NewContinuousFlow單件流.ppt

,The flow of products at a steady, predictable and consistent velocity through production operations. 產(chǎn)品按穩(wěn)定，可預(yù)測(cè)和一致的速率通過(guò)生產(chǎn)操作,Vs 比較,The ideal is one-piece flow at and between processes. 理想的方法是在工序間實(shí)現(xiàn)單件流,Continuous Flow Production（連續(xù)流動(dòng)生產(chǎn)）,Continuous Flow(連續(xù)流動(dòng)）,JIT Production Characteristics(準(zhǔn)時(shí)化生產(chǎn)的特性）,Work Statement Analysis（工作狀況分析） Equipment in order of processes（設(shè)備按工藝排列） Small and inexpensive equipment（用小而經(jīng)濟(jì)的設(shè)備） One-piece flow production（單件流生產(chǎn)) Production in Product Cell (or Fishbone “Rib”) (再獨(dú)立單元內(nèi)生產(chǎn)） Multi-process-handling workers（掌握多種技能的工人） Standing operations, moving while working(站立工作，隨著工作移動(dòng)） Ergonomically-correct operations（符合人體工程學(xué)-正確的操作） Production paced to takt time (按照節(jié)拍時(shí)間進(jìn)行生產(chǎn)） Balance Operations in the cell,“Standard operations” defined and implemented（在獨(dú)立單元內(nèi)平衡作業(yè)且“標(biāo)準(zhǔn)作業(yè)方式”被定義和實(shí)施） Level Production（均衡生產(chǎn)）,(Usually done by Industrial Engineering with Factory Management)（通常由工業(yè)工程師完成） Category 1 60% of production.（類別1 60%的生產(chǎn)） Category 2 next 25% of production.（類別2 隨后的25%的生產(chǎn)） Category 3 last 15% of production（類別3 最后的15%的生產(chǎn)）,Example （例如） :,Product / Quantity (PQ) Analysis （產(chǎn)品/數(shù)量分析）,Work Statement Analysis （工作狀況分析）,Continuous Flow (連續(xù)流動(dòng)）,Process Route Analysis (工藝路線分析）,Based on usage: Determine standard routings.（決定標(biāo)準(zhǔn)路線） Group part numbers with similar routings.（將相識(shí)路線的產(chǎn)品號(hào)歸類） Determine possible cells for part number groupings.（由產(chǎn)品號(hào)歸類決定可能的獨(dú)立生產(chǎn)單元） Evaluate capacity, bottlenecks, and equipment which must be shared.（評(píng)估產(chǎn)能，瓶頸和必須共享的設(shè)備）,Work Statement Analysis（工作狀況分析）,Continuous Flow (連續(xù)流動(dòng)）,13,16,17,17 _,5,8,6,6,6,5,8,Locate Equipment in Order of Processes（按照工藝次序放置設(shè)備）,Continuous Flow (連續(xù)流動(dòng)）,Things to consider: （需考慮的事情） Choose small, dedicated machines.（選擇小而專用的機(jī)器） Install casters on equipment for flexibility (ability to change layout daily if needed).（為了靈活，為設(shè)備裝上輪腳） Minimize distance between operations.（減少工序間的距離） Avoid large, fast equipment in a cell (only fast enough).（盡量避免在使用大而快的設(shè)備） Store materials, supplies, and tooling at point of use.（將材料，供應(yīng)和工裝放在要使用的地方）,Small & Inexpensive Equipment（用小而經(jīng)濟(jì)的設(shè)備）,Continuous Flow (連續(xù)流動(dòng)）,Takt time = 75 sec 節(jié)拍時(shí)間=75秒,Identify and eliminate wastes and constraints which limit one-piece flow.（識(shí)別并消除影響單件流生產(chǎn)的浪費(fèi)和限制） “One-less-at-a-time” drives you to one-piece flow.（以每次減少一件的方式來(lái)推動(dòng)單件流）,Strive to Produce and Move One Piece at a Time（爭(zhēng)取做到單件流生產(chǎn)）,Continuous Flow (連續(xù)流動(dòng)）,Product requires three processes that take one minute each（產(chǎn)品需經(jīng)過(guò)三個(gè)工序，每個(gè)工序需用一分鐘） Processing first batch in batches of 10 requires 30 minutes（如以10個(gè)為一批生產(chǎn)用時(shí)30分鐘） Processing first “batch” one-at-a-time requires only 12 minutes（如以單件流進(jìn)行生產(chǎn)僅需12分鐘）,Traditional Batch Processing （傳統(tǒng)的成批加工）,10 minutes,10 minutes,10 minutes,Total Batch A processing time: 30 minutes（所有A 批次的加工時(shí)間為30分鐘）,Continuous Flow Processing （連續(xù)流動(dòng)的加工方法）,Total Batch A processing time: 12 minutes （所有A 批次的加工時(shí)間為12分鐘）Only 3 minutes for 1st part（僅3分鐘一個(gè)）,1,2,3 4 5 6 7 8 9 10 11 12,3,Continuous Flow (連續(xù)流動(dòng)）,Strive to Produce and Move One Piece at a Time（爭(zhēng)取做到單件流生產(chǎn)）,Out（出）,In（進(jìn)）,One-Piece Flow（單件流）,One-Piece Flow（單件流）,Batch Process 成批加工 (Requires a Lot Size of 120)批量為120,Batch Conveyance（批量運(yùn)輸）,Maximum Total Inventory of 120 at this location （此處的最大庫(kù)存量為120）,Ready,Processed,Dealing With Monuments（針對(duì)超大裝備）,Continuous Flow (連續(xù)流動(dòng)）,Enable people to leave machine and move to next process.使人能離開(kāi)機(jī)器并移動(dòng)到下一個(gè)工序） Apply autonomation (automation with a human touch).（應(yīng)用自動(dòng)化） Install devices to stop machine when finished or problem occurs (Jidoka). （安裝當(dāng)加工完成或出現(xiàn)問(wèn)題時(shí)能停止的裝置） Install mistake-proofing devices.（安裝防錯(cuò)裝置） Eliminate watching machines and waiting.（消除看管機(jī)器和等待的時(shí)間) Perform another value-adding task while machine is working.(機(jī)器工作時(shí)做另一項(xiàng)有價(jià)值的工作）,After（現(xiàn)在）,Uh-oh, theres a problem. Id better stop and signal someone to come here.（有問(wèn)題，我應(yīng)該找人來(lái)看一下。）,Move While Working: Separate People from Machines （工作時(shí)移動(dòng)：將人從機(jī)器中解放出來(lái)）,Continuous Flow (連續(xù)流動(dòng)）,What skills are needed to operate the cell? （操作獨(dú)立工作區(qū)所需的技能？） Who performs what tasks? （誰(shuí)來(lái)完成任務(wù)？） How will we work together in the cell? （在獨(dú)立工作區(qū)，我們?nèi)绾螀f(xié)同工作？） Design for mutual assistance and use defined “passing zones.”（以互助的方式設(shè)計(jì)）,Multi-Process-Handling Workers （掌握多種技能的工人）,Continuous Flow (連續(xù)流動(dòng)）,John Mary Frank,3 3 3 3,2 3 3,5 3 3,6 3 3,4 3 3 3,1 3 3,Process Skills（工序所需技能）,People（人）,7 3 3 3,Ask: “How fast should we produce?”（問(wèn)：“我們生產(chǎn)需多快？”） Plan production rate and material flows to match real consumption by the customer (may include some planned stock of finished goods).（生產(chǎn)速率和材料的流動(dòng)應(yīng)與顧客的實(shí)際需求相匹配（可以包含一些計(jì)劃內(nèi)的成品庫(kù)存） Match production rates and speeds to consumption of finished goods. （使生產(chǎn)速率與成品消耗相一致） Required production rate is the Takt time.（所需要的生產(chǎn)速率即節(jié)拍）,Plan,Customer Consumption（顧客消費(fèi)）,A Parts 400,B Parts 800,C Parts 600,D Parts 200,Produce Paced to Takt Time (按照節(jié)拍時(shí)間進(jìn)行生產(chǎn)）,Continuous Flow (連續(xù)流動(dòng)）,14 12 10 8 6 4 2 0,Takt time = 10,A,B,C,D,E,F,G,H,1,2,3,4,5,Operator,Problem! Operator cant make Takt time.,Balance Operations,Continuous Flow (連續(xù)流動(dòng)）,14 12 10 8 6 4 2 0,Takt time = 10,1,2,3,4,5,Operator（操作人員）,One solution: Redistribute the work. （一種方案：重新分配工作）,WASTE of Time (people waiting)浪費(fèi)：等待時(shí)間,Line Balance （平衡生產(chǎn)線）,Continuous Flow (連續(xù)流動(dòng)）,14 12 10 8 6 4 2 0,Takt time = 10,1,2,3,4,5,Operator,Another solution: If we can split up E, we can free up an operator and eliminate a lot of waste.（另一種方案：如可能拆分E,我們可以解放出一個(gè)操作人員并消除很多浪費(fèi)）,OPT = operator cycle time/takt time,Line Balance（平衡生產(chǎn)線）,Continuous Flow (連續(xù)流動(dòng)）,JIT Production Characteristics,Work Statement Analysis （工作狀況分析） Equipment in order of processes （設(shè)備按工藝排列） Small and inexpensive equipment （用小而經(jīng)濟(jì)的設(shè)備） One-piece flow production （單件流生產(chǎn)) “U”-shaped work flow, counterclockwise（ “U”型逆時(shí)針布置工作流） Multi-process-handling workers （掌握多種技能的工人） Standing operations, moving while working(站立工作，隨著工作移動(dòng)） Ergonomically-correct operations （符合人體工程學(xué)-正確的操作） Production paced to takt time (按照節(jié)拍時(shí)間進(jìn)行生產(chǎn)） Balance Operations in the cell,“Standard operations” defined and implemented（在獨(dú)立單元內(nèi)平衡作業(yè)且“標(biāo)準(zhǔn)作業(yè)方式”被定義和實(shí)施