First, the concept of synchronous beat production

Synchronous beat production means that each production line should be synchronized with the assembly dialogue. Each working procedure of each production line is not allowed to work alone, but to start at the same time. The latter procedure is not taken away, and the former procedure is not processed. The production line only keeps the necessary in-process reserves.

There is only one quantity of WIP flowing between adjacent processes in the production line, which is a more advanced form of synchronous beat production and is called "first-class" production. The production requirements of "one stream" must be strictly in accordance with the beat, implement process discipline and operate according to standard operating procedures; The semi-finished products flowing between processes shall not exceed the clamping quantity of the previous process.

Second, the main points of synchronous beat production mode

1, centering on people's work, arrange the homework combination within the specified takt time.

Through the calculation of the operation combination table, one person can operate multiple machines, saving people to complete the production operation to the maximum extent. Connecting U-shaped production line is a machine configuration method to meet the requirements of saving people. The important feature of U-shaped machine configuration is that the inlet and outlet of the production line are in the same position, and the operation of the inlet and outlet of the production line is held by the same operator. The operators on the production line must be multi-functional and adopt multi-machine operation.

2. If the daily assembly quantity or assembly rhythm is fixed, then each production line will be processed according to the unified rhythm.

3. An organic whole should be formed between workshops and processes on the production line.

There is no need for post-treatment and no pre-treatment. Determine the number of machines that each operator is responsible for according to the beat and processing capacity.

4, only keep the necessary standard in-process reserves in the process.

If "one process" production is adopted, the WIP between processes shall not exceed the clamping quantity of the previous process. Overproduction is not allowed.

5. Eliminate ineffective labor and factors that lead to parts collision.

To achieve the above points, it is generally necessary to achieve the following three elements:

① Appropriate machine configuration design;

② Training multi-skilled operators;

③ Continuous evaluation and regular revision of standard operating procedures.

Third, the organization method of synchronous beat production

1, check the working hours, and prepare the work instruction and work combination table.

Time analysis of each process. Check working hours according to manual time and moving time respectively. Calculate the operator's working ability from the manual time, determine the number of machine tools to be supervised, increase the inspection time, formulate standard operation methods, and prepare work instructions and standard operation combination tables.

2. Transform the plane layout of equipment and machine tools to improve work efficiency.

According to the requirements of multi-machine operation, adjust the plane layout of equipment, shorten the distance between equipment, adjust the height of equipment, realize the automation of machine tools (automatic advance and retreat, automatic stop), improve work efficiency, and achieve the purpose of saving time and effort.

3, innovation and transformation of the station equipment, reduce ineffective labor, eliminate parts bruised.

Design and manufacture workstation appliances that meet the requirements of eliminating ineffective labor and preventing collision, and modify existing material racks, slideways, inter-process conveying devices, cleaning, sending and picking tools, etc.

4, only keep the necessary work in progress.

Specify the necessary quantity of WIP, and specify the storage location.