Ứng dụng sơ đồ dòng giá trị để cải tiến năng suất tại chuyền lắp ráp bodyshop dòng xe GLC công ty TNHH mercedes benz vietnam

ĐẠI HỌC QUỐC GIA TP HCM TRƯỜNG ĐẠI HỌC BÁCH KHOA PHAN MINH HIẾU ỨNG DỤNG SƠ ĐỒ DÒNG GIÁ TRỊ ĐỂ CẢI TIẾN NĂNG SUẤT TẠI CHUYỀN LẮP RÁP BODYSHOP DỊNG XE GLC CƠNG TY TNHH MERCEDES-BENZ VIETNAM CHUN NGÀNH: QUẢN TRỊ KINH DOANH MÃ SỐ KHÓA LUẬN THẠC SĨ TP.HCM 8/2017 VIETNAM NATIONAL UNIVERSITY, HCM CITY BACH KHOA UNIVERSITY PHAN MINH HIEU APPLY VALUE STREAM MAPPING TO IMPROVE CAPACITY AT GLC BODYSHOP MERCEDES-BENZ VIETNAM LIMITED COMPANY MAJOR : BUSINESS ADMINISTRATION ID : 60340102 MASTER REPORT TP.HCM 8/2017 -i- CƠNG TRÌNH ĐƯỢC HỒN THÀNH TẠI TRƯỜNG ĐẠI HỌC BÁCH KHOA ĐẠI HỌC QUỐC GIA TP HỒ CHÍ MINH Cán hướng dẫn khoa học: Tiến Sĩ Nguyễn Thị Đức Nguyên Cán chấm nhận xét 1: Cán chấm nhận xét 2: Khóa luận thạc sĩ bảo vệ Trường Đai học Bách Khoa, ĐHQG TP.HCM ngày 27 tháng 07 năm 2017 Thành phần Hội đồng đánh giá khóa luận thạc sĩ gồm: TS Nguyễn Thúy Quỳnh Loan TS Nguyễn Thị Thu Hằng TS Đường Võ Hùng Xác nhận Chủ tịch Hội đồng đánh giá khóa luận Trưởng khoa Quản lý Chuyên Ngành CHỦ TỊCH HỘI ĐỒNG TRƯỞNG KHOA - ii ĐẠI HỌC QUỐC GIA TP HỒ CHÍ MINH CỘNG HỊA XÃ HỘI CHỦ NGHĨA VIỆT NAM TRƯỜNG ĐẠI HỌC BÁCH KHOA Độc lập – Tự – Hạnh phúc - NHIỆM VỤ KHÓA LUẬN THẠC SĨ Họ tên học viên: PHAN MINH HIẾU MSHV: 13170660 Ngày, tháng, năm sinh: 20/06/1983 Nơi sinh: Bình Định Chuyên ngành: I QUẢN TRỊ KINH DOANH MS: 60 34 01 02 TÊN ĐỀ TÀI: ỨNG DỤNG SƠ ĐỒ DÒNG GIÁ TRỊ ĐỂ CẢI TIẾN NĂNG SUẤT TẠI CHUYỀN LẮP RÁP BODYSHOP DÒNG XE GLC, CÔNG TY TNHH MERCEDES-BENZ VIỆT NAM II NHIỆM VỤ VÀ NỘI DUNG: - Xác định xây dựng dòng giá trị dòng xe GLC chuyền lắp ráp BodyShop - Nhận diện lãng phí phân tích nguyên nhân - Đề xuất giải pháp để nâng cao suất xây dựng dòng giá trị tương lai III NGÀY GIAO NHIỆM VỤ: 15/03/2017 IV NGÀY HOÀN THÀNH NHIỆM VỤ: 05/07/2017 V CÁN BỘ HƯỚNG DẪN: TS NGUYỄN THỊ ĐỨC NGUYÊN Tp HCM, ngày 07 tháng 08 năm 2017 CÁN BỘ HƯỚNG DẪN CHỦ NHIỆM BỘ MÔN TRƯỞNG KHOA - iii - LỜI CẢM ƠN Đầu tiên xin gửi lời cảm ơn sâu sắc đến mẹ, vợ gái không ngừng giúp đỡ động viên suốt thời gian học cao học làm khóa luận Tơi xin chân thành cảm ơn sâu sắc Thầy, Cô khoa Quản Lý Công Nghiệp, trường Đại học Bách Khoa Thành phố Hồ Chí Minh, truyền đạt kiến thức tận tình hướng dẫn tơi suốt thời gian học tập làm khóa luận Tơi xin chân thành cảm ơn cô TS Nguyễn Thị Đức Nguyên tận tình hướng dẫn giúp tơi hồn thành tốt khóa luận Tôi xin chân thành cảm ơn bạn đồng nghiệp công ty TNHH MercedesBenz Việt Nam giúp đỡ tơi suốt q trình làm khóa luận TP.HCM, Ngày 07 tháng 08 năm 2017 Phan Minh Hiếu - iv - TÓM TẮT KHÓA LUẬN Sản lượng xưởng lắp ráp BodyShop dịng xe GLC Cơng ty TNHH Mercedes-Benz Việt Nam (MBV) đạt xe/ngày, đạt 80% so với sản lượng thiết kế (10 xe/ngày), sản phẩm ngày ưa chuộng thị trường Việt Nam sau mắt vào ngày 21 tháng năm 2016 (thời gian khách hàng nhận xe sau đặt hàng lên đến 13 tháng) Ứng dụng sơ đồ dòng giá trị (CVSM) để thể thực trạng tổng thể suất BodyShop GLC, giúp nhận diện điểm thắc cổ chai (bottleneck) loại lãng phí cách có hệ thống, có 05 trạm trạm: Z2.3, Z2.2, Sub Eng Comp, Sub Sidewall Finish nút thắc cổ chai Phân tích cụ thể cơng việc trạm nút thắc cổ chai, ứng dụng công cụ phân tích thống kê pareto xác định loại lãng phí chủ yếu biểu đồ xương cá để phân tích nguyên nhân, xác định loại lãng phí chờ đợi lãng phí tìm trả lại cơng cụ hai loại lãng phí lớn chuyền BodyShop dòng xe GLC Các giải pháp đề xuất để loại bỏ loại lãng phí phát giảm tải cho điểm thắc cổ chai, từ nâng cao suất nhằm đạt mục tiêu suất 10 xe ngày, đáp ứng mục tiêu đề khóa luận -v- ABSTRACT At Mercedes-Benz Vietnam, produced vehicles at Body workshop (Bodyshop) of GLC model is just vehicles per day, achived 80% design capacity (10 veh/day), whereas this is more and more interesting model at Vietnam market from the time it’s lauched, the customer ‘s waiting time to get the vehicle from order increase to 13 months Applied current state value stream mapping (CVSM) to show the current status of capacity at GLC BodyShop help us systematically recognize where is the bottleneck and what kind of wastes, stations Z2.3, Z2.2, Sub Eng Comp, Sub Sidewall and Finish are the bottlenecks Investigate the works at bottleneck stations, using Pareto tool to define main wastes and fishbone tool to find the root cause, waste of waiting and put up/ put down manually tools is the most at BodyShop GLC Proposed methods were raised to eliminate defined wastes and improve define bottlenect and the capacity will be increase The future-state value stream mapping showed that capacity increase to 10 vehicles/ day from vehicles/ day, and match with the purpose of this thesis - vi - LỜI CAM ĐOAN Tôi xin cam đoan: Đây cơng trình thực riêng tơi dự hướng dẫn cô Tiến sĩ Nguyễn Thị Đức Nguyên, số liệu trích dẫn có nguồn gốc đầy đủ Các kết trình bày khóa luận trung thực chưa công bố cơng trình khác Tác giả khóa luận Phan Minh Hiếu - vii - MỤC LỤC CHƯƠNG GIỚI THIỆU ĐỀ TÀI 1.1 Lý hình thành đề tài 1.2 Mục tiêu thực 1.3 Phạm vi thực 1.4 Phương pháp thực 1.4.1 Quy trình thực 1.4.2 Nhu cầu thông tin phương pháp thu thập 1.4.2.1 Thông tin thứ cấp 1.4.2.2 Thông tin sơ cấp CHƯƠNG CƠ SỞ LÝ THUYẾT 2.1 Khái niệm sản xuất tin gọn – Lean Manufacturing 2.2 2.2.1 2.2.2 Lãng phí sản xuất phân loại Khái niệm Các loại lãng phí 2.2.2.1 Sản xuất dư thừa (Overproduction) 2.2.2 2.2.2 2.2.2.4 Gia công thừa (Overprocessing) 2.2.2 2.2.2 2.2.2.7 Tạo sản phẩm lỗi (Making defective parts) 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 Lý thuyết sơ đồ dòng giá trị Dòng giá trị (Value Stream) Chọn họ sản phẩm: Xác định thơng số q trình Xây dựng sơ đồ dòng giá trị (CVSM) Lập sơ đồ dòng giá trị tương lai (FVSM) 2.4 2.4.1 2.4.2 Biểu đồ xương cá Giới thiệu Cách tạo biểu đồ xươn - viii - CHƯƠNG XÂY DỰNG DÒNG GIÁ TRỊ HIỆN TẠI CHUYỀN BODYSHOP DÒNG XE GLC 3.1 Giới thiệu Công ty TNHH Mercedes-Benz Việt Nam 3.2 Giới thiệu xưởng lắp ráp Body GLC 3.3 Các thông số đầu vào 3.4 Sơ đồ dòng giá trị dòng xe GLC BS 3.4.1 Các loại ký hiệu 3.4.2 Sơ đồ CVSM: 3.5 Nhận xét CVSM: CHƯƠNG NHẬN DIỆN LÃNG PHÍ VÀ PHÂN TÍCH NGUYÊN NHÂN 4.1 Nhận diện lãng phí 4.2 Phân tích nguyên nhân 4.2.1 Brain Storming 4.2.1.1 Thời gian chờ đợi 4.2.1.2 Thời gian tìm trả lại cơng cụ làm việc 4.2.2 Xác định nguyên nhân gốc CHƯƠNG ĐỀ XUẤT GIẢI PHÁP VÀ XÂY DỰNG DÒNG GIÁ TRỊ TƯƠNG LAI38 5.1 Giải pháp đề xuất 38 5.1.1 Trang bị thêm súng hàn bố trí lại súng hàn 38 5.1.2 Trang bị thêm súng bơm keo máy nung keo 38 5.1.3 Bố trí lại cơng việc cho hợp lý trạm: 39 5.2 Sơ đồ dòng giá trị tương lai (FVSM) 41 5.3 Nhận xét FVSM: 43 CHƯƠNG KẾT LUẬN VÀ ĐỀ NGHỊ 44 6.1 Kết luận 44 6.2 Đề nghị 44 OP1 OP2 2.4 welding of simple spots (Geo & Respots) 2.4 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) OP2 2.5 restore welding gun C8 Put up and put down manually tools OP1 wait for OP2 Waiting OP1 OP2 3.1 Load SW inner lh in framer 3.1 Load SW inner lh in framer Load middle part up to approx 1000x750 (radius 3m) Load middle part up to approx 1000x750 (radius 3m) OP1 4.1 close clamps to Close or open clamps manually OP2 4.1 close clamps to 10 Close or open clamps manually OP1 START STEP2 rh walk to right side Walk Operator (1 m) OP2 walk to right side Walk Operator (1 m) OP2 wait for OP1 Waiting OP1 OP2 1.1 Get SW inner lh out from box in front of fra 1.1 Get SW inner lh out from box in front of fra Load big part, Operator manually (radius 3m) Load big part, Operator manually (radius 3m) OP1 OP1 OP1 2.1 walk to get hand jig and part or 2.2 load part or in hand jig 2.3 load hand jig in SW inner Walk Operator (1 m) Load small part manually (radius 1m) Load small part manually (radius 1m) OP2 OP2 2.1 walk to get gun wait for OP1 Put up and put down manually tools Waiting OP1 OP2 2.4 welding of simple spots (Geo & Respots) 2.4 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) OP2 2.5 restore welding gun C8 Put up and put down manually tools OP1 wait for OP2 Waiting OP1 OP2 3.1 Load SW inner lh in framer 3.1 Load SW inner lh in framer Load middle part up to approx 1000x750 (radius 3m) Load middle part up to approx 1000x750 (radius 3m) OP1 4.1 close clamps 16 to 20 Close or open clamps manually OP2 4.1 close clamps 21 to 24 Close or open clamps manually OP1 OP1 OP2 OP1 walk outside of frame lh wait for OP2 walk outside of frame lh wait for OP2 END OF STEP2 Walk Operator (1 m) Waiting Walk Operator (1 m) Waiting OP1 OP1 OP1 START STEP3 (gluing finished already by OP 3.1 close frame lh 3.2 close locking clamp 1x 3.3 walk outside of frame rh Load big part, Operator manually (radius 3m) Close or open clamps manually Walk Operator (1 m) OP2 OP2 3.1 close frame lh 3.2 close locking clamp 2x Load big part, Operator manually (radius 3m) Close or open clamps manually OP1 OP1 3.4 close frame rh 3.5 close locking clamp 1x Load big part, Operator manually (radius 3m) Close or open clamps manually OP2 4.1 close clamps 13 to 17 of framer lh Close or open clamps manually OP1 OP1 5.1 walk to insert jig (rear frame) 5.2 load insert jig (rear frame) Walk Operator (1 m) Load big part by hoist, manually (radius 3m) OP2 OP2 OP2 wait for OP1 (loading of frame) 5.2 load insert jig (rear frame) 5.3 close locking clamps Waiting Load big part by hoist, manually (radius 3m) Close or open clamps manually OP1 OP1 5.3 walk to insert jig (front frame) 5.4 load insert jig (front frame) Walk Operator (1 m) Load big part by hoist, manually (radius 3m) OP2 wait for OP1 (loading of frame) Waiting OP2 OP2 5.4 load insert jig (front frame) 5.5 close locking clamps Load big part by hoist, manually (radius 3m) Close or open clamps manually OP1 6.1 step into body to support welding Walk Operator (1 m) OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 6.1 walk to get gun X15 lh 6.2 welding of simple geo spots with X15 6.3 change to gun C8 6.4 welding of difficult geo spots with C8 6.5 welding of simple geo spots with C8 6.6 change to gun C21 6.7 welding of simple geo spots with C21 6.8 change to gun UU 6.9 welding of difficult spots with UU 6.10 welding of simple geo spots with UU 6.11 restore welding gun UU Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Spot welding manually, Geo (difficult) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools OP1 OP1 OP1 6.2 support OP1 and OP2 for difficult welding o waiting till geo welding is finished 6.11 get out of the body Spot welding manually, Geo (difficult) Waiting Walk Operator (1 m) OP2 wait for OP1 Waiting OP2 7.1 open lh 2x lockings clamps of rear/front fram Close or open clamps manually OP1 OP1 OP1 8.1 unload insert jig (front frame) 8.2 walk to rear frame 8.3 unload insert jig (rear frame) Unload big part by hoist manually (radius 3m) Walk Operator (1 m) Unload big part by hoist manually (radius 3m) OP2 7.4 open all clamps to 10, 13 to 17, Close or open clamps manually OP2 wait till rear frame is unloaded by OP1 Waiting OP2 OP2 10.2 push SW frame (lh) out 10.3 walk to SW frame (rh) Load big part, Operator manually (radius 3m) Walk Operator (1 m) OP2 10.4 push SW frame (rh) out Load big part, Operator manually (radius 3m) OP1 OP1 11.1 walk to insert jig (frame) 11.2 open clamps to 11 on insert jig Walk Operator (1 m) Close or open clamps manually OP1 OP1 12.1 push insert jig in back position 12.2 unload insert jig (frame) Unload middle part up to 1000x750 (radius 3m) Unload big part by hoist manually (radius 3m) OP1 OP1 OP1 **Current Situation - Respoting in Z2.1A Geo** Calculation is simplified (lh) Get guns / change guns / restore Guns (lh) Respoting of difficult spots (lh) Respoting of 140 simple spots Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) OP2 OP2 OP2 (rh) Get guns / change guns / restore Guns (rh) Respoting of difficult spots (rh) Respoting of 140 simple spots Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) OP1 12.3 unload body Unload big part by hoist manually (radius 3m) Station: Z2.2 6/16/2017 OP Process Step Content START STEP1 OP1 1.1 Load underbody from Station 6010 Load big part by hoist, manually (radius 3m) OP2 1.1 Load underbody from Station 6010 Load big part by hoist, manually (radius 3m) OP1 2.1 walk to pneumatic control panel W alk Operator (1 m) 40 OP1 2.2 close pneumatic clamps Press one hand start 44 OP2 2.1 walk to clamps 1, W alk Operator (1 m) OP2 2.2 close clamps 1, Close or open clamps manually OP3 3.1 walk to rack to get SW (lh) W alk Operator (1 m) OP3 3.2 load SW in frame (lh) Load big part, Operator manually (radius 3m) OP3 3.3 close red clamps 1, on frame (lh) Close or open clamps manually OP4 3.1 walk to rack to get SW (lh) W alk Operator (1 m) OP4 3.2 load SW in frame (lh) Load big part, Operator manually (radius 3m) OP4 3.3 close red clamps 3, on frame (lh) Close or open clamps manually OP3 3.4 walk to rack to get SW (rh) W alk Operator (1 m) OP3 3.5 load SW in frame (rh) Load big part, Operator manually (radius 3m) OP3 3.6 close red clamps 1, on frame (rh) Close or open clamps manually OP4 3.4 walk to rack to get SW (rh) W alk Operator (1 m) OP4 3.5 load SW in frame (rh) Load big part, Operator manually (radius 3m) OP4 3.6 close red clamps 1, on frame (rh) Close or open clamps manually OP1 5.1 walk to frame (lh) W alk Operator (1 m) 46 OP1 5.2 push sliding unit in frame (lh) down Close or open clamps manually 56 OP1 5.3 close locking clamps Close or open clamps manually 68 OP1 5.4 walk to frame (rh) W alk Operator (1 m) 76 OP1 5.5 push sliding unit in frame (rh) down Close or open clamps manually 92 OP1 5.6 close locking clamps Close or open clamps manually 10 OP2 6.1 walk to get part W alk Operator (1 m) OP2 6.2 load part into insert jig no Load middle part up to approx 1000x750 (radius 3m) OP2 6.3 close pins 1, and clamps 3, Close or open clamps manually OP2 7.1 / 9.1walk to get part / W alk Operator (1 m) OP2 7.2 / 9.2 load part / into insert jig no / Load middle part up to approx 1000x750 (radius 3m) OP2 7.3 / 9.3 close pins 1, and clamps 3, Close or open clamps manually OP3 8.1 walk to get part W alk Operator (1 m) OP3 8.2 load part into insert jig no Load middle part up to approx 1000x750 (radius 3m) OP3 8.3 close pins 1, and clamps 3, Close or open clamps manually END STEP1 START STEP2 OP4 1.1 get the gluing gun (Betamate) Put up and put down manually tools OP4 1.2 apply sealer on right side Sealer application manually, simple (100mm) OP4 10.1 apply sealer on rear roof frame (rh) Sealer application manually, simple (100mm) OP4 10.2 walk to left side W alk Operator (1 m) OP4 10.1 apply sealer on rear roof frame (rh) Sealer application manually, simple (100mm) OP4 1.3 restore gluing gun Put up and put down manually tools OP4 3.1 walk outside of frame (lh) W alk Operator (1 m) OP1 1.3 get the gluing gun (Terostat) Put up and put down manually tools 11 OP1 1.4 apply sealer on left side Sealer application manually, simple (100mm) 22 OP1 2.1 walk to right side W alk Operator (1 m) 38 OP1 2.2 apply sealer on right side Sealer application manually, simple (100mm) 38 OP1 2.3 change cartridge (Terostat to Betamate) Put up and put down manually tools 50 OP1 2.4 walk to left side W alk Operator (1 m) 58 OP1 2.5 apply sealer on left side Sealer application manually, simple (100mm) 59 OP1 2.6 restore gluing gun Put up and put down manually tools 102 OP3 3.1 walk outside of frame (lh) W alk Operator (1 m) OP2 wait for OP1 and OP4 W aiting OP3 wait for OP1 and OP4 W aiting OP4 wait for OP1 W aiting OP1 3.1 walk outside of frame (rh) W alk Operator (1 m) 117 OP2 3.1 walk outside of frame (rh) W alk Operator (1 m) OP1 3.2 close frame (rh) Load big part, Operator manually (radius 3m) 121 OP1 3.3 close locking clamp Close or open clamps manually 124 OP2 3.2 close frame (rh) Load big part, Operator manually (radius 3m) OP2 3.3 close locking clamp Close or open clamps manually OP3 3.2 close frame (rh) Load big part, Operator manually (radius 3m) OP3 3.3 close locking clamp Close or open clamps manually OP4 3.2 close frame (rh) Load big part, Operator manually (radius 3m) OP4 3.3 close locking clamp Close or open clamps manually OP1 4.1 close clamps 35 to 47 Close or open clamps manually 124 OP2 4.1 close clamps 48 to 60 Close or open clamps manually OP3 4.1 close clamps to 17 Close or open clamps manually OP4 4.1 close clamps 18 to 30 Close or open clamps manually OP1 OP1 5.1 / 6.1 walk to insert jig / 5.2 / 6.2 load insert jig / W alk Operator (1 m) Load big part by hoist, manually (radius 3m) 129 131 OP2 OP2 5.1 / 6.1 step in to body 5.2 / 6.2 support loading insert jig / W alk Operator (1 m) Load big part by hoist, manually (radius 3m) 0 OP3 OP3 7.1 walk to insert jig 7.2 load insert jig W alk Operator (1 m) Load big part by hoist, manually (radius 3m) 0 OP4 OP4 7.1 step in to body 7.2 support loading insert jig W alk Operator (1 m) Load big part by hoist, manually (radius 3m) OP1 8.1 get gun X21 Put up and put down manually tools OP2 wait for OP1 W aiting OP1 OP1 8.2 welding of difficult geo spots with X21 8.3 welding of simple geo spots with X21 Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) 139 144 OP2 OP2 8.2 support OP1 welding of difficult geo spots w 8.3 support OP1 welding of simple geo spots w Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) 0 OP3 8.1 get gun X21 Put up and put down manually tools OP4 wait for OP3 W aiting OP3 OP3 8.2 welding of difficult geo spots with X21 8.3 welding of simple geo spots with X21 Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) 0 OP4 OP4 8.2 support OP3 welding of difficult geo spots w 8.3 support OP3 welding of simple geo spots w Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) 0 OP1 8.4 restore welding gun X21 Put up and put down manually tools 150 OP1 9.1 walk to insert jig no.1 W alk Operator (1 m) 159 OP2 wait for OP1 W aiting OP1 OP2 9.2 load insert jig no 9.2 load insert jig no Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) OP2 9.3 close pins 7, Close or open clamps manually 0 135 0 160 **Process step 10 (apply glue on rear roof frame) OP3 8.4 restore welding gun X21 Put up and put down manually tools OP3 11.1 walk to insert jig no W alk Operator (1 m) OP4 11.2 walk to get part W alk Operator (1 m) OP4 OP4 wait for OP3 11.3 load part in body while OP3 is loading inse W aiting Load big part by hoist, manually (radius 3m) 0 OP3 11.3 load insert jig no Load big part by hoist, manually (radius 3m) OP4 OP4 12.1 walk to get foam parts 12.2 clip foam part for ASD 2x W alk Operator (1 m) clip or seal Foarm Parts 0 OP3 OP3 OP3 OP3 14.1 walk to get welding gun X21 14.2 welding of simple geo spots with X21 at re 14.3 walk to front roof frame wait fo OP2 Put up and put down manually tools Spot welding manually, Geo (simple) W alk Operator (1 m) W aiting 0 0 OP3 OP2 14.4 welding of simple geo spots with X21 at fr 14.4 support OP welding of simple geo spots Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) 0 OP1 OP1 OP1 14.1 walk to get welding gun X21 14.2 welding of simple geo spots with X21 at re 14.3 walk to front roof frame Put up and put down manually tools Spot welding manually, Geo (simple) W alk Operator (1 m) 164 174 175 OP2 wait for OP1 W aiting OP1 OP2 14.4 welding of simple geo spots with X21 at fr 14.4 support OP welding of simple geo spots Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) 176 OP1 OP1 OP1 OP1 OP1 OP1 OP1 14.5 change to gun C16 (lh) 14.6 welding of simple geo spots with C16 14.7 change to gun C5 (lh) 14.8 welding of 20 simple geo spots with C5 14.9 change to gun X13 (lh) 14.8 welding of simple geo spots with X13 14.9 restore welding gun X13 Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools 178 187 194 204 221 229 235 OP3 OP3 OP3 OP3 OP3 OP3 OP3 14.5 change to gun C16 (lh) 14.6 welding of simple geo spots with C16 14.7 change to gun C5 (lh) 14.8 welding of 19 simple geo spots with C5 14.9 change to gun X13 (lh) 14.8 welding of simple geo spots with X13 14.9 restore welding gun X13 Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools 0 0 0 OP4 OP4 OP4 OP4 13.1 walk to get drilling machine 13.2 dill holes at fender area (lh) 13.3 deburr holes at fender area (lh) 13.4 walk to fender area right side W alk Operator (1 m) Drilling manually Deburr after drilling W alk Operator (1 m) 0 0 OP4 OP4 OP4 13.5 dill holes at fender area (lh) 13.6 deburr holes at fender area (lh) 13.7 restore drilling machine Drilling manually Deburr after drilling Put up and put down manually tools 0 OP2 OP2 OP2 OP2 OP2 OP2 OP2 13.7 walk to get blind rivet gun wait for OP4 till drilling + debirr left side is finishe 13.8 apply blind rivets at fender area (lh) 13.9 walk to fender area right side wait for OP4 till drilling + debirr right side is finish 13.10 apply blind rivets at fender area (rh) 13.11 restore blind rivet gun W alk Operator (1 m) W aiting Riveting manually W alk Operator (1 m) W aiting Riveting manually Put up and put down manually tools 0 0 0 OP2 OP3 OP4 wait for OP1 till geo welding is finished wait for OP1 till geo welding is finished wait for OP1 till geo welding is finished END STEP2 W aiting W aiting W aiting 0 0 246 OP1 START STEP3 1.1 open clamps + locking clamps on insert ji Close or open clamps manually OP2 1.1 open clamps + locking clamps on insert ji Close or open clamps manually OP1 OP2 OP2 2.1 unload insert jigs 2.1 support unload insert jigs wait for OP1 Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) W aiting 250 0 OP1 OP1 OP2 2.2 walk insert jigs 2/3 2.3 unload insert jigs 2/3 2.3 support unload insert jigs 2/3 W alk Operator (1 m) Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 257 257 264 OP3 1.1 open 11 clamps + locking clamps on insert Close or open clamps manually OP4 1.1 open 11 clamps + locking clamps on insert Close or open clamps manually OP3 OP4 OP4 2.1 unload insert jigs 2.1 support unload insert jigs wait for OP3 Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) W aiting 0 OP3 OP3 OP4 2.2 walk insert jigs 5/8 2.3 unload insert jigs 5/8 2.3 support unload insert jigs 5/8 W alk Operator (1 m) Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 0 OP1 OP1 OP1 3.1 walk to sliding unit in frame (lh) 3.2 open clamps on sliding unit 3.3 pull up sliding unit (lh) W alk Operator (1 m) Close or open clamps manually Close or open clamps manually OP2 3.4 open clamps on frame (lh) Close or open clamps manually OP1 3.4 open clamps on frame (lh) Close or open clamps manually 267 OP3 OP3 OP3 3.1 walk to sliding unit in frame (rh) 3.2 open clamps on sliding unit 3.3 pull up sliding unit (rh) W alk Operator (1 m) Close or open clamps manually Close or open clamps manually 0 OP4 3.4 open clamps on frame (rh) Close or open clamps manually OP3 3.4 open clamps on frame (rh) Close or open clamps manually OP1 3.5 open locking clamp of SW frame (lh) Close or open clamps manually 270 OP2 3.5 open locking clamp of SW frame (lh) Close or open clamps manually OP1 OP2 3.6 push SW frame (lh) out 3.6 push SW frame (lh) out Unload big part, Operator manually (radius 3m) Unload big part, Operator manually (radius 3m) OP3 3.5 open locking clamp of SW frame (lh) Close or open clamps manually OP4 3.5 open locking clamp of SW frame (lh) Close or open clamps manually OP3 OP4 3.6 push SW frame (lh) out 3.6 push SW frame (lh) out END STEP3 Unload big part, Operator manually (radius 3m) Unload big part, Operator manually (radius 3m) 0 264 266 267 270 0 273 OP1 START STEP4 1.1 walk to get welding gun C11 W alk Operator (1 m) OP2 1.1 walk to body right side W alk Operator (1 m) OP1 OP2 1.2 welding of difficult respots with gun C11 tog 1.2 support welding of difficult welding spots wi Spot welding manually, Respot (difficult) Spot welding manually, Respot (difficult) 276 OP1 OP1 1.3 change to gun C5 (lh) 1.4 welding of 24 simple respots with gun C5 Put up and put down manually tools Spot welding manually, Respot (difficult) 281 289 OP2 OP2 1.3 walk to get gun C5 (rh) 1.4 welding of 24 simple respots with gun C5 Put up and put down manually tools Spot welding manually, Respot (difficult) 0 OP3 OP3 OP3 OP3 OP3 3.1 walk to get punch rivet gun 3.2 apply punch rivet (lh) 3.3 walk to right side 3.4 apply punch rivet (rh) 3.5 restore punch rivet gun Put up and put down manually tools punch rivet first point W alk Operator (1 m) punch rivet first point Put up and put down manually tools 0 0 OP4 OP4 OP4 OP4 OP4 OP4 OP4 2.1 walk to get drilling machine 2.2 dill holes at fender area (lh) 2.3 deburr holes at fender area (lh) 2.4 walk to fender area right side 2.5 dill holes at fender area (lh) 2.6 deburr holes at fender area (lh) 2.7 restore drilling machine W alk Operator (1 m) Drilling manually Deburr after drilling W alk Operator (1 m) Drilling manually Deburr after drilling Put up and put down manually tools 0 0 0 0 OP4 OP4 OP4 OP4 4.1 walk to pneumatic control panel 4.2 open pneumatic clamps 4.3 walk to clamps 1, 4.4 open clamps 1, W alk Operator (1 m) Press one hand start W alk Operator (1 m) Close or open clamps manually OP1 OP2 5.1 unload body 5.1 unload body Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 0 0 306 Station: Z2.3 6/16/2017 Process Step Content OP1 OP1 1.1 Get the foam parts from rack (16m) 1.2 Clip foam parts in the long member lh/rh Walk Operator (1 m) clip or seal Foarm Parts OP2 2.1 retract locater pins 2x(1, 2) and Close or open clamps manually OP1 3.1 Load long members lh + rh Load big part, Operator manually (radius 3m) OP2 4.1 load engine compartment (part3) Load big part by hoist, manually (radius 3m) OP1 OP1 OP1 OP1 OP1 5.1 Close clamps 6, and ascend retractable pin wait for engine compartment OP2 6.1 close clamps 11 - 13 7.1 walk to get gun 7.2 welding of simple geo spots with X21 Close or open clamps manually Waiting Close or open clamps manually Walk Operator (1 m) Spot welding manually, Geo (simple) OP2 OP2 OP2 OP2 7.1 walk to get gun 7.2 welding of simple geo spots with X21 7.3 walk to get gun waiting for support of OP for diffcult weld spots Walk Operator (1 m) Spot welding manually, Geo (simple) Walk Operator (1 m) Waiting OP2 OP1 7.3 welding of simple geo spots with UZ togeht 7.3 welding of simple geo spots with UZ togeht Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) OP1 OP1 OP1 8.1 get the glueing gun 8.2 apply sealer on long member lh + rh 8.3 Change Position for next glueing operation Put up and put down manually tools Sealer application manually, simple (100mm) Change position (gun,studwelding gun or sealer gun) OP1 OP1 9.1 apply sealer on engine compartment 9.2 put down glueing gun Sealer application manually, simple (100mm) Put up and put down manually tools OP2 7.4 Put down the welding gun Put up and put down manually tools OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 10.1 Walk to main floor rack 10.2 Load big part by hoist, manually (radius 3m) 10.3 Put up the punching gun 10.4 punch rivet first point 10.5 punch rivet 2nd point 10.6 Put down the punching gun Waiting for finished gluing operation of OP1 10.7 Load main floor by hoist, manually 10.8 Close clamps 22, 23 and retract pin 4,5 Walk Operator (1 m) Load big part by hoist, manually (radius 3m) Put up and put down manually tools punch rivet first point punch rivet additional point Put up and put down manually tools Waiting Load big part by hoist, manually (radius 3m) Close or open clamps manually OP1 waiting till main floor is loaded by OP2 Waiting OP1 OP1 11.1 apply sealer on main floor (CGIS in Step 10 11.2 put down glueing gun (CGIS in Step 10) Sealer application manually, simple (100mm) Put up and put down manually tools OP2 OP2 OP2 12.1 walk to insert jig (big frame) 12.2 load insert jig (big frame) 12.3 close clamps 2x25, 27 Walk Operator (1 m) Load big part by hoist, manually (radius 3m) Close or open clamps manually OP1 12.2 Support loading of insert jig OP1 12.3 close clamps 2x24, 28 Close or open clamps manually OP2 OP1 13.1 Load rear floor 13.1 Load rear floor Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) OP2 OP1 14.1 retract pins 15, 17 14.1 retract pins 14, 16 Close or open clamps manually Close or open clamps manually OP2 OP1 15.1 close clamps 19, 21 15.1 close clamps 18, 20 Close or open clamps manually Close or open clamps manually OP2 OP1 16.1 close clamps 27, 29 16.1 close clamps 26, 28 Close or open clamps manually Close or open clamps manually OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 17.1 walk to get gun X14 17.2 welding of difficult spots (Geo & Respots) 17.3 welding of simple spots 17.4 change to gun UL 17.5 welding of difficult spots (Geo & Respots) 17.6 welding of simple spots 17.7 change to gun X21 17.8 welding of 57 simple spots 17.9 restore the welding gun X21 Walk Operator (1 m) Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools OP1 OP1 OP1 OP1 OP1 OP1 OP1 OP1 OP1 17.1 walk to get gun UE 17.2 welding of difficult spots (Geo & Respots) 17.3 welding of simple spots 17.4 change to gun UL 17.5 welding of difficult spots (Geo & Respots) 17.6 welding of simple spots 17.7 change to gun X21 17.8 welding of 58 simple spots 17.9 restore the weling gun X21 OP1 waiting till welding operation of OP2 is finished Waiting OP2 OP2 18.1 open clamps 26, 28 19.1 open clamps of frame Close or open clamps manually Close or open clamps manually OP1 OP1 18.1 open clamps 26, 28 19.1 open clamps of frame Close or open clamps manually Close or open clamps manually OP2 OP1 19.2 unload frame 19.2 unload frame Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) OP2 OP2 OP2 20.1 walk to get gun X21 20.2 welding of 17 simple respots 20.3 restore welding gun X21 Walk Operator (1 m) Spot welding manually, Respot (simple) Put up and put down manually tools OP1 OP1 OP1 20.1 walk to get gun X21 20.2 welding of 16 simple respots 20.3 restore welding gun X21 Walk Operator (1 m) Spot welding manually, Respot (simple) Put up and put down manually tools OP2 OP2 OP2 21.1 get the gluing gun 21.2 apply sealer on connection member lh + rh 21.3 put down the gluing gun Put up and put down manually tools Sealer application manually, simple (100mm) Put up and put down manually tools OP1 wait till gluing of connection members is finished OP2 OP1 22.2 load connection member in insert jig 22.2 load connection member in insert jig Load big part, Operator manually (radius 3m) Load big part, Operator manually (radius 3m) OP2 23.1 Load insert jig (frame) Load big part by hoist, manually (radius 3m) (Geo & Respots) (Geo & Respots) (Geo & Respots (Geo & Respots) (Geo & Respots) (Geo & Respots Walk Operator (1 m) Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools OP2 23.2 close clamp 30 Close or open clamps manually OP1 OP1 23.1 Load insert jig (frame) 23.2 close clamp 31 Load big part by hoist, manually (radius 3m) Close or open clamps manually OP2 OP2 OP2 OP2 OP2 OP2 24.1 walk to get gun X21 24.2 welding of difficult spots (Geo) 24.3 welding of simple spots 24.4 change to gun ZU 24.5 welding of simple respots 24.5 restore welding gun ZU Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools OP1 OP1 OP1 OP1 OP1 OP1 24.1 walk to get gun X21 24.2 welding of difficult spots (Geo) 24.3 welding of simple spots 24.4 change to gun ZU 24.5 welding of simple respots 24.5 restore welding gun ZU OP2 25.1 open clamps Close or open clamps manually OP1 25.1 open clamps Close or open clamps manually OP2 OP1 25.2 unload insert jig 25.2 unload insert jig Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) OP2 26.1 open all clamps Close or open clamps manually OP1 26.1 open all clamps Close or open clamps manually OP2 OP1 27.1 unload underbody 27.1 unload underbody Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) (Geo & Respots) (Geo & Respots) Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Station: Finish Process Step Step Transport part from previous station Transport part from previous station OP1 OP2 1.1 1.2 OP1 OP1 OP2 2.1 2.2 2.2 OP1 OP1 11.1 11.2 OP1 12.1 OP2 OP2 OP2 3.1 3.2 3.3 Close the clamps to **sequence changed** Get the foam part walk to the Part 2&3 Install the foam part to part 2&3 OP2 3.4 Load the part to clamping frame OP2 4/5 Ascend pin and close clamp 2,3 (lh) OP1 OP1 OP1 3.1 3.2 3.3 walk to get part Load the part to clamping frame (rh) Ascend pin 15 and close clamp 16,17 (rh) OP2 OP2 6.1 6.2 Close LH slide frame Close Clocking clamp OP2 7.1 Close clamp 4-14 OP1 OP1 6.1 6.2 Close RH slide frame Close Clocking clamp OP1 7.1 Close clamp 18-28 OP2 OP1 8.1 8.1 Load insert jig (rear frame) with hoist Support loading clamping frame OP1 8.2 Close locking clamps (rh) OP2 OP2 8.2 8.3 walk to clamp (lh) Close locking frame (lh) OP1 9.1 Close clamp 1,2 of cross frame (lh) go to Close pneumatic clamps Close pneumatic clamps Close Clamp 1&2 **sequence changed** Get the part (lh) Load the part into clamping frame OP2 9.1 Close clamp 3,4 of cross frame (rh) OP1 OP1 OP1 10.1 10.2 wait till clamping is finished Get the Gun AI Weld GEO spot with AI acc to WI-161-ED-182 OP2 OP2 10.1 10.2 Get the Gun AI Weld GEO spot with AI acc to WI-161-ED-182 OP1 OP1 10.3 10.4 Change the Gun X22 Weld GEO spot with X22 acc to WI-161-ED-18 OP2 OP2 OP2 10.3 10.4 10.5 Change the Gun X22 Weld GEO spot with X22 acc to WI-161-ED-18 restore gun X22 OP1 OP1 OP1 10.5 10.6 10.7 Change the Gun C9 Weld GEO spot with C9 acc to WI-161-ED-182 restore gun C9 OP2 waiting for OP1 OP1 OP2 13.1 13.1 Close clamping frame 6030 HMS to body Close clamping frame 6030 HMS to body OP1 OP2 13.2 13.2 Close locking clamps Close locking clamps OP1 OP2 14.1 14.1 Close Clamp 7,8 Close Clamp 9,29 OP1 OP2 1.1 STEP Get the Gun C9 waiting for OP1 OP1 OP2 1.2 1.2 Weld GEO C9 support OP1 OP1 OP2 OP1 OP2 1.3 Change the Gun X7 waiting for OP1 Weld GEO X7 support OP1 OP1 OP2 OP1 1.5 1.4 1.4 1.6 Change the Gun AI waiting for OP1 Weld GEO AI OP2 OP1 OP2 OP1 1.6 support OP1 **sequence changed** 6.1 Weld 39 respot AI together with OP2 6.1 Weld 39 respot AI together with OP1 OP1 6.2 restore welding gun AI **sequence changed** 2.1 Open all Clamp and pins (lh) OP2 2.1 Open all Clamp and pins (rh) OP1 3.1 Unload insert jig (rear frame) with hoist OP2 OP2 OP2 4.1 Walking to frame 4.2 push rear frame out (HMS) 4.3 push frames out (lh/rh) OP1 OP1 6.1 Get the gun AI (lh) 6.2 Weld 29 spot OP2 OP2 6.1 Get the gun AI (rh) 6.2 Weld 34 spot OP1 OP1 6.3 Change the Gun C9 (lh) 6.4 Weld 23 C9 OP2 OP2 6.3 Change the Gun C9 (rh) 6.4 Weld 17 C9 OP2 OP2 OP1 7.1 Open Pneumatic clamps 7.2 Move the body to next station 7.2 Help the opther ÓP move the body to next statio ... Chuyên ngành: I QUẢN TRỊ KINH DOANH MS: 60 34 01 02 TÊN ĐỀ TÀI: ỨNG DỤNG SƠ ĐỒ DÒNG GIÁ TRỊ ĐỂ CẢI TIẾN NĂNG SUẤT TẠI CHUYỀN LẮP RÁP BODYSHOP DỊNG XE GLC, CƠNG TY TNHH MERCEDES- BENZ VIỆT NAM II NHIỆM... nhận xe sau đặt hàng lên đến 13 tháng) Cải tiến nâng cao suất dây chuyền sản -2- xuất xe GLC vấn đề cấp bách MBV thời điểm tại, chuyền BodyShop Đề tài Ứng dụng sơ đồ dòng giá trị để cải tiến suất. .. -18- CHƯƠNG XÂY DỰNG DÒNG GIÁ TRỊ HIỆN TẠI CHUYỀN BODYSHOP DÒNG XE GLC 3.1 Giới thiệu Công ty TNHH Mercedes- Benz Việt Nam Công ty TNHH Mercedes- Benz Việt Nam (MBV) công ty liên doan tập đoàn