L公司电源适配器生产力改善研究

发布时间：2018-03-30 18:13

本文选题：电源适配器　切入点：生产力改善　出处：《吉林大学》2017年硕士论文

【摘要】：本文通过介绍国内外电源适配器的发展和L公司生产力的现状分析,运用精益生产理论中的八大浪费寻找公司内部存在的主要问题,结合工业工程常用的分析方法,以降本增效为核心,围绕产品设计、产品工艺和生产效率三个方面展开研究改善。在产品设计面主要包括植件率的改善、免剪脚免补焊和组装段简化组装三个方面。改善植件率通过导入先进技术的植件设备,更新旧有设备,提高立式插件的能力,同时也将异型插件机纳入范畴,减少手插件以节省插件作业员人工成本,提高整体的植件水平。在取消剪脚补焊工序时,透过产品结构电子性能的本质,追本溯源剪脚和补焊问题的产生,从源头抓设计和品质,以达到取消效果。组装段简化组装时结合前站取消T-Pin,直接将铝套两端做成可焊接材质,对线材简化成连接模式,下铝套和绝缘盒一体式设计,上铝套改为四爪卡扣,插座增加防呆功能以遵循简化工艺流程,保障生产品质。制程面包括生产动作浪费、生产线线平衡、生产线瓶颈工位动作研究与时间分析三大方面。制定合理的生产节拍,标准化生产单位数量,使生产稳定、有序;消除浪费动作,减少浪费时间,提升产能,减少人力;改善线平衡,重排作业动作,平衡工位,提升每小时产能;改善停线时间,减少因异常产生的停线时间,将治具、物料等影响因素备份,达到快速处理的目的。并且将所有改善标准化,写入作业指导书执行文件,将改善效果固定延续,长久有效。最终实现一个流的生产从推式生产成功过度到拉式生产。生产效率面包含寻找自动化课题的来源,自动化团队的建设,自动化方案的可行性评估,效益可行性评估、自动化进度管控和自动化标准化。自动化课题的来源从生产现状中的浪费和简化人工作业方面着手,在发现课题后,成立高素质能力的自动化团队,朝着节省人工,提高生产效率的主题,研发自动化方案、评估自动化方案的动作工时可行性和效益的可行性,再到自动化进度的管控和标准化。从发现问题到分析问题再到解决问题,环环相扣,一步步深入深入评估,最后至自动化的标准化以及DFA项目的编撰。在完成三大方面的改善后,再对改善后的成果与效果追踪。L公司1楼车间原S型线体已经改成直线型设计,在物料的运输、一个流生产、线平衡率和生产效率方面都比旧线体明显上了一个台阶,现场5S环境均达到了较高的水平。生产力指标达成年度设计的目标,100%达成改善效果。该线体人力从原来44.5人改善到25.7人,每小时人均产能从16.2提升到31.1,改善幅度高达92%。
[Abstract]:This paper introduces the development of power adapters at home and abroad and the analysis of the present situation of productivity in L Company, uses the eight waste in lean production theory to find out the main problems existing in the company, and combines the analysis methods commonly used in industrial engineering. Focusing on reducing cost and increasing efficiency, research and improvement is carried out around three aspects: product design, product process and production efficiency. Three aspects: no shearing foot, no repair and welding, and simple assembly. To improve the implant rate, to update the old equipment by introducing advanced technology, to improve the capability of the vertical plug-in, and to include the special-shaped plug-in machine in the field. Reduce the manual plug in order to save the labor cost of the plug-in operator, improve the overall level of the implant. When canceling the repair welding process of the shears, through the nature of the electronic properties of the product structure, trace back to the source of the shearing foot and repair welding problems, The design and quality should be emphasized from the source to achieve the cancellation effect. When the assembly section is simplified and assembled, T-Pinting is cancelled in combination with the front station, and the two ends of the aluminum sleeve are made into solderable materials directly, and the wire rod is simplified into the connection mode, and the integrated design of the lower aluminum sleeve and the insulating box is made. The aluminum sleeve is changed to four claw buckles, and the socket adds the function of preventing stay in order to follow the simplified process flow and ensure the production quality. The process surface includes the waste of production action, the balance of production line, Production line bottleneck position action research and time analysis three aspects: make reasonable production rhythm, standardize the number of production units, make production stable and orderly, eliminate wasted action, reduce waste time, improve production capacity, reduce manpower; Improve line balance, rearrange operation action, balance work station, increase production capacity per hour, improve line stoppage time, reduce stoppage time due to abnormal occurrence, back up influencing factors such as fixtures, materials, etc. To achieve the purpose of rapid processing. And all improvements standardized, written in the job instruction execution document, will improve the effect of a fixed continuation, Long effective. Finally realize a flow of production from push production success to pull production. Production efficiency bread contains looking for the source of automation topics, automation team building, feasibility evaluation of automation scheme, benefit feasibility evaluation, Automation schedule Control and Automation Standardization. The source of automation project is waste of production status quo and simplification of manual work. After discovering the project, set up a high quality and ability automation team to save labor. The theme of improving production efficiency, developing automation programs, evaluating feasibility and effectiveness of action hours of automation programs, and then controlling and standardizing automation progress. From problem detection to analysis to problem solving, Closely linked, step by step in-depth evaluation, and finally, automation standardization and the compilation of DFA projects. After completing three major improvements, Then tracking the improved results and results. The original S-shaped line body of the first floor workshop of L Company has been changed into a straight line design. It has obviously advanced a step higher than the old line body in terms of material transportation, one flow production, line balance rate and production efficiency. The field 5S environment has reached a higher level. The productivity target of the annual design has been achieved by 100%, and the line manpower has been improved from 44.5 people to 25.7 people, and the per capita productivity per hour has increased from 16.2 to 31.1.The improvement rate is as high as 92 percent.
【学位授予单位】：吉林大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TN86

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