JIT推式與拉式系統(tǒng)

1、及時(shí)化生產(chǎn)系統(tǒng)1及時(shí)化(just in time，JIT)概述提出者：豐田汽車副社長，大野耐一(Taiichi Ohno)。意義將需要的物品在必須的時(shí)間供應(yīng)必須的品質(zhì)與數(shù)量到需要的地點(diǎn)。目的消除混亂使系統(tǒng)彈性化降低籌置與前置時(shí)間存量最小化消除浪費(fèi)及時(shí)化生產(chǎn)系統(tǒng)2JIT目標(biāo)和建築架構(gòu)的歸納 產(chǎn)品設(shè)計(jì)流程設(shè)計(jì)人員因素製造規(guī)劃避免中斷使系統(tǒng)有彈性排除浪費(fèi)平衡迅速的流程最終目標(biāo)支援目標(biāo)建築架構(gòu)及時(shí)化生產(chǎn)系統(tǒng)3常見的資源浪費(fèi)1超額生產(chǎn)(overproduction)等候時(shí)間(waiting time)不必要的運(yùn)送(unnecessary transporting)存貨(inventory)加工浪費(fèi)(pr

2、ocessing waste)不必要的生產(chǎn)步驟產(chǎn)出瑕疵品及時(shí)化生產(chǎn)系統(tǒng)4常見的資源浪費(fèi)2無效的工作方法(inefficient work method)不佳的佈置和物料搬運(yùn)模式，增加在製品存貨產(chǎn)品不良再製成本消費(fèi)者不滿意造成銷售損失及時(shí)化生產(chǎn)系統(tǒng)5Waste in Operations及時(shí)化生產(chǎn)系統(tǒng)6Waste in Operations及時(shí)化生產(chǎn)系統(tǒng)7Waste in Operations及時(shí)化生產(chǎn)系統(tǒng)8The Principles of the TOYOTA Production System (TPS)1All work must be completely specified as t

3、o content, sequence, timing, and outcome.Every customer-supplier connection must be direct, unambiguously specifying the people involved, the form and quantity of the services or goods to be provided, the way the requests are made by each customer, and the expected time in which the requests will be

4、 met.及時(shí)化生產(chǎn)系統(tǒng)9The Principles of the TOYOTA Production System (TPS)2The pathway for every service and product must be simple and direct.Any improvement to the system must be made in accordance with the scientific method, under the guidance of a teacher, at the lowest possible organizational level.及時(shí)化生

5、產(chǎn)系統(tǒng)10Basic Elements of JIT1標(biāo)準(zhǔn)的零件(產(chǎn)品設(shè)計(jì))模組化設(shè)計(jì)(產(chǎn)品設(shè)計(jì))高產(chǎn)能的系統(tǒng)(產(chǎn)品設(shè)計(jì))可同時(shí)生產(chǎn)(產(chǎn)品設(shè)計(jì))將員工視為資產(chǎn)(人員/組織的要素)訓(xùn)練員工，使其變成多能工(人員/組織的要素)持續(xù)改善(人員/組織的要素)成本會(huì)計(jì)(人員/組織的要素)領(lǐng)導(dǎo)與專案管理(人員/組織的要素)及時(shí)化生產(chǎn)系統(tǒng)11Basic Elements of JIT2Cellular layouts (製程設(shè)計(jì)Pull production system(製造規(guī)劃與控制)Flexible resources (製程設(shè)計(jì))Kanban production control(製造規(guī)劃與控制)S

6、mall-lot production(製程設(shè)計(jì))Quick setups (製程設(shè)計(jì))Uniform production levels (製造規(guī)劃與控制)Quality at the source(製程設(shè)計(jì))Total productive maintenance (製造規(guī)劃與控制)Supplier networks(製造規(guī)劃與控制)及時(shí)化生產(chǎn)系統(tǒng)12Flexible ResourcesMultifunctional workers (多能工)Perform more than one jobGeneral purpose machines (通用設(shè)備)Perform several ba

7、sic functionsStudy operators & improve operations及時(shí)化生產(chǎn)系統(tǒng)13Cellular LayoutsGroup dissimilar machines in manufacturing cell to produce family of partsWork flows in one direction through cellCycle time adjusted by changing worker paths及時(shí)化生產(chǎn)系統(tǒng)14Manufacturing Cell with Worker RoutesWorker 1Worker 2Worker

8、 3Cell 1及時(shí)化生產(chǎn)系統(tǒng)15Worker Routes Lengthened as Volume DecreasesCell 5Worker 2Cell 2Worker 1Cell 1Worker 3Cell 3Cell 4及時(shí)化生產(chǎn)系統(tǒng)16推式與拉式系統(tǒng)推式系統(tǒng)(push system)(例如，MPR)當(dāng)工作在某工作站完成時(shí)，產(chǎn)出就被推往下一站。拉式系統(tǒng)(pull system)(例如，JIT)工作移動(dòng)的控制落於下一站;每一工作站從前一站拉拔所需產(chǎn)出。及時(shí)化生產(chǎn)系統(tǒng)17Kanban Production Control System(看板生產(chǎn)管制系統(tǒng))Kanban card indic

9、ates standard quantity of productionDerived from two-bin inventory system(雙倉制)Kanban maintains discipline of pull productionProduction kanban(生產(chǎn)看板) authorizes productionWithdrawal kanban(提領(lǐng)看板) authorizes movement of goods及時(shí)化生產(chǎn)系統(tǒng)18A Sample Kanban及時(shí)化生產(chǎn)系統(tǒng)19The Origin of Kanbana) Two-bin inventory syste

10、mb) Kanban inventory systemReorder cardBin 1Bin 2Q - RKanbanRRQ = order quantityR = reorder point - demand during lead time及時(shí)化生產(chǎn)系統(tǒng)20Types of Kanbans Dual kanbans及時(shí)化生產(chǎn)系統(tǒng)21Single-Card Kanban SystemReceiving postKanban card for product 1Kanban card for product 2Fabrication cellO1O2O3O2Storage areaEmpty

11、 containersFull containersAssembly line 1Assembly line 2及時(shí)化生產(chǎn)系統(tǒng)22Storage areaEmpty containersFull containersSingle-Card Kanban SystemReceiving postKanban card for product 1Kanban card for product 2Fabrication cellO1O2O3O2Assembly line 1Assembly line 2及時(shí)化生產(chǎn)系統(tǒng)23Storage areaEmpty containersFull contain

12、ersSingle-Card Kanban SystemReceiving postKanban card for product 1Kanban card for product 2Fabrication cellO1O2O3O2Assembly line 1Assembly line 2及時(shí)化生產(chǎn)系統(tǒng)24Storage areaEmpty containersFull containersSingle-Card Kanban SystemReceiving postKanban card for product 1Kanban card for product 2Fabrication c

13、ellO1O2O3O2Assembly line 1Assembly line 2及時(shí)化生產(chǎn)系統(tǒng)25Storage areaEmpty containersFull containersSingle-Card Kanban SystemReceiving postKanban card for product 1Kanban card for product 2Fabrication cellO1O2O3O2Assembly line 1Assembly line 2及時(shí)化生產(chǎn)系統(tǒng)26Storage areaEmpty containersFull containersSingle-Card

14、Kanban SystemReceiving postKanban card for product 1Kanban card for product 2Fabrication cellO1O2O3O2Assembly line 1Assembly line 2及時(shí)化生產(chǎn)系統(tǒng)27Storage areaEmpty containersFull containersSingle-Card Kanban SystemReceiving postKanban card for product 1Kanban card for product 2Fabrication cellO1O2O3O2Asse

15、mbly line 1Assembly line 2及時(shí)化生產(chǎn)系統(tǒng)28看板系統(tǒng) single kanban及時(shí)化生產(chǎn)系統(tǒng)29Dual kanban vs. single kanbanDual kanbanIs used when material is not necessarily moving between two consecutive processes, or when there is more than one input to a process and the inputs are dispersed throughout the facility.Single kanba

16、nIs used when the processes are tightly linked.及時(shí)化生產(chǎn)系統(tǒng)30Types of KanbansKanban SquareMarked area designed to hold itemsSignal KanbanTriangular kanban used to signal production at the previous workstationMaterial KanbanUsed to order material in advance of a processSupplier KanbansRotate between the f

17、actory and suppliers及時(shí)化生產(chǎn)系統(tǒng)31Types of Kanbans kanban square and kanban racks及時(shí)化生產(chǎn)系統(tǒng)32Types of Kanbans signal kanbans及時(shí)化生產(chǎn)系統(tǒng)33看板管理系統(tǒng)之規(guī)則不要把不良品交給後製程。由後製程到前製程來領(lǐng)取零件。前製程僅生產(chǎn)將被後製程領(lǐng)用去的數(shù)量。生產(chǎn)必須平衡?？窗逯蛔鰹槲⒄{(diào)整的手段，其張數(shù)必須減到最少。製程必須安定化、合理化。及時(shí)化生產(chǎn)系統(tǒng)34Single-Card Kanban SystemKANBANPart Number:1234567ZLocation:Aisle 5Bin 4

18、7Lot Quantity:6Supplier:WS 83Customer:WS 116Each container must have a cardAssembly always withdraws from fabrication (pull system)Containers cannot be moved without a kanbanContainers should contain the same number of partsOnly good parts are passed alongProduction should not exceed authorization及時(shí)

19、化生產(chǎn)系統(tǒng)35看板(容器)數(shù)量之決定1K=容器數(shù)量。d=工作中心之計(jì)劃使用率(預(yù)期每日需求) 。p=每箱容器零件之平均加工時(shí)間。W=在生產(chǎn)過程中之平均等候時(shí)間，加上每箱物料的搬運(yùn)時(shí)間。C=標(biāo)準(zhǔn)容器之零件容量。X=政策變數(shù)。反應(yīng)生產(chǎn)系統(tǒng)的效率(10%以內(nèi))及時(shí)化生產(chǎn)系統(tǒng)36看板(容器)數(shù)量之決定2k=在前置時(shí)間期間的平均需求+安全庫存每箱內(nèi)的單位數(shù)量=d(w+p)(1+x)c及時(shí)化生產(chǎn)系統(tǒng)37看板(容器)數(shù)量之決定3whereN = number of kanbans or containersd = average demand over some time periodL = lead ti

20、me to replenish an orderS = safety stockC = container sizeNo. of Kanbans =average demand during lead time + safety stockcontainer sizeN =dL + SC及時(shí)化生產(chǎn)系統(tǒng)38容器數(shù)量決定範(fàn)例某汽車零件公司生產(chǎn)4輪傳動(dòng)車的方向盤及暫停系統(tǒng)中的搖桿手臂組合。一般1箱零件在製造週期中需要0.02天的加工及0.08天的物料處理和等候時(shí)間。零件每日的需求為2000個(gè)單位。管理部門認(rèn)為搖桿手臂組合的需求不確定，所以其安全庫存為需求量的10%。若每箱內(nèi)各有22個(gè)零件，則應(yīng)授權(quán)的

21、箱子數(shù)量為多少。及時(shí)化生產(chǎn)系統(tǒng)39小批量 (Small-lot production) 的效益降低在製品存貨減少因品質(zhì)發(fā)生問題時(shí)所產(chǎn)生的檢驗(yàn)和重加工成本減少儲(chǔ)存空間問題更容易顯現(xiàn)增加生產(chǎn)彈性易於進(jìn)行作業(yè)平衡及時(shí)化生產(chǎn)系統(tǒng)40Inventory Hides Problems及時(shí)化生產(chǎn)系統(tǒng)41Lower Levels of Inventory Expose Problems及時(shí)化生產(chǎn)系統(tǒng)42Components of Lead Time(前置時(shí)間的元素)Processing timeReduce number of items or improve efficiencyMove timeReduc

22、e distances, simplify movements, standardize routingsWaiting timeBetter scheduling, sufficient capacitySetup timeGenerally the biggest bottleneck及時(shí)化生產(chǎn)系統(tǒng)43快速籌置 (Quick setups)Single-digit setupThe goal of having a setup time of less than 10 minutes.快速換模又稱一分鐘換模術(shù) (single-minute exchange of dies, SMED)及時(shí)

23、化生產(chǎn)系統(tǒng)44快速籌置的實(shí)施步驟1. 將換模作業(yè)流程劃分外部整備作業(yè)與內(nèi)部整備作業(yè)。2. 儘可能把內(nèi)部整備作業(yè)改變成外部整備作業(yè)。3. 消除內(nèi)部整備所需的調(diào)整作業(yè)。4. 外部整備作業(yè)的標(biāo)準(zhǔn)化。5. 推動(dòng)平行作業(yè)。6. 利用機(jī)械提高換模效率。7. 其他管理部門的充分配合。及時(shí)化生產(chǎn)系統(tǒng)45Common Techniques for Reducing Setup Time1及時(shí)化生產(chǎn)系統(tǒng)46Common Techniques for Reducing Setup Time2及時(shí)化生產(chǎn)系統(tǒng)47Common Techniques for Reducing Setup Time3及時(shí)化生產(chǎn)系統(tǒng)48平準(zhǔn)化

24、生產(chǎn) (Uniform Production)Results from smoothing production requirementsKanban systems can handle +/- 10% demand changesThe way to reduce variability in productionSmooths demand across planning horizonMixed-model assembly steadies component production及時(shí)化生產(chǎn)系統(tǒng)49平準(zhǔn)化範(fàn)例1The APP of TOYOTA: 4500 vehicles per

25、week. Two full shifts, five days per week 450 per shift (480 minutes)Three models are produced: Camry (C), Avalon (A), and Sienna (S).200 Camry, 150 Avalons, and 100 Siennas per shiftCycle time: 480/450=1.067 (min)及時(shí)化生產(chǎn)系統(tǒng)50平準(zhǔn)化範(fàn)例2First 200 Cs 150 As 100SsHigh average cycle inventory levelLumpy requir

26、ementsSecond4 Cs 3 As 2Ss The cycle =9(1.067)=9.60 (50 times per shift)及時(shí)化生產(chǎn)系統(tǒng)51平準(zhǔn)化範(fàn)例3ThirdC S C A C A C S AThe setup times must be very short.Component requirements is steadyCapacity requirements are smoothed及時(shí)化生產(chǎn)系統(tǒng)52Quality at the Source1Jidoka (自働化) 在生產(chǎn)過程中自動(dòng)偵測(cè)缺點(diǎn)Andon (安童) 在每個(gè)工作站裝置燈號(hào)系統(tǒng)，以指示問題及落後狀態(tài)。

27、Undercapacity scheduling allows for planning, problem solving & maintenance及時(shí)化生產(chǎn)系統(tǒng)53Quality at the Source2防呆裝置日文發(fā)音為POKAYOKE ，是指在模具，工具，機(jī)器設(shè)備上設(shè)計(jì)防止錯(cuò)誤(不良)發(fā)生的裝置，一旦作業(yè)員做錯(cuò)或需要作業(yè)上的警示時(shí)，防呆裝置可以預(yù)防或使機(jī)器停下來，確保不產(chǎn)生不良品。目視管理系統(tǒng) (visual control)： 係透過顯示板之顯示得以快速且明顯地發(fā)現(xiàn)異常、浪費(fèi)、故障、斷料等現(xiàn)場不順暢之情形，而達(dá)到能速謀對(duì)策的一種管理系統(tǒng)。及時(shí)化生產(chǎn)系統(tǒng)54Visual Contr

28、ol及時(shí)化生產(chǎn)系統(tǒng)55Visual Control及時(shí)化生產(chǎn)系統(tǒng)56Visual Control及時(shí)化生產(chǎn)系統(tǒng)57Kaizen (改善)Continuous improvementRequires total employment involvementEssence of JIT is willingness of workers toSpot quality problemsHalt production when necessaryGenerate ideas for improvementAnalyze problemsPerform different functions及時(shí)化生產(chǎn)系

29、統(tǒng)58Total Productive Maintenance (TPM)Breakdown maintenanceRepairs to make failed machine operationalPreventive maintenanceSystem of periodic inspection & maintenance to keep machines operatingTPM combines preventive maintenance & total quality concepts及時(shí)化生產(chǎn)系統(tǒng)59TPM Requires Management to:Design produ

30、cts that can be easily produced on existing machinesDesign machines for easier operation, changeover, maintenanceTrain & retrain workers to operate machinesPurchase machines that maximize productive potentialDesign preventive maintenance plan spanning life of machine及時(shí)化生產(chǎn)系統(tǒng)60導(dǎo)入JIT的基礎(chǔ)5S運(yùn)動(dòng)定義功能整理 (seir

31、i, organization)把東西分成必要與不必要，將不必要的東西撤走。排除資源空間的浪費(fèi)。整頓 (seiton, tidiness)需要的東西排放整齊以便取用。排除尋找，縮短作業(yè)或產(chǎn)品線切換、準(zhǔn)備時(shí)間。清掃 (seiso, cleanliness)把工作場所掃除清潔，去除雜物及灰塵。提升效率，排除隱藏的工業(yè)災(zāi)害與品質(zhì)不良。清潔 (seiketsu, maintenance) 保持整理、整頓、清掃所建立之成果。確保作業(yè)安全，延長設(shè)備壽命，提升產(chǎn)品品質(zhì)。修養(yǎng) (shitsuke, discipline)對(duì)於規(guī)定的事項(xiàng)確實(shí)遵守並養(yǎng)成習(xí)慣。加強(qiáng)小團(tuán)體之自主性活動(dòng)。及時(shí)化生產(chǎn)系統(tǒng)61Supplier Policies1Locate near to the customerUse small, side loaded trucks and ship mixed loadsConsider establishing small warehouses near to the customer or consolidating