{"id":13467,"date":"2019-09-09T14:05:50","date_gmt":"2019-09-09T12:05:50","guid":{"rendered":"https:\/\/exegens.com\/?p=13467"},"modified":"2020-02-06T18:25:48","modified_gmt":"2020-02-06T16:25:48","slug":"karakuri-kaizen-pasul-inainte-de-industria-4-0","status":"publish","type":"post","link":"https:\/\/exegens.com\/ro\/karakuri-kaizen-pasul-inainte-de-industria-4-0\/","title":{"rendered":"Karakuri Kaizen: Pasul \u00eenainte de Industria 4.0"},"content":{"rendered":"

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1. Karakuri Kaizen: Introducere \u0219i defini\u021bie<\/strong><\/h4>\n

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Cre\u0219terea nivelului de automatizare a fluxurilor de produc\u021bie cu echipamente automate cu costuri reduse este \u0219i va r\u0103m\u00e2ne o provocare pentru a asigura: (1) cre\u0219terea capacit\u0103\u021bii, (2) procese cu echipamente fiabile \u0219i evitarea defectelor, (3) timpi de configurare (set-up) scur\u021bi, (4) ) utilizarea timpilor standard pentru procese \u0219i opera\u021biuni manuale, (5) reducerea ciclului operatorilor prin reducerea activit\u0103\u021bilor pentru func\u021biile de baz\u0103 \u0219i mai ales auxiliare etc.<\/p>\n

Aceast\u0103 automatizare cu costuri reduse se afl\u0103 \u00een sfera de aplicare a Karakuri Kaizen<\/strong>. Karakuri Kaizen<\/strong> este un concept inspirat din Karakuri Puppet. P\u0103pu\u0219ile Karakuri sunt marionete tradi\u021bionale japoneze mecanizate sau automate, realizate ini\u021bial din secolul al XVII-lea p\u00e2n\u0103 \u00een secolul al XIX-lea. Potrivit dic\u021bionarului K\u014djien, defini\u021bia Karakuri este urm\u0103toarea: \u201eKarakuri [means of manipulating] (from the conjunctive form of the verb karakuru) 1. a device made to move through the manipulation of strings. By extension, a device or contrivance. 2. a plot. 3. Synonym of Karakuri ningy\u014d – a doll which achieves movement through the use of a wind-up clockwork mechanism.\u201d<\/em><\/p>\n

Revenind la Karakuri Kaizen<\/strong>, acestea sunt proiecte de \u00eembun\u0103t\u0103\u021bire care se concentreaz\u0103 pe dezvoltarea dispozitivelor mecanice care utilizeaz\u0103 gravita\u021bia pentru a \u00eembun\u0103t\u0103\u021bi sistemul de produc\u021bie (deci nu sunt dispozitive electrice, pneumatice sau hidraulice; nu sunt conectate la calculatoare sau elemente ale paradigmei industriei 4.0).<\/p>\n

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2. Pozi\u021bionarea Karakuri Kaizen \u00een logica \u00eembun\u0103t\u0103\u021birilor<\/strong><\/h4>\n

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Cre\u0219terea nivelului de automatizare este \u00een domeniul \u00eembun\u0103t\u0103\u021birilor, uneori mai radicale\/ sistemice, mai scumpe (Kaikaku<\/strong>, incluz\u00e2nd proiecte pentru implementarea Industriei 4.0), alteori mai radicale \u0219i mai pu\u021bin costisitoare (folosind Methods Design Concept – MDC<\/strong>) sau uneori \u00een zona \u00eembun\u0103t\u0103\u021birilor sistematice \u0219i mai pu\u021bin costisitoare – Karakuri Kaizen<\/strong>.<\/p>\n

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Cre\u0219terea nivelului de automatizare prin Karakuri Kaizen<\/strong> este urm\u0103torul pas dup\u0103 \u00eembun\u0103t\u0103\u021biri sistematice sau proiecte KAIZEN<\/strong> (mici \u00eembun\u0103t\u0103\u021biri incrementale), care sunt adesea axate pe ECRS<\/strong> (mizeaz\u0103 pe eliminare, combinare, reorganizare \u0219i simplificare \u0219i este o metod\u0103 de analiz\u0103 a proceselor de inginerie industrial\u0103 – de asemenea utilizat de MDC).<\/p>\n

Prin urmare, dezvoltarea \u0219i implementarea Karakuri Kaizen<\/strong> este de obicei faza anterioar\u0103 a Industriei 4.0<\/strong>. Dup\u0103 cum se \u0219tie deja, Industria 4.0<\/strong> \u00ee\u0219i propune s\u0103 creasc\u0103 nivelul de automatizare a fluxurilor de produc\u021bie cu echipamente de automatizare care au costuri destul de mari \u0219i implic\u0103 toate tipurile de transform\u0103ri complexe, nu doar mecanice, ca \u00een cazul Karakuri Kaizen<\/strong>.<\/p>\n

Din perspectiva paradigmei de transformare a Manufacturing Cost Policy Deployment (MCPD)<\/strong>, ca \u00een cazul oric\u0103rui proiect Kaizen sau Kaikaku<\/strong> pentru \u00eembun\u0103t\u0103\u021birea costurilor de fabrica\u021bie (MCI)<\/strong>, toate Karakuri Kaizen<\/strong> trebuie s\u0103 fie eficace \u0219i fezabile \u0219i s\u0103 contribuie la realizarea profitului \u021bint\u0103 de produc\u021bie. Cu toate acestea, dincolo de g\u00e2ndirea profitabilit\u0103\u021bii, companiile dezvolt\u0103 deseori proiecte Karakuri Kaizen<\/strong> pentru sus\u021binerea strategiilor eco-industriale.<\/p>\n

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3. Dezvoltarea Karakuri Kaizen<\/strong><\/h4>\n

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Derularea proiectelor Karakuri Kaizen<\/strong> care sunt at\u00e2t eficace c\u00e2t \u0219i eficiente reprezint\u0103 o provocare inginereasc\u0103 \u0219i economic\u0103 pentru multe echipe de profesioni\u0219ti din companii diferite. Voi descrie cum s\u0103 v\u0103 g\u00e2ndi\u021bi la proiectele Karakuri Kaizen<\/strong> pe baza experien\u021bei mele din diferite proiecte coordonate de mine, proiecte care au f\u0103cut parte din transformarea companiilor cu ajutorul MCPD<\/strong>.<\/p>\n

Prin urmare, la fel ca orice proiect kaizen pentru MCI, proiectele Karakuri Kaizen<\/strong> sunt derivate din Critical to Annual Manufacturing Profitability Tree (CAMPT)<\/strong> – Arborele de profitabilitate a produc\u021biei critic\u0103 \u0219i anual\u0103<\/strong> \u0219i \u00ee\u0219i propun s\u0103 proiecteze \u0219i s\u0103 produc\u0103 noi dispozitive inovatoare sau solu\u021bii tehnice\/ mecanice necesare pentru a satisface volumele cererii anumitor produse, pentru a reduce manopera, pentru a elimina c\u0103derile \u0219i defectele. Prin urmare, dup\u0103 stabilirea conexiunii fiec\u0103rui Karakuri Kaizen<\/strong> cu KPI-uri legate de costul pierderilor – losses & waste – (CLW)<\/strong>, se trece la \u00een\u021belegerea temei, mai precis, la stabilirea echipamentului\/ liniei\/ procesului proiectului karakuri kaizen, \u00een\u021beleg\u00e2nd motivul pentru alegerea Karakuri<\/strong> (diagrame, tendin\u021be etc.) \u0219i stabilirea tipului de dispozitiv – intrare \u00een proces, \u00een interiorul procesului sau dup\u0103 proces. Dup\u0103 \u00een\u021belegerea subiectului dezvolt\u0103rii de solu\u021bii tehnice inovatoare integrate \u00eentr-un dispozitiv Karakuri<\/strong>, este necesar\u0103 crearea echipei Karakuri Kaizen<\/strong>. Aceast\u0103 echip\u0103 este din orice zon\u0103 a fabricii (echipa este multifunc\u021bional\u0103 \u0219i con\u021bine speciali\u0219ti \u00een inginerie industrial\u0103, proiectare de instrumente, \u00eentre\u021binere, automatizare etc.). \u00cen primul r\u00e2nd, echipa trebuie s\u0103 \u00een\u021beleag\u0103 obiectivul de baz\u0103 al solu\u021biei tehnice viitoare, parametrii de viitor ai dispozitivului Karakuri<\/strong>, s\u0103 \u00een\u021beleag\u0103 fenomenul necesar a fi abordat (s\u0103 examineze datele actuale \u0219i anterioare pentru procesul de analiz\u0103 a oportunit\u0103\u021bii dezvolt\u0103rii dispozitivului Karakuri<\/strong>) \u0219i timpul necesar pentru finalizarea dispozitivului Karakuri<\/strong> \u0219i apoi se decide exact ce date trebuie colectate \u0219i analizate pentru dezvoltarea dispozitivului Karakuri<\/strong>.<\/p>\n

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\"\" Dup\u0103 ce echipa este deja format\u0103 \u0219i \u00een\u021belege pe deplin obiectivul proiectului Karakuri Kaizen<\/strong>, este stabilit un plan de activitate pentru fiecare membru al echipei, mai precis un plan de activitate detaliat pe membrii echipei (cine va face, ce va face, c\u00e2nd va face?), planul va include, de asemenea, programul reuniunilor echipei, estimarea timpului pentru activit\u0103\u021bile inter-corelate, \u00eentocmirea diagramei activit\u0103\u021bii \u0219i, \u00een acela\u0219i timp, echipa stabile\u0219te \u021bintele detaliate pentru viitorul dispozitiv Karakuri<\/strong>, converg\u00e2nd \u021bintele c\u0103tre \u021bintele anuale \u0219i multianuale pentru CLW<\/strong>, activitate care necesit\u0103 o aten\u021bie deosebit\u0103 \u0219i proiectarea dispozitivului Karakuri<\/strong>.<\/p>\n

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Prin urmare, \u021bintele sunt stabilite pentru:<\/p>\n

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  • nevoile afacerii \u0219i nevoia de productivitate (Cycle Time\/Takt Time pentru dispozitivul Karakuri<\/strong>; eficacitatea dspozitivului Karakuri sau OEE<\/strong> ca % – fiabilitate; timpul de configurare (setup) necesar – flexibilitate; \u021bint\u0103 pentru lucr\u0103tori vs. nivel automatizare);<\/li>\n<\/ul>\n

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    • definirea func\u021biilor de baz\u0103 \u0219i auxiliare ale dispozitivului Karakuri<\/strong>; bazate pe \u00een\u021belegerea principiilor \u0219i parametrilor necesari (c\u00e2t mai detaliate \u0219i scrise de m\u00e2n\u0103): desene ale mecanismelor\/ pieselor\/ distan\u021belor\/ greut\u0103\u021bilor\/ casetelor; descrierea principiilor \u0219i parametrilor de func\u021bionare a timpilor de transfer \u0219i a transferului de greutate; descrierea pa\u0219ilor pentru procesul viitor al dispozitivului Karakuri<\/strong>; lista pieselor care ar trebui implicate \u00een procesele dispozitivului Karakuri<\/strong>; descrie\u021bi lan\u021bul (procesul) cinematic din care va face parte mecanismul viitorului dispozitiv Karakuri<\/strong>, acest lucru va ajuta la determinarea c\u00e2t mai precis\u0103 a condi\u021biilor \u00een care fenomenul trebuie \u00eembun\u0103t\u0103\u021bit;<\/li>\n<\/ul>\n

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      • desenarea dispozitivului Karakuri<\/strong> \u0219i lista materialelor componente – caracteristici \u0219i toleran\u021be pentru ansambluri, subansambluri \u0219i piese; pentru nivelul de calitate al materialelor;<\/li>\n<\/ul>\n

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        • spa\u021biul disponibil la nivelul shop floor<\/strong> – capacitatea \u0219i func\u021bionarea proceselor \u0219i activit\u0103\u021bilor \u00eenvecinate nu trebuie afectate;<\/li>\n<\/ul>\n

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          • toleran\u021bele procesului tehnologic al dispozitivului\u00a0 Karakuri<\/strong>\u00a0(Capability Cmk<\/sub>);<\/li>\n<\/ul>\n

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            • \u021binta ratei de de\u0219euri (scrap rate target<\/strong>) ca % (calitate; dac\u0103 este cazul);<\/li>\n<\/ul>\n

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              • costul investi\u021biei \u0219i costul de func\u021bionare (costurile cu consumabilele): analiza costurilor pe \u00eentreg ciclul de via\u021b\u0103 (LCCA);<\/li>\n<\/ul>\n

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                • estimarea costurilor cu mentenan\u021ba ale viitorului dispozitiv Karakuri <\/strong>(mentenabilitatea); disponibilitate piese de schimb\/ servicii;<\/li>\n<\/ul>\n

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                  • perioada de amortizare a dispozitivului Karakuri<\/strong>;<\/li>\n<\/ul>\n

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                    • timpul de fabrica\u021bie sau timpul de finalizare pentru dispozitivul Karakuri<\/strong>, care trebuie sincronizat cu capacitatea de produc\u021bie \u021bint\u0103 a \u00eentregului sistem \u00een care este integrat dispozitivul Karakuri<\/strong>; teste de mers \u00een gol; compatibilitate cu infrastructura;<\/li>\n<\/ul>\n

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                      • norme de siguran\u021b\u0103 \u00een func\u021bionare – siguran\u021b\u0103 (operabilitate; dac\u0103 este cazul); ergonomie \u0219i igien\u0103 etc.<\/li>\n<\/ul>\n

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                        Dup\u0103 stabilirea \u021bintelor, proiectarea \u0219i listele de materiale, se realizeaz\u0103 analiza make or buy<\/strong> pentru dispozitivul Karakuri<\/strong>. Apoi, dup\u0103 implementarea dispozitivului Karakuri<\/strong>, se verific\u0103 rezultatele \u0219i beneficiile (capacitatea dispozitivului Karakuri; capabilitatea dispozitivului Karakuri<\/strong> \u0219i dac\u0103 sunt necesare modific\u0103ri cu privire la dispozitivul Karakuri<\/strong>). Apoi este elaborat un plan pentru observarea \u0219i colectarea datelor pentru viitorul dispozitiv Karakuri<\/strong>. Fiecare \u021bint\u0103 a parametrilor proiecta\u021bi a dispozitivului Karakuri<\/strong> va fi verificat\u0103 la timp. Profitabilitatea dispozitivului Karakuri<\/strong> este verificat\u0103 dup\u0103 6-12-24 luni. Ultimul pas este standardizarea \u0219i extinderea \u00eembun\u0103t\u0103\u021birii, mai precis: implementarea SOP, extinderea \u00eembun\u0103t\u0103\u021birii la alte procese\/ mecanisme similare; marcarea vizual\u0103 a \u00eembun\u0103t\u0103\u021birii dispozitivului Karakuri<\/strong> la nivelul shop floor \u0219i, desigur, felicitarea echipei.<\/p>\n

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                        4. Rezultate a\u0219teptate<\/strong><\/h4>\n

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                        Prin urmare, rezultatul de baz\u0103 scontat al dispozitivului Karakuri<\/strong> este cre\u0219terea nivelului de automatizare inovatoare a fluxurilor de produc\u021bie cu echipamente de automatizare care au costuri reduse, beneficiind de experien\u021ba acumulat\u0103 la nivelul shop floor pentru a face munca mai u\u0219oar\u0103, mai rapid\u0103 \u0219i de o calitate mai bun\u0103 . \u00centotdeauna \u00een paradigma MCPD<\/strong>, fiecare proiect Karakuri Kaizen<\/strong> sau mijloacele CLW trebuie s\u0103 fie convergente cu \u021bintele CLW \u00een continuare, convergent cu profitul \u021bint\u0103 de produc\u021bie anual \u0219i multianual. Dac\u0103 este posibil, atunci c\u00e2nd este posibil, utilizarea Karakuri Kaizen<\/strong> \u00eencearc\u0103 s\u0103 \u00eent\u00e2rzie aplicarea elementelor din Industria 4.0, care sunt adesea mai scumpe \u0219i mai complexe.<\/p>\n

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                        [\/vc_column_text][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"

                        [vc_row][vc_column width=”1\/1″][vc_column_text] 1. Karakuri Kaizen: Introducere \u0219i defini\u021bie [\/vc_column_text][vc_column_text] Cre\u0219terea nivelului de automatizare a fluxurilor de produc\u021bie cu echipamente automate cu costuri reduse este \u0219i va r\u0103m\u00e2ne o provocare pentru a asigura: (1) cre\u0219terea capacit\u0103\u021bii, (2) procese cu echipamente fiabile \u0219i evitarea defectelor, (3) timpi de configurare (set-up) scur\u021bi, (4) ) utilizarea timpilor standard pentru […]<\/p>\n","protected":false},"author":2,"featured_media":13468,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[214,376],"tags":[358,357,356,280,281,283,371],"class_list":["post-13467","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-mcpd","category-transformare-digitala-profitabila","tag-automatizare","tag-industry-4-0","tag-karakuri-kaizen","tag-manufacturing-cost-policy-deployment","tag-manufacturing-cost-policy-deployment-ro","tag-mcpd-ro","tag-smart-factory"],"yoast_head":"\nKarakuri Kaizen: Pasul \u00eenainte de Industria 4.0 - Exegens\u00ae<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/exegens.com\/ro\/karakuri-kaizen-pasul-inainte-de-industria-4-0\/\" \/>\n<meta property=\"og:locale\" content=\"ro_RO\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Karakuri Kaizen: Pasul \u00eenainte de Industria 4.0 - Exegens\u00ae\" \/>\n<meta property=\"og:description\" content=\"[vc_row][vc_column width=”1\/1″][vc_column_text] 1. 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