2.2 1.5P 08版室外机工序测量时间及标准工时表
工位序号工 步实 测 时 间 x124.872.192.411.784.48Σxi剔除异工步标作业工位标常值后时T（s）人数时ST均值(s)34.192.152.751.564.78453.872.533.001.344.784.853.662.7512.756783.383.503.661.313.886.854.162.7810.065.813.253.625.833.695.536.855.252.826.223.2192.693.043.501.654.341011122.622.932.821.204.565.883.402.759.75123456789101112131415161718取底盘拔机脚护套放流程卡放底盘于工板上贴条形码上减震胶脚压机就位贴条形码于压机底部固定压机接地线压缩机螺母、垫片就位固定螺母冷凝器就位螺钉固定（取螺钉）放中隔板螺钉固定（取螺钉）安装固定阀座板（2钉)固定高压阀（1钉）固定高压阀（1钉)固定低压阀（2钉）拔压机胶塞开高低压阀芯插四通阀组件插毛细管组件插压机排气管焊接吸气管接口焊接排气管接口焊接低压阀接口焊接排气管与四通阀接口焊接冷凝器进气管接口焊接毛细管1焊接毛细管2取电机支架组件就位螺钉固定（取螺钉）拔压机盒盖取放压机环消声棉放压缩机衬片放电气板组件插线取背网就位扎扎带剪扎带2.782.092.851.303.504.815.445.223.723.633.344.782.753.312.722.6711.478.509.9112.254.032.783.471.153.565.415.783.752.312.783.693.811.381.203.403.605.536.933.433.913.072.1512.979.853.783.792.432.872.162.531.501.454.534.346.406.604.623.063.433.162.412.382.4412.7812.3511.21x'x'*1.1545.533.794.3631.602.633.0336.653.053.5116.821.401.6149.754.154.7768.545.716.5743.673.644.1932.182.683.08133.8511.1512.8370.855.906.7936.084.024.6248.183.013.4672.476.046.9541.903.494.0270.155.856.7280.726.737.7459.664.975.7247.453.954.5574.116.187.1037.163.103.5630.852.572.9680.866.747.7567.315.616.4579.946.667.6658.674.895.6255.764.655.3458.754.905.6356.194.685.3857.954.835.55AmT/m112.52111.3417.27112.83111.41110.40110.74113.45111.65114.27114.11110.97111.026.066.875.756.256.385.665.503.785.563.814.784.753.403.462.912.812.662.532.713.092.756.566.376.286.946.787.974.402.913.023.223.232.953.843.564.355.475.945.596.106.195.357.975.936.546.406.345.816.665.365.154.814.694.884.584.738.257.937.402.532.632.462.556.635.315.796.516.076.095.593.062.713.503.153.092.883.162.222.813.002.722.562.552.759.367.167.887.256.066.724.535.565.785.565.725.395.595.597.435.846.966.797.726.666.094.254.974.844.874.654.534.974.564.284.724.474.684.694.664.265.014.884.674.854.734.764.364.574.684.824.734.614.964.234.884.844.764.794.825.032.302.222.162.202.162.272.163.453.343.253.303.253.413.253.814.004.784.434.974.264.154.154.323.284.193.914.683.941.561.651.751.541.451.641.6710.0310.4111.0611.9111.7212.318.561.901.861.851.921.971.561.753.913.253.783.743.653.253.564.373.944.374.314.534.784.325.344.463.534.454.784.094.1210.0510.7110.9811.8212.7513.719.842.001.781.981.931.982.002.105.226.445.445.473.633.663.994.113.153.193.543.125.464.905.166.124.063.474.083.877.135.157.036.327.007.696.846.695.064.935.065.162.722.662.722.786.286.506.616.513.083.103.093.132.432.292.532.562.436.936.226.226.416.135.625.735.575.455.756.616.236.516.436.675.914.885.004.625.184.974.434.905.194.214.915.784.884.905.124.674.574.825.124.284.984.734.964.795.141.822.292.062.082.1725.912.162.743.433.103.113.2638.873.243.974.054.174.094.2850.964.253.994.164.284.514.2049.614.131.521.431.411.581.7018.901.5815.0013.9311.4610.3110.85137.5511.461.911.871.861.741.7221.911.833.973.873.953.993.9444.863.744.514.364.374.404.2952.554.384.414.324.224.124.1752.014.3313.989.4814.8210.6811.61140.4311.702.48111.763.724.884.75111.451.8113.18113.182.104.30111.435.044.9813.46210.361.921.792.002.012.2123.681.972.27
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1920212223241.912.311.812.001.972.032.131.871.972.392.412.3225.122.092.41固定压机端子盖5.546.256.815.535.754.985.636.075.254.254.694.7565.505.466.284.756.345.004.814.724.785.605.566.576.165.735.7565.775.486.30固定四通阀线圈挂电气板组件于中隔板上1.571.571.671.381.391.471.521.531.341.411.271.3217.441.451.67固定电气板螺钉（取螺钉2）9.5410.629.507.197.537.567.326.286.786.818.108.2195.447.959.15固定地线于电气板（1钉）10.7215.728.4812.0412.3211.2212.879.659.5311.4010.9811.23136.1611.3513.05插线（电机线3四通阀线圈2）15.3715.5113.5713.8614.8814.2914.0714.0515.4213.5514.3914.59167.2013.9316.02理线、扎线10.8411.2512.0111.9412.7811.1310.6911.1611.6211.2811.4210.58136.7011.3913.10插线0.670.590.660.640.660.670.700.640.600.676.535.915.355.346.215.815.805.565.755.432.442.692.662.842.462.912.962.842.932.4213.7811.069.7510.4312.4712.4117.009.4712.6612.067.417.757.037.476.977.196.496.937.817.005.664.945.286.064.344.474.874.655.284.9412.1312.5012.7214.7213.5613.8213.3113.7812.639.5013.3112.4311.6912.4712.6511.1512.1611.2212.4712.562.502.162.752.302.923.002.872.542.362.458.6510.317.259.789.8810.258.9110.2810.2510.298.976.535.537.887.858.037.427.616.957.357.888.1611.319.7512.099.238.456.667.126.816.037.255.165.310.675.272.7512.147.624.9712.8912.222.7410.2118.6817.9719.15113.05116.02剪扎带风叶就位25螺母固定26安装快速接头27接管开抽真空机、上接头113.860.747.890.660.765.6168.575.716.5719.712.8232.722.733.1412.56145.7912.1513.97113.977.2186.887.248.33114.165.4260.885.075.8312.97154.5312.8814.81114.8112.24146.5712.2114.05114.0514.108.4010.7410.6328拆管、注氟29封口30包消音棉整管31首检漏32内检包阻尼胶33贴电机支架垫棉3.194.033.164.44贴中隔板密封条（2条）9.128.138.257.22取放右侧板（与电气板固定）3.032.443.573.37349.889.817.759.91螺钉固定（取螺钉）35右侧板与阀座板固定（5钉)12.185.8836前面板定位37前面板与底盘固定（3钉）11.12383940414243前面板与电机支架组件固定（2）6.28转向1.25左立柱装配（2钉）10.10右侧板与冷凝器固定（2钉）6.88定位顶盖板10.63顶盖板装配（3钉)12.68安检8.223.09商检上电8.061.034.211.443.504.049.758.474.124.163.288.538.159.504.063.253.943.893.563.273.542.3440.263.363.8611.287.329.599.569.037.227.599.16108.109.0110.3614.4012.8513.8710.9112.199.5711.0912.9410.5911.9412.06144.5912.0513.866.138.697.626.666.638.817.256.786.447.117.1285.127.098.1611.0012.009.6616.0014.2810.949.2511.7512.5611.8511.23141.6411.8013.575.935.755.595.875.535.224.595.255.355.625.7566.735.566.391.351.471.251.351.151.451.251.301.221.151.2015.391.281.477.936.878.258.638.917.156.789.346.448.058.1096.558.059.258.539.1910.1811.064.006.475.885.285.194.478.2210.4710.1511.289.1015.6812.0013.7810.5911.7516.9311.9410.5613.3512.392.883.192.872.753.357.977.227.820.991.030.984.134.254.611.681.341.385.878.0013.909.683.257.520.894.291.535.677.007.439.1910.7512.7510.5511.973.182.977.627.561.001.024.214.421.411.382.3130.902.582.96110.12116.189.6811.137.206.3187.637.308.40110.239.647.128.649.58112.089.3410.7416.315.666.417.656.1376.506.387.333.563.653.873.283.5144.253.694.2429.597.848.857.858.10101.138.439.96114.22113.8618.16113.5717.87111119.257.0410.9714.2513.4713.615.0344插管开机45商检收氟（高压）46收氟（低压）拆管7.917.568.570.750.981.024.474.784.631.721.281.313.443.474.284.039.288.8110.2510.623.454.069.219.786.126.0573.416.127.049.389.50112.549.3810.9712.4512.17148.6812.3914.259.3514.58140.5811.7213.472.882.7537.163.103.568.107.2293.137.768.9211.001.0511.740.981.134.184.2652.444.375.03147卸快速接头48末检漏
3.693.443.883.694.784.004.404.079.6510.3411.8710.3410.508.659.8410.344
1.281.5917.341.451.663.223.873.553.9443.143.604.13110.674.094.404.284.4850.914.244.8813.9710.0610.3510.31123.9410.3311.88111.888.599.0710.248.52114.879.5711.01111.01
49安装高、低压阀帽50安装高、低压钠子51贴铭牌放3联，贴条形码大抽手就位52螺钉固定（取螺钉）放连接管53贴商标54固定前网（4钉)5556贴档案联贴纤维胶放附件清洁机身57总检抬机放纸底托58放纸板套胶袋59固定连接管10.6910.129.1511.039.786.258.389.436.636.159.108.79105.508.7910.1110.8810.358.728.6310.7510.4410.2810.258.069.689.859.91117.809.8211.294.864.474.214.504.974.444.504.624.924.854.474.8455.654.645.336.817.257.847.667.157.447.758.668.256.126.358.2589.537.468.582.972.752.372.752.152.132.192.282.322.281.992.0328.212.352.702.532.352.752.342.602.951.793.502.103.502.782.3531.542.633.021.691.691.751.281.751.631.501.661.531.371.721.5319.101.591.837.635.377.225.824.656.383.683.974.153.415.566.1063.945.336.1312.4412.4410.829.9410.6212.9411.6210.9410.6813.0412.0012.70140.1811.6813.434.604.474.914.254.554.414.814.754.654.964.844.9456.144.685.383.504.003.854.104.304.603.983.784.504.703.873.9949.174.104.711.441.281.781.931.501.971.851.381.431.691.561.5019.311.611.8518.8516.0320.0018.2520.7521.9721.8718.0721.5020.7520.1219.78237.9419.8322.806.845.726.165.126.545.236.516.575.816.635.726.6373.486.127.045.425.385.005.585.185.144.504.806.005.505.325.3263.145.266.054.744.525.625.564.444.944.445.684.765.505.564.8860.645.055.813.242.603.583.023.443.903.123.503.003.003.803.2439.443.293.787.446.307.826.888.308.386.867.267.588.127.447.8290.207.528.646.725.128.329.136.976.287.477.947.877.527.357.5688.257.358.46110.11111.29113.9117.5616.13113.43110.09212.3317.04212.1418.4660套纸箱贴条码装顶盖泡沫61打封箱钉62抬机下线3.222.533.543.633.253.653.833.603.813.183.093.3140.643.393.89110.455.976.195.675.535.475.034.856.755.375.876.005.6868.385.706.5517.3817.1417.8017.7016.7617.1817.8018.0617.2017.8017.6617.84210.3217.5320.16213.336.505.926.005.705.5867.845.655.765.745.964.864.825.566.145.8011.6212.8217.5016.4410.6813.9813.3813.3211.8217.6213.9713.87167.0213.9216.0128.00
2.3 1.5P 08版室外机的装配生产线线平衡率
根据以上数据，可以得出1.5P 08版机型的装配生产线线平衡率：
平衡率=ST总/（瓶颈时间*N）*100% （2.4） ST总=∑（各工序标准时间*各工序人数）=765.16s 瓶颈工序为:插线(电机线3端口、四通阀线圈2端口) 瓶颈时间=16.02s 作业总人数N=68 平衡率=70.24% 工位数=62
日产能=10h*3600/16.02=2247台
由现有的平衡率可知，要想达到现在工厂平衡率接近85%的目标，还有很大的改善空间。这只是志高一款机型的总装线时间分析，实际上在志高很多机型都因为诸多原因
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存在生产线不平衡的现象。仅仅通过加班来提高产能都是不可取的，不仅使员工作业疲劳，公司也不能获得更大的效益，所以目前的志高正在着手推进精益生产，改善各种机型的装配生产线线平衡率。
2.4 总装线当前线平衡分析图
图2.2 改善前线平衡分析图
由图中可以看到，各工序的时间参差不齐，和瓶颈工序有较大的落差，通过精益生产对装配线进行改善是很有必要的。瓶颈工序插线(电机线3端口、四通阀线圈2端口)16.02s明显高出整体水平，制约着整个生产线，在平衡分析时，要尽量先从瓶颈着手，消除瓶颈。
2.5 室外机生产线中存在的问题
2.5.1 IE人员的测时并没有最佳化
因为实习的岗位是工艺员，我并没有过多的参与IE的测时，只参与了这款机型的测时。在测时时，我发现我们测量的结果比较理想化，只是将规定的宽放和评比列入计算，并没有考虑工人实际操作过程中可能遇到的突发情况。对于个别工人在操作时由于失误等原因造成的异常值过于偏离，我们采取的措施是直接去掉，重新来测，在测量出的结果中，实际上已经不存在偏差较大的异常值，测时的结果比较理想化。
2.5.2 工序时间相差较大
在生产旺季，工序时间的不均衡，会大大影响产能的提高。瓶颈工序的存在，使得一些岗位的空闲时间比较多，等待过长。
2.5.3 因为不良品的返工造成的尾数影响整体效率
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在生产过程中，经常会有因各种各样的质量问题而出现的不良品，不良在装配时因为本身的不合格（尺寸不对、预焊组件的偏差过大等）而导致时间拖延，而且在确定被返工之后，返工回来的不良品要重新上线。在上线时还要使用相同的人力，有时在返工的不良品拿到线时已经切换到其他的产品，这样对这些尾数有些零部件还要重新切换。这些返工的尾数不仅造成浪费，还影响了流水线的整体效率。
2.5.4 员工的积极性不高
流水线生产的方式，使得员工每天都重复着同一个动作，长时间的重复使得员工本就觉得枯燥。而且在生产旺季，每天都要加班，很多员工都不愿意去加班，这样就导致了员工的厌烦心理，情绪不高。员工的积极性不高势必会影响产能，使得整体效率降低，影响装配线的平衡率。
2.5.5 生产旺季新员工大量涌入
快进入夏季的3、4月份，因为大量的销售订单使得空调的生产进入旺季，淡旺季对员工的需求量明显不同。旺季大量新员工的涌入，势必会给生产带来极大的影响，影响质量的同时也会影响装配线的进度。虽然对新员工也做过相应的培训，但是对于一些关键岗位，新员工的操作毕竟没有老员工纯熟。
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