工序自檢和互檢。
In order to achieve a flow of production, quality inspection must be included in the production line planning as a production process, and inspection procedures should be set to ensure product quality. At the same time, we should strengthen the awareness of "quality is produced by manufacturing, not by inspection", and strengthen self inspection and mutual inspection of working procedures.
為了滿足盡量寬泛的產品進行混流生產，切實推行看板管理，各種產品用看板進行身份標示，各工序按看板要求進行組織生產。
In order to meet the mixed model production of products as wide as possible and implement Kanban management practically, various products are identified by Kanban, and each process is organized according to Kanban requirements.
7.軟環境的建設
Construction of soft environment
必須配套建立起各種軟性的制度。生產線物料補給制度、停線制度、代崗制度等等，并切實加以執行。
All kinds of soft systems must be set up. Production line material supply system, stop line system, on behalf of the post system and so on, and effectively implement.
非標自動化設備