Application Of Process Activity Mapping For Waste Reduction A Case Study In Foundry Industry
Application Of Process Activity Mapping For Waste Reduction A Case Study In Foundry Industry
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工艺活动映射在减少废物中的应用——铸造行业的案例研究
DOI：
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发表时间：
2012
期刊：
影响因子：
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通讯作者：
P. Naik
中科院分区：
文献类型：
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作者：
C. Pude;G. R. Naik;P. Naik
价值流映射技术包括绘制步骤、活动、物料流、通信以及与过程或转换相关的其他过程元素的流程图。在这方面，价值流映射帮助组织识别目标过程中的非增值元素，并通过主要流程（从原材料到客户的怀抱）带来使用相同资源的产品或一组产品。过程活动映射是价值流映射（VSM）工具，它起源于工业工程。尽管过程分析是最常见的，但该技术有许多名称。观察了废物对工艺的当前影响。研究过程活动映射步骤，并确定浪费。研究了不同的流程布局，选择了减少运输时间的最佳布局。本文以xyz铸造厂为例，从详细的时间研究开始，采用当前状态图和未来状态图的不同步骤，从原材料到最终产品的制图过程开始。描述了步骤，包括将现有废物转化为标准废物的废物消除技术。编制了统计图表，对瓶颈产品进行了识别。以xyz铸造厂为例，通过流程活动映射来减少废物，以确定流程和非增值活动。本研究仅关注铸造生产线（1号线即KOYO生产线），该生产线贡献了铸造厂98%的铸件。价值流映射工具用于分析物料流和信息流。该生产线是半自动化的，铸件经过滚筒、输送机、分砂、制砂、敲除、脱渣、抛丸等工序。绘制其他产品的价值流活动也会得到类似的结果，只是数值上的差异很小，因为有些铸件很简单，需要热/冷箱工艺，而有些铸件很复杂，需要冷/热箱工艺。然而，本文选择瓶颈产品unterage作为研究对象。本研究是一个应用于铸造过程的案例研究，铸造过程是连续过程，生产线是半自动化的，分析使用了过程活动映射工具。该工具是通过问卷调查、访谈和与车间经理和操作员的头脑风暴会议来选择的(2)。市场部、生产计划和控制部门、样板车间已经帮助我们给出了铸造生产线的过去记录值，例如市场部给出了每月的客户订单，生产计划部门给出了铸造车间的总体布局，样板车间根据他们的工作经验给出了简单和复杂的工作分类等。
Value Stream mapping technique involves flowcharting the steps, activities, material flows, communications, and other process elements that are involved with a process or transformation. In this respect, Value stream mapping helps an organization to identify the non-value-adding elements in a targeted process and brings a product or a group of products that use the same resources through the main flows, from raw material to the arms of customers. Process activity mapping is a Value stream mapping (VSM) tool has its origins in industrial engineering. The technique is known by a number of names although process analysis is the most common. Current effects of wastes on processes are observed. Process activity mapping steps are studied and wastes are identified. Different flow layouts are studied and best layout is selected that reduces the transport time. In this paper a case study in xyz foundry is carried out with current state map and future state map after following the different steps starting from the detailed time study of mapping process from raw material to final product. The steps including waste elimination techniques with conversion of existing waste into standard wastes are described. Statistical charts are prepared for the identification of bottleneck product is presented. A case study in xyz foundry for waste reduction with process activity mapping is carried out to identify the process flow and non value adding activities. The study is focused only on foundry production line (Line 1 namely KOYO production line) which contributes to 98% of the castings of the foundry. The Value stream mapping tool is used to analyze both the flow of materials and the flow of information. The line is semi-automated and the casting goes through various processes drums, conveyors, sand separation, sand preparation, knock out, degating, shot blasting etc. Mapping the value stream activities of other products would give similar results with small differences in numerical values as some castings are simple, requires hot/cold box process while some are complex requiring cold/hot box process. However the bottleneck product Unterlage is selected for the study. This study is a case study applied for the foundry processes which are continuous processes as production lines are semi automated and the analysis uses the process activity mapping tool. This tool is selected with questionnaires, interviews and brainstorming sessions with manager and operators on the shop floor (2). Marketing, production planning & control dept., pattern shop has helped us to give past record values of foundry production line for e.g. marketing dept. has given monthly customer order, production planning dept. has given the total foundry layout, pattern shop has given classification of simple and complicated jobs depending upon their work experience etc.