Transcript Document

Andon
(Process Control Board)
17 July 2015
Page 1
Andon
What is Andon ?
Japanese translation: Lantern
• A visual control that enables the operator to inform the Team
Leader (or responsible line cover) that an abnormal condition
exists.
Note: IT IS NOT A TOOL TO STOP THE LINE, IT IS
IN FACT A TOOL TO KEEP THE LINE RUNNING
Author: Dave Bate
Vaillant Training, Belper
17 July 2015
Page 2
Andon
Process Control Overview
LINE 1
PLAN 153
PROD 146
DOWN 021
12:05
1
Vehicle Flow
PRE
2
3
4
5
6
PST
HELP
EQUIP
QUALITY
SYSTEM HEALTHY
ONE TOUCH
FIRST TIME
10%
30%
50%
EVERY
TIME
70%
L10
ONE TOUCH
FIRST TIME
EVERY TIME
ONE TOUCH
FIRST TIME
EVERY TIME
90%
L10
L10
ONE TOUCH
FIRST TIME
EVERY TIME
L10
Yamazumi Board
H A L EW O O D
Team:
GL X1:
GL X2:
Last Update:
Yamazumi Key:
Work Classification
Value Added Work
Non-Value Added Work
Essential NVAW
Option Work
Variant Work
Working Position
R1
R2
C1
C2
L1
L2
R3
R4
C3
C4
L3
L4
S1
Icons
Associated
ENVAW
Associated
NVAW
Quality
Critical
15%
85%
Time – 1sec=5mm
5%
40%
60%
35%
Retractor LH
Retractor RH
Carpet Fit
Loom
Processes
Author: Dave Bate
Vaillant Training, Belper
17 July 2015
Page 3
Andon
• Is activated by :
• the process operator manually
• automatically by links to equipment
• Provides real time information.
• Trigger for problem solving.
• Prevents concerns being passed onto the next
process ie Supports JIDOKA
• Key driver towards Lean Manufacturing.
Author: Dave Bate
Vaillant Training, Belper
17 July 2015
Page 4
•PULL IF QUALITY OR SAFETY ISSUE
•PULL TO ALERT T/L OF ANY
ABNORMALITY
•STOP- CALL- WAIT
Author: Dave Bate
Vaillant Training, Belper
17 July 2015
Page 5
PROBLEM
Author: Dave Bate
INDICATION
Vaillant Training, Belper
RESPONSE
17 July 2015
Page 6
Andon
What does it look like ?
• Simple to read.
• Information easy to understand at a glance.
• Prominent location for the line support to see.
• Shows location of the concern, not detail.
LINE 1
PLAN 153
PROD 146
DOWN 021
12:05
1
PRE
2
3
4
5
6
PST
HELP
EQUIP
QUALITY
SYSTEM HEALTHY
Author: Dave Bate
Vaillant Training, Belper
17 July 2015
Page 7
Andon
Hardware overview:
LINE 1
PLAN 153
PROD 146
DOWN 021
12:05
1
PRE
2
3
4
5
EQUIP
QUALITY
Pull cords and beacons
Author: Dave Bate
SYSTEM HEALTHY
Vaillant Training, Belper
6
PST
HELP
Andon
How does it work ? Line running
PLAN
153
146
DOWN 021
LINE 1
PROD
12:05
ATTEND
PRE
CRD
1
2
3
4
5
HELP
EQUIP
PST
QUALITY
P
SYSTEM HEALTHY
Author: Dave Bate
6
Vaillant Training, Belper
Andon
How does it work ? Concern - Cord Pulled
Pull cords and beacons
LINE 1
PLAN 153
PROD 146
DOWN 021
12:05
1
PRE
2
3
4
5
EQUIP
QUALITY
SYSTEM HEALTHY
Author: Dave Bate
6
PST
HELP
Vaillant Training, Belper
Andon
How does it work ? Relevant position
lights up
PLAN
153
146
DOWN 021
LINE 1
PROD
12:05
ATTEND
PRE
CRD
1
2
3
4
5
HELP
EQUIP
PST
QUALITY
P
SYSTEM HEALTHY
Author: Dave Bate
6
Vaillant Training, Belper
Andon
Marquee
LINE 1
PLAN 153
PROD 146
DOWN 021
12:05
1
PRE
2
3
4
5
6
PST
HELP
EQUIP
QUALITY
SYSTEM HEALTHY
The marquee shows the following information:
System healthy
Production Held Information
System fault Information
Emergency Stop information
Buffer warning levels
Maintenance Call Information
Author: Dave Bate
Vaillant Training, Belper
Andon
Chimes
The purpose of the chimes is to alert the personnel in that area that
there has been a change in status on either the line side equipment or
on the local Andon board.
Every team on the line is allocated a sounder. Each sounder has the
ability to sound individual chimes.
Every line is usually allocated two chimes:
1st chime is for the purpose of warning the local team.
2nd chime is for the purpose warning the whole line.
Author: Dave Bate
Vaillant Training, Belper
Andon
De-coupling and Managed Buffers.
Effective use of an Andon system relies upon the introduction
of de-coupled production lines with managed buffers.
De-coupled lines allow production areas to stop without
immediate effect to following and preceding areas.
It ensures that, within reason, a continuous flow of
production is maintained by using the managed buffers
between the lines.
Author: Dave Bate
Vaillant Training, Belper
17 July 2015
Page 14
Andon
De-coupling and Managed Buffers.
Total line stop
Stn 1
Stn1 - Stn 60
Stn 60
Line stop
Stn 1
Line stop
Stn 20
Stn 41
Line stop
Stn 60
Managed buffers
Stn1-Stn20
Production continues
Stn 21
Author: Dave Bate
Vaillant Training, Belper
Stn 40
until preceding buffer
short
17 July 2015
Page 15
How big should the buffer be?
How to manage the buffer?
Set the buffer quantity based upon the line performance / downtime
Reduce buffers
as pulls &
downtime
reduce
No of
pulls
10 mins ~ 5 cars
(depends on Takt)
1
Author: Dave Bate
2
5
3
10
Time in secs
Vaillant Training, Belper
20
17 July 2015
Page 16