精益生產(chǎn)之超市系統(tǒng)課件

精益生產(chǎn)之超市系統(tǒng)第1頁，共42頁。精益生產(chǎn)之超市系統(tǒng)第1頁，共42頁。1ObjectivesofthisModule這個(gè)模塊的目標(biāo)Participantswillbeableto:參與者能夠Identifywheresupermarketsareneededwithinavaluestreamtosupportapullsystem識(shí)別出在價(jià)值流的哪里需要設(shè)置超市來支持拉動(dòng)系統(tǒng)UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用PFEP數(shù)據(jù)庫來正確的估算及維護(hù)超市Linksupermarketstotheoverallkanbansystemsandconveyanceroutes將超市與整個(gè)看板體系及運(yùn)輸路線鏈接起來第2頁，共42頁。ObjectivesofthisModule這個(gè)模塊的2Topics主題WhatisaSupermarket?什么是超市？ThreeStepsofSupermarketDesign超市設(shè)計(jì)的3大步驟SupermarketLocation超市地址SupermarketSizing超市大小PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫DesignDeliveryRoutes設(shè)計(jì)交付路線RunningtheSupermarket運(yùn)行超市GroupExercises團(tuán)隊(duì)練習(xí)第3頁，共42頁。Topics主題WhatisaSupermarket?3JargonBuster專業(yè)術(shù)語Supermarket超市PFEP(PlanforEveryPart)單個(gè)零件方案Addresssystem地址系統(tǒng)Kanban看板Routes路線VMI供給商管理庫存JargonBusterPFEP?Supermarket?Addresssystem?第4頁，共42頁。JargonBuster專業(yè)術(shù)語Supermarket超市4WhatisaSupermarket?什么是超市Operation工序20Operation工序10PULL拉動(dòng)Supermarkets超市Shipping出貨Rawmaterials原材料In-processstock在制品庫存Finishedgoods成品第5頁，共42頁。WhatisaSupermarket?什么是超市Ope5WhatisaSupermarket?什么是超市？Adeliberatelydesignedmaterialstoresareawithcontrolledquantitiesofmaterials成心設(shè)定的區(qū)域儲(chǔ)存可控?cái)?shù)量的材料Thedownstreamprocesstakeswhatisneededandthesupermarketowner(theupstreamprocess)replenishments下游工序拿取需要的材料，超市的所有人〔上游工序〕進(jìn)展補(bǔ)料Unliketraditionalstoresarea,noorderforms,paperworktransactions,orstockrequisitionsareneededotherthankanban不同于傳統(tǒng)的儲(chǔ)存區(qū)域，沒有除看板以外的訂單格式，紙質(zhì)的交割或者物料申請(qǐng)第6頁，共42頁。WhatisaSupermarket?什么是超市？A6HeijunkaBox321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品超市143WhatisaSupermarket?什么是超市RawMaterialsSupermarket原材料超市25761KanbanPost看板架1234CellKanbanPost看板架1234Cell453PartsSupermarket零件超市234453第7頁，共42頁。HeijunkaBox3212343212343212347WhatisaSupermarket?什么是超市？Amaterialstoresareawhich:物料儲(chǔ)存區(qū)：Putsmaterialclosetopointofuse將物料放置在靠近使用點(diǎn)Eliminatesshortages消除物料短缺現(xiàn)象Setsminimumandmaximumlevelsforinventory設(shè)定最大庫存及最小庫存量Usesfloorspaceefficiently更有效的利用空間Simplifiesorderingandmaterialhandling訂購及物料搬運(yùn)簡單化Removesnonvalueaddedactivities:(receiving,puttingaway,kitting,counting,cycling,requisitions)消除不增值的動(dòng)作：〔收貨，擺料，配料，點(diǎn)數(shù)，循環(huán)，申請(qǐng)〕Improvesmaterialflowintheproductcells改善生產(chǎn)線的物料流程Andmakesthestatusofmaterialsvisible讓物料狀態(tài)可視化第8頁，共42頁。WhatisaSupermarket?什么是超市？A8WhatisaSupermarket?什么是超市？Simplevisualsystemsshowmaterialflow簡單可視化的物料流Location,addressandquantitycontrol位置，地址及數(shù)量管理第9頁，共42頁。WhatisaSupermarket?什么是超市？Si9WhatisaSupermarket?什么是超市？Supermarketsandmaterialpresentation超市及物料準(zhǔn)備Achieveexcellent6S實(shí)現(xiàn)卓越的6SPresentmaterialsandtheirinformationvisibly讓物料及信息更加目視化Eliminatedefects消除不良Usegravityfeeds使用重力送料Reducemotionforloadingandunloading減少上料及退料的動(dòng)作MaintainFIFO維護(hù)先進(jìn)先出第10頁，共42頁。WhatisaSupermarket?什么是超市？Su10ThreeStepsofSupermarketDesign超市設(shè)計(jì)的3大步驟Setsupermarketlocation設(shè)置超市的地址Wherewillsupermarketshelpusmost?超市設(shè)置在哪里更有幫助Determinesupermarketsizing定義超市大小PFEPdatabasetodeterminequantitiesPFEP數(shù)據(jù)庫來定義數(shù)量Spacerequired空間的要求Designdeliveryroutes定義送貨路線Standardworkforwithdrawalanddeliveryofpartsandcontainers補(bǔ)料及送貨及周轉(zhuǎn)箱的標(biāo)準(zhǔn)作業(yè)第11頁，共42頁。ThreeStepsofSupermarketDes11Step1:SupermarketsLocation第一步：超市選址

Typicalsupermarketlocations典型的超市地址Attheendoftheproducerprocesswheneverpossible,asarule在有可能的情況下設(shè)置在在生產(chǎn)工序的尾部Atpointofuse(VMI,Citems)在使用點(diǎn)〔供給商管理庫存，C類零件〕Atreceiving(forexternalsuppliers)在收貨區(qū)〔外部供給商〕第12頁，共42頁。Step1:SupermarketsLocation第一12Closetothepointofuseaspossible越靠近使用點(diǎn)越好Directdeliverytothesupermarket直接交貨到超市Minimizerepeatedhandling將重復(fù)搬運(yùn)減少到最少12Step1:SupermarketsLocation第一步：超市選址第13頁，共42頁。Closetothepointofuseasp13Step1:SupermarketsLocation第一步：超市選址

StandardApproach標(biāo)準(zhǔn)的方法Locatesupermarketsattheendofthesupplierprocessorproductionline將超市設(shè)置在供給流程的最尾端或生產(chǎn)線Makeproblemsimmediatelyvisibletotheproducerprocess將問題立刻可視化的傳遞到生產(chǎn)工序Donotsacrificevisibilityforthesakeofoptimizingtheworkofmaterialhandlers不為優(yōu)化物料搬運(yùn)工作的緣故而犧牲可視化第14頁，共42頁。Step1:SupermarketsLocation第一14Step1:SupermarketsLocation第一步：超市選址

Line生產(chǎn)線F1Line生產(chǎn)線F2Line生產(chǎn)線F3Supermarket超市1Supermarket超市2Supermarket超市3Line生產(chǎn)線A1Line生產(chǎn)線A2Line生產(chǎn)線A3234第15頁，共42頁。Step1:SupermarketsLocation第一15Step1:SupermarketsLocation第一步：超市選址

CentralizedSupermarket集中化的超市Duetohighvolumeandormix,thefacilitylayout,thesupermarketmaynotalwaysfitattheendoftheline因?yàn)榇笈炕蚨嗥贩N，工廠格局的原因，超市也許不能總是設(shè)置在生產(chǎn)線的尾部。Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstreamanddownstreamprocesstominimizematerialhandling集中化的超市用于當(dāng)他們?cè)O(shè)置在上游及下游工序來減少物料搬運(yùn)Supermarketsforincomingpartsforassemblymaybelocatednearthereceivingdock來料零件超市可以設(shè)置在靠近收貨區(qū)第16頁，共42頁。Step1:SupermarketsLocation第一16Step1:SupermarketsLocation第一步：超市選址

234Line生產(chǎn)線F1Line生產(chǎn)線F2Line生產(chǎn)線F3ConsolidatedSupermarket統(tǒng)一的超市Line生產(chǎn)線A1Line生產(chǎn)線A2Line生產(chǎn)線A3第17頁，共42頁。Step1:SupermarketsLocation第一17GroupExercise#1團(tuán)隊(duì)練習(xí)#1Goseeactivity去現(xiàn)場看WalkthroughthevaluestreamfromendtoendUsevaluestreammapstoassist通過現(xiàn)場查看整個(gè)價(jià)值流—在價(jià)值流程圖的幫助下Identifylocationswithinsitevaluestreamswheresupermarketsareneeded在價(jià)值流程圖中識(shí)別出哪里需要超市Documentonfuturestatemapswhereapplicable將適用的地方在未來價(jià)值流程圖上表達(dá)Wherecanwe…哪里我們可以Supportkanbansystemefforts?支持看板系統(tǒng)？Minimizeinventorylevels?最小化庫存水平？Improvevisibilityandeliminateshortages?提升可視化及消除物料短缺？第18頁，共42頁。GroupExercise#1團(tuán)隊(duì)練習(xí)#1Gose18Step2:SupermarketSizing第二步：超市大小Howmuchofeachpartwillwekeeplineside?每個(gè)零件我們需要多少在生產(chǎn)線旁Frequencyofconveyance運(yùn)輸?shù)念l率Quantityofconveyance運(yùn)輸?shù)臄?shù)量Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartofanoverallroute通過高頻率小批量的交付來最小化生產(chǎn)線旁的物料第19頁，共42頁。Step2:SupermarketSizing第二步：19Step2:SupermarketSizing第二步：超市大小Inordertodeterminesupermarketsize,weneedtoknow…為了定義超市的大小，我們需要知道Usagevolume(quantity)用量的多少〔數(shù)量〕Whatistheschedulingmethod?什么是方案的方法？Hastheusagebeenleveled?用量被均衡化了嗎？Hasthemixbeensmoothed?生產(chǎn)種類被穩(wěn)定了嗎？Isthereafrozentimewindow?有一個(gè)凍結(jié)的時(shí)間窗口嗎？Deliveryfrequencyupstream上游工序的交貨頻率Deliveryquantity交貨數(shù)量Containersize周轉(zhuǎn)箱大小Locationofsignal信號(hào)的位置Weight重量Andmore等等第20頁，共42頁。Step2:SupermarketSizing第二步：20ThePlanforEveryPart(PFEP)answers:單個(gè)零件方案解答了：Howisthepartpurchased?零件如何進(jìn)展采購？Whoproducesthispart?誰生產(chǎn)這個(gè)零件？Howisitpackaged?零件如何包裝？Howisthepartreceived?零件如何收貨？Whereisitstored?在哪里儲(chǔ)存？Whereisitspointofuse?在哪里使用？Howisitdeliveredtopointofuse?如何交付到使用點(diǎn)?Step2:SupermarketSizing第二步：超市大小第21頁，共42頁。ThePlanforEveryPart(PFEP)21SamplePFEPData數(shù)據(jù)的案例PartNumber物料編號(hào)Thenumberusedtoidentifythematerialsatthissite在工廠內(nèi)物料的識(shí)別編號(hào)Description描述Commonnameofmaterial物料的通用名稱Dailyusage每天用量Averagequantityofmaterialusedperday物料每天是平均使用量PointofUse使用點(diǎn)Processorareawherethematerialisconsumed物料在哪個(gè)工序進(jìn)行消耗PointofStorage儲(chǔ)存點(diǎn)Addressorlocationwherematerialisstored物料存儲(chǔ)的地址Orderfrequency訂單頻率Howoftenthematerialisorderedfromthesupplier下物料訂單的頻率Suppliername供應(yīng)商N(yùn)ameofthesupplierofmaterial零件供應(yīng)商的名稱Suppliercity供應(yīng)商城市Citywherethesupplierofthismaterialislocated零件供應(yīng)商所在城市Supplierregion供應(yīng)商地區(qū)Prefecture,state,district,orprovincewheresupplierislocated零件供應(yīng)商所在區(qū)域Suppliercountry供應(yīng)商國家Countrywheresupplierislocated供應(yīng)商所在的國家Containertype包裝箱類型Typeofthecontainerusedforthismaterial物料使用的周轉(zhuǎn)箱類型Containerweight包裝箱重量Howmuchanemptycontainerweighs空箱的重量Weightperpart零件單重Howmuchoneunitofthismaterialweighs單個(gè)零件的重量Totalpkg.weight整箱重量Weightofafullcontainerofthismaterial物料滿箱的總重PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫第22頁，共42頁。SamplePFEPData數(shù)據(jù)的案例PartNum22Containerlength周轉(zhuǎn)箱長度Lengthordepthofcontainer周轉(zhuǎn)箱的長度或深度Containerwidth周轉(zhuǎn)箱的寬度Widthofcontainer周轉(zhuǎn)箱的寬度Containerheight周轉(zhuǎn)箱高度Heightofcontainer周轉(zhuǎn)箱的高度Useperassembly每個(gè)產(chǎn)品的用量Quantityofmaterialusedforonefinishedproduct零件在單個(gè)成品中的用量Hourlyusage每小時(shí)的使用量Maximumquantityofmaterialsconsumedperhour每小時(shí)最大是使用量Standardcontainerquantity標(biāo)準(zhǔn)的周轉(zhuǎn)箱數(shù)量Quantityofmaterialinonefullcontainer滿箱中的零件數(shù)量Hourlycontainerusage每小時(shí)的周轉(zhuǎn)箱用量Maximumquantityofcontainersconsumedperhour每小時(shí)周轉(zhuǎn)箱的最大使用量Shipmentsize送貨的批量大小Standardshipmentsize(inusagedays)標(biāo)準(zhǔn)的出貨大小Carrier貨運(yùn)公司Nameoftransportationservicecompany運(yùn)輸服務(wù)公司的名稱Timeintransit運(yùn)輸時(shí)間Traveltimefromsuppliertosite(indays)從供應(yīng)商處到工廠的時(shí)間（天數(shù)）Kanbanquantity看板數(shù)量Quantityofkanbancardsorpullsignalsinsystem拉動(dòng)信號(hào)系統(tǒng)中看板卡的數(shù)量Supplierquality供應(yīng)商質(zhì)量Performanceratingforquality(percentage)質(zhì)量的成績（百分比）Supplierdelivery供應(yīng)商交付Performanceratingfordelivery(percentage)出貨的成績（百分比）SamplePFEPData數(shù)據(jù)的案例PFEP(PlanforEveryPart)PFEP數(shù)據(jù)庫第23頁，共42頁。Containerlength周轉(zhuǎn)箱長度Lengthor23PFEPDatabasePFEP數(shù)據(jù)庫PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫第24頁，共42頁。PFEPDatabasePFEP數(shù)據(jù)庫PFEP(Pla24Foreachpartnumberinthesupermarket:在超市中的每個(gè)零件編號(hào)：Whatistheaveragedailyusage?平均每天用量是多少？Whatistheincomingshipmentsize(daysusage)?來料出貨的大小〔多少天的用量〕？Howmuchbufferisrequired(daysusage)?需要的緩沖庫存〔多少天的用量〕？PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫第25頁，共42頁。Foreachpartnumberinthesu25PlannedMaximumInventory方案的最大庫存=Dailyusage每天用量xShipmentsizeindays’usage出貨的大小〔多少天的用量〕xDays’usagepurchasedpartssafetystock〔采購件平安庫存使用的天數(shù)〕Safetystock:平安庫存：Howmanydaysinventorydoweneedtoguardagainst…我們需要多少天的庫存來保障Supplierissues?供給商問題？Transportationissues?運(yùn)輸問題Internalissues?內(nèi)部問題？DeterminingBufferSize定義緩沖庫存的大小第26頁，共42頁。PlannedMaximumInventory方案的最大26MaximumContainerQuantity最大周轉(zhuǎn)箱數(shù)量=PlannedMaximumInventoryLevel方案的最大庫存水平/ContainerQuantity包裝箱數(shù)量CalculatingContainerQuantity計(jì)算周轉(zhuǎn)箱數(shù)量第27頁，共42頁。MaximumContainerQuantity最大周轉(zhuǎn)27UpdatingthePFEP更新PFEP第28頁，共42頁。UpdatingthePFEP第28頁，共42頁。28GroupExercise#2團(tuán)隊(duì)練習(xí)#2Supermarketsizing超市大小CreatePFEPDatabase創(chuàng)立PFEP數(shù)據(jù)庫Usethisinformationtosizethesupermarket使用這些信息來確定超市大小Designpilotsupermarketbasedonsizeandeaseofstorageandretrieval根據(jù)尺寸及儲(chǔ)存的容易程度設(shè)計(jì)試產(chǎn)的超市的大小第29頁，共42頁。GroupExercise#2團(tuán)隊(duì)練習(xí)#2Superm29Step3:DesignDeliveryRoutes第三步：設(shè)計(jì)送貨路線HeijunkaBox均衡化生產(chǎn)箱321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品超市1234Cell453KanbanPost看板架143RawMaterialsSupermarket原材料超市251234Cell761KanbanPost看板架PartsSupermarket零件超市234第30頁，共42頁。Step3:DesignDeliveryRoutes30Step3:DesignDeliveryRoutes第三步：設(shè)計(jì)送貨路線

Setroutedrivetimeatnomorethan33%ofthenon-loadtimeoftheroute設(shè)置路線運(yùn)輸時(shí)間不超過路線空載時(shí)間的33%Onlymovematerialwhenauthorizedbythepullsignal只有在收到被授權(quán)的拉動(dòng)信號(hào)后才移動(dòng)物料Ensurekanbansystemrulesarefollowedandworkersremovepullsignalswhenusingthefirstpieceinacontainer確保員工按照規(guī)那么操作：在使用周轉(zhuǎn)箱中第一個(gè)物料時(shí)員工發(fā)出信號(hào)Synchronizethelunchandbreaktimesofthematerialhandlerontheroutewiththoseoftheworkersintheareasbeingsupported將物料搬運(yùn)員與生產(chǎn)線員工的午飯時(shí)間及休息時(shí)間進(jìn)展同步Followspecificroutetimesandfrequenciesandinsurethatroutedeliveryisnotinterruptedforanyreason按照特定的路線時(shí)間及頻率來保證運(yùn)輸交貨不被任何原因被打斷Standardizeworkonthedeliveryroutetoeliminateallwastedmotionandimprovecontinuously標(biāo)準(zhǔn)化在交貨路線上的作業(yè)來消除所有的動(dòng)作浪費(fèi)及持續(xù)進(jìn)展改進(jìn)第31頁，共42頁。Step3:DesignDeliveryRoutes31Step3:DesignDeliveryRoutes第三步：設(shè)計(jì)送貨路線Designateone-wayandtwo-wayaislesalongnaturalflowpathsinthefacility指定的單向和雙向沿自然流動(dòng)路徑的通道設(shè)施Designallroutestoflowthroughtheplantandbacktothesupermarket設(shè)計(jì)所有的通過工廠的路線及返回到超市Designstopsanddeliverypointsalongtheroutetominimizethenonvalue-addedworkforthematerialhandler在路線上設(shè)計(jì)停頓點(diǎn)及交貨點(diǎn)來最小化物料員非增值的工作Designstopsanddeliverypointsalongtheroutetominimizenonvalue-addedworkfortheoperatorwhoisbeingsupplied在路線上設(shè)計(jì)停頓點(diǎn)及交貨點(diǎn)來最小化生產(chǎn)線員工非增值的工作Startwithone-hourdeliveryroutes,aimingfora95%efficiency(57minutes)從一小時(shí)的送貨路線開場，目標(biāo)到達(dá)95%的效率Setloadingtimeatthesupermarketat33%orlessofthecoupleddeliverytime在超市設(shè)置取料時(shí)間是總交貨時(shí)間的33%或更少第32頁，共42頁。Step3:DesignDeliveryRoutes32MaterialHandlerStandardWorkExample物料員標(biāo)準(zhǔn)作業(yè)的案例Step步驟StandardWorkElements標(biāo)準(zhǔn)作業(yè)步驟ConveyanceCycleTime運(yùn)輸周期時(shí)間1Traveltofirstdeliverypoint到第一個(gè)送貨點(diǎn)120seconds秒秒2Pickupwithdrawalkanbanatfirststation(deliverypoint)從第一個(gè)工位拿取補(bǔ)料看板卡10seconds秒3Pickupemptycontainersandloadontotrolley拿取空箱放置到物料車上20seconds秒4Delivermaterialtofirststation將物料交付到第一個(gè)工位45seconds秒5Traveltonextdeliverypoint移動(dòng)到下一個(gè)送貨點(diǎn)10seconds秒6Traveltoseconddeliverypoint移動(dòng)到第二個(gè)送貨點(diǎn)15seconds秒7Pickupwithdrawalkanbanatfirststation(deliverypoint)從第一個(gè)工位拿取補(bǔ)料看板卡10seconds秒8Pickupemptycontainersandloadontotrolley拿取空箱放置到物料車上20seconds秒9Delivermaterialtosecondstation將物料交付到第二個(gè)工位45seconds秒10Traveltosupermarket移動(dòng)到超市120seconds秒11Sortkanbancardsforbestpickingsequence根據(jù)取料的順序挑選看板卡10seconds秒12Dropoffemptycontainerspickedupduringroute將空箱放置到相應(yīng)的位置45seconds秒13Collectcontainersneededforpickingandconveyance收集需要的周轉(zhuǎn)箱及運(yùn)輸45seconds秒14Pickpartsandplacethemontrolley(averageof10itemsx10seconds秒perpick)取物料及將物料放置到運(yùn)輸車上（平均10個(gè)零件X每次10秒）100seconds秒15Placewithdrawalkanbancardsinrespectivecontainers將補(bǔ)料看板卡放置到相應(yīng)的周轉(zhuǎn)箱10seconds秒Totaltimeforroute總的路線時(shí)間625sec秒Step3:DesignDeliveryRoutes第三步：設(shè)計(jì)送貨路線第33頁，共42頁。MaterialHandlerStandardWork33PUSH-basedMaterialHandlingRoute推動(dòng)-基于物料搬運(yùn)路線CCBACCBBAASupermarket超市CBABulkdelivery(E.g.4hoursupply)交貨大小Requiresextraspace需要額外的空間AAABBBBACCCCC123第34頁，共42頁。PUSH-basedMaterialHandlingR34PULL-basedMaterialHandlingRoute拉動(dòng)-基于物料搬運(yùn)路線CBACBACCBBAASupermarket超市CBA1234567Time-fixeddelivery(30minutessupply)固定時(shí)間的交貨Mixedloadconveyance多品種的運(yùn)輸?shù)?5頁，共42頁。PULL-basedMaterialHandlingR35Line#1Line#28:009:0010:0011:0012:0012:3013:30Shift1345234343345234552552041041761761761119321321311761321234Finishedgoodssupermarket成品超市CustomerPull客戶拉動(dòng)???√√???ABProductionLine生產(chǎn)線761Kanbancollected,delivered看板收集及交付LinkSupermarketwithPullSystem將超市與拉動(dòng)體系進(jìn)展鏈接Tofinishedgoodssupermarket送至成品超市Heijunkabox均衡化生產(chǎn)箱第36頁，共42頁。Line#1Line#28:009:0010:0011:36GroupExercise#3團(tuán)隊(duì)連續(xù)#3Designroutes路線設(shè)計(jì)Designmaterialhandlingroutesbetweensupermarketsandpointsofuse在設(shè)計(jì)物料在超市及使用點(diǎn)間的運(yùn)輸路線Practice,timeanddocumentthework練習(xí)，時(shí)間及將工作文件化Documentprovisionalstandardwork,practiceandimprove文件化暫定的標(biāo)準(zhǔn)作業(yè)，練習(xí)及提高第37頁，共42頁。GroupExercise#3團(tuán)隊(duì)連續(xù)#3Design37RunningtheSupermarket運(yùn)行超市SupermarketGoldenRules超市的金科玉律Theproducingprocesstakesownershipoftheinventoryinthesupermarket(regardlessofphysicallocation)生產(chǎn)工序負(fù)責(zé)超市中的庫存〔不管實(shí)質(zhì)的地址〕Thedownstreamprocessregularlywithdraws(pulls)whattheyneedintheamounttheyneed下游工序定期的取他們所需要的物料Clearsignalsareexchangedbetweenupstreamanddownstreamprocesseswhenmaterialiswithdrawnfromthesupermarket當(dāng)從超市取物料時(shí)上下游工序間的信號(hào)交換第38頁，共42頁。RunningtheSupermarket運(yùn)行超市Sup38Setminimumandmaximuminventorylevelsforallpartsinthesupermarket在超市中設(shè)置最大及最小的庫存水平Locatethepurchasedpartssupermarketclosetothereceivingdock將采購件超市設(shè)置到靠近收貨區(qū)Identifythepointofuseaddressonthestoragelocationfortheitemsinthesupermarket在存儲(chǔ)地點(diǎn)識(shí)別出超市內(nèi)的物料的使用點(diǎn)Simplifyhandlingofcontainers(useflowracks,etc.)簡單化的搬運(yùn)周轉(zhuǎn)箱Createanoverflowareainahighlyvisibleplace在目視化的區(qū)域設(shè)計(jì)過量庫存區(qū)RunningtheSupermarket運(yùn)行超市第39頁，共42頁。Setminimumandmaximuminvent39Measurementsforcontinuousimprovementofsupermarketoperation:持續(xù)改進(jìn)超市操作的測(cè)量Safety:recordableincidents平安：可記錄的事故Quality:zerodefects質(zhì)量：零缺陷Delivery:zerolinestops交貨：零停線Cash:inventoryreduction現(xiàn)金：庫存減少Productivity:numberofmaterialhandlers生產(chǎn)力：物料員的數(shù)量RunningtheSupermarket運(yùn)行超市第40頁，共42頁。Measurementsforcontinuousim40Sustainingsupermarkets可持續(xù)的超市Establishstrongvisualcontrols建立強(qiáng)大的目視化管理Includesupermarketauditsinleaderstandardwork在組長的標(biāo)準(zhǔn)工作中包括對(duì)超市的Checktheconditionofsupermarkets檢查超市的狀態(tài)Checkinventorylevels檢查庫存的水平Checkthattheprocessisfollowed檢查流程是否遵守Verifykanbanquantityintheloop在循環(huán)中驗(yàn)證看板的數(shù)量RunningtheSupermarket運(yùn)行超市第41頁，共42頁。Sustainingsupermarkets可持續(xù)的超市R41人有了知識(shí)，就會(huì)具備各種分析能力，明辨是非的能力。所以我們要勤懇讀書，廣泛閱讀，古人說“書中自有黃金屋?！蓖ㄟ^閱讀科技書籍，我們能豐富知識(shí)，培養(yǎng)邏輯思維能力；通過閱讀文學(xué)作品，我們能提高文學(xué)鑒賞水平，培養(yǎng)文學(xué)情趣；通過閱讀報(bào)刊，我們能增長見識(shí)，擴(kuò)大自己的知識(shí)面。有許多書籍還能培養(yǎng)我們的道德情操，給我們巨大的精神力量，鼓舞我們前進(jìn)。第42頁，共42頁。人有了知識(shí)，就會(huì)具備各種分析能力，第42頁，共42頁。42精益生產(chǎn)之超市系統(tǒng)第1頁，共42頁。精益生產(chǎn)之超市系統(tǒng)第1頁，共42頁。43ObjectivesofthisModule這個(gè)模塊的目標(biāo)Participantswillbeableto:參與者能夠Identifywheresupermarketsareneededwithinavaluestreamtosupportapullsystem識(shí)別出在價(jià)值流的哪里需要設(shè)置超市來支持拉動(dòng)系統(tǒng)UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用PFEP數(shù)據(jù)庫來正確的估算及維護(hù)超市Linksupermarketstotheoverallkanbansystemsandconveyanceroutes將超市與整個(gè)看板體系及運(yùn)輸路線鏈接起來第2頁，共42頁。ObjectivesofthisModule這個(gè)模塊的44Topics主題WhatisaSupermarket?什么是超市？ThreeStepsofSupermarketDesign超市設(shè)計(jì)的3大步驟SupermarketLocation超市地址SupermarketSizing超市大小PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫DesignDeliveryRoutes設(shè)計(jì)交付路線RunningtheSupermarket運(yùn)行超市GroupExercises團(tuán)隊(duì)練習(xí)第3頁，共42頁。Topics主題WhatisaSupermarket?45JargonBuster專業(yè)術(shù)語Supermarket超市PFEP(PlanforEveryPart)單個(gè)零件方案Addresssystem地址系統(tǒng)Kanban看板Routes路線VMI供給商管理庫存JargonBusterPFEP?Supermarket?Addresssystem?第4頁，共42頁。JargonBuster專業(yè)術(shù)語Supermarket超市46WhatisaSupermarket?什么是超市Operation工序20Operation工序10PULL拉動(dòng)Supermarkets超市Shipping出貨Rawmaterials原材料In-processstock在制品庫存Finishedgoods成品第5頁，共42頁。WhatisaSupermarket?什么是超市Ope47WhatisaSupermarket?什么是超市？Adeliberatelydesignedmaterialstoresareawithcontrolledquantitiesofmaterials成心設(shè)定的區(qū)域儲(chǔ)存可控?cái)?shù)量的材料Thedownstreamprocesstakeswhatisneededandthesupermarketowner(theupstreamprocess)replenishments下游工序拿取需要的材料，超市的所有人〔上游工序〕進(jìn)展補(bǔ)料Unliketraditionalstoresarea,noorderforms,paperworktransactions,orstockrequisitionsareneededotherthankanban不同于傳統(tǒng)的儲(chǔ)存區(qū)域，沒有除看板以外的訂單格式，紙質(zhì)的交割或者物料申請(qǐng)第6頁，共42頁。WhatisaSupermarket?什么是超市？A48HeijunkaBox321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品超市143WhatisaSupermarket?什么是超市RawMaterialsSupermarket原材料超市25761KanbanPost看板架1234CellKanbanPost看板架1234Cell453PartsSupermarket零件超市234453第7頁，共42頁。HeijunkaBox32123432123432123449WhatisaSupermarket?什么是超市？Amaterialstoresareawhich:物料儲(chǔ)存區(qū)：Putsmaterialclosetopointofuse將物料放置在靠近使用點(diǎn)Eliminatesshortages消除物料短缺現(xiàn)象Setsminimumandmaximumlevelsforinventory設(shè)定最大庫存及最小庫存量Usesfloorspaceefficiently更有效的利用空間Simplifiesorderingandmaterialhandling訂購及物料搬運(yùn)簡單化Removesnonvalueaddedactivities:(receiving,puttingaway,kitting,counting,cycling,requisitions)消除不增值的動(dòng)作：〔收貨，擺料，配料，點(diǎn)數(shù)，循環(huán)，申請(qǐng)〕Improvesmaterialflowintheproductcells改善生產(chǎn)線的物料流程Andmakesthestatusofmaterialsvisible讓物料狀態(tài)可視化第8頁，共42頁。WhatisaSupermarket?什么是超市？A50WhatisaSupermarket?什么是超市？Simplevisualsystemsshowmaterialflow簡單可視化的物料流Location,addressandquantitycontrol位置，地址及數(shù)量管理第9頁，共42頁。WhatisaSupermarket?什么是超市？Si51WhatisaSupermarket?什么是超市？Supermarketsandmaterialpresentation超市及物料準(zhǔn)備Achieveexcellent6S實(shí)現(xiàn)卓越的6SPresentmaterialsandtheirinformationvisibly讓物料及信息更加目視化Eliminatedefects消除不良Usegravityfeeds使用重力送料Reducemotionforloadingandunloading減少上料及退料的動(dòng)作MaintainFIFO維護(hù)先進(jìn)先出第10頁，共42頁。WhatisaSupermarket?什么是超市？Su52ThreeStepsofSupermarketDesign超市設(shè)計(jì)的3大步驟Setsupermarketlocation設(shè)置超市的地址Wherewillsupermarketshelpusmost?超市設(shè)置在哪里更有幫助Determinesupermarketsizing定義超市大小PFEPdatabasetodeterminequantitiesPFEP數(shù)據(jù)庫來定義數(shù)量Spacerequired空間的要求Designdeliveryroutes定義送貨路線Standardworkforwithdrawalanddeliveryofpartsandcontainers補(bǔ)料及送貨及周轉(zhuǎn)箱的標(biāo)準(zhǔn)作業(yè)第11頁，共42頁。ThreeStepsofSupermarketDes53Step1:SupermarketsLocation第一步：超市選址

Typicalsupermarketlocations典型的超市地址Attheendoftheproducerprocesswheneverpossible,asarule在有可能的情況下設(shè)置在在生產(chǎn)工序的尾部Atpointofuse(VMI,Citems)在使用點(diǎn)〔供給商管理庫存，C類零件〕Atreceiving(forexternalsuppliers)在收貨區(qū)〔外部供給商〕第12頁，共42頁。Step1:SupermarketsLocation第一54Closetothepointofuseaspossible越靠近使用點(diǎn)越好Directdeliverytothesupermarket直接交貨到超市Minimizerepeatedhandling將重復(fù)搬運(yùn)減少到最少12Step1:SupermarketsLocation第一步：超市選址第13頁，共42頁。Closetothepointofuseasp55Step1:SupermarketsLocation第一步：超市選址

StandardApproach標(biāo)準(zhǔn)的方法Locatesupermarketsattheendofthesupplierprocessorproductionline將超市設(shè)置在供給流程的最尾端或生產(chǎn)線Makeproblemsimmediatelyvisibletotheproducerprocess將問題立刻可視化的傳遞到生產(chǎn)工序Donotsacrificevisibilityforthesakeofoptimizingtheworkofmaterialhandlers不為優(yōu)化物料搬運(yùn)工作的緣故而犧牲可視化第14頁，共42頁。Step1:SupermarketsLocation第一56Step1:SupermarketsLocation第一步：超市選址

Line生產(chǎn)線F1Line生產(chǎn)線F2Line生產(chǎn)線F3Supermarket超市1Supermarket超市2Supermarket超市3Line生產(chǎn)線A1Line生產(chǎn)線A2Line生產(chǎn)線A3234第15頁，共42頁。Step1:SupermarketsLocation第一57Step1:SupermarketsLocation第一步：超市選址

CentralizedSupermarket集中化的超市Duetohighvolumeandormix,thefacilitylayout,thesupermarketmaynotalwaysfitattheendoftheline因?yàn)榇笈炕蚨嗥贩N，工廠格局的原因，超市也許不能總是設(shè)置在生產(chǎn)線的尾部。Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstreamanddownstreamprocesstominimizematerialhandling集中化的超市用于當(dāng)他們?cè)O(shè)置在上游及下游工序來減少物料搬運(yùn)Supermarketsforincomingpartsforassemblymaybelocatednearthereceivingdock來料零件超市可以設(shè)置在靠近收貨區(qū)第16頁，共42頁。Step1:SupermarketsLocation第一58Step1:SupermarketsLocation第一步：超市選址

234Line生產(chǎn)線F1Line生產(chǎn)線F2Line生產(chǎn)線F3ConsolidatedSupermarket統(tǒng)一的超市Line生產(chǎn)線A1Line生產(chǎn)線A2Line生產(chǎn)線A3第17頁，共42頁。Step1:SupermarketsLocation第一59GroupExercise#1團(tuán)隊(duì)練習(xí)#1Goseeactivity去現(xiàn)場看WalkthroughthevaluestreamfromendtoendUsevaluestreammapstoassist通過現(xiàn)場查看整個(gè)價(jià)值流—在價(jià)值流程圖的幫助下Identifylocationswithinsitevaluestreamswheresupermarketsareneeded在價(jià)值流程圖中識(shí)別出哪里需要超市Documentonfuturestatemapswhereapplicable將適用的地方在未來價(jià)值流程圖上表達(dá)Wherecanwe…哪里我們可以Supportkanbansystemefforts?支持看板系統(tǒng)？Minimizeinventorylevels?最小化庫存水平？Improvevisibilityandeliminateshortages?提升可視化及消除物料短缺？第18頁，共42頁。GroupExercise#1團(tuán)隊(duì)練習(xí)#1Gose60Step2:SupermarketSizing第二步：超市大小Howmuchofeachpartwillwekeeplineside?每個(gè)零件我們需要多少在生產(chǎn)線旁Frequencyofconveyance運(yùn)輸?shù)念l率Quantityofconveyance運(yùn)輸?shù)臄?shù)量Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartofanoverallroute通過高頻率小批量的交付來最小化生產(chǎn)線旁的物料第19頁，共42頁。Step2:SupermarketSizing第二步：61Step2:SupermarketSizing第二步：超市大小Inordertodeterminesupermarketsize,weneedtoknow…為了定義超市的大小，我們需要知道Usagevolume(quantity)用量的多少〔數(shù)量〕Whatistheschedulingmethod?什么是方案的方法？Hastheusagebeenleveled?用量被均衡化了嗎？Hasthemixbeensmoothed?生產(chǎn)種類被穩(wěn)定了嗎？Isthereafrozentimewindow?有一個(gè)凍結(jié)的時(shí)間窗口嗎？Deliveryfrequencyupstream上游工序的交貨頻率Deliveryquantity交貨數(shù)量Containersize周轉(zhuǎn)箱大小Locationofsignal信號(hào)的位置Weight重量Andmore等等第20頁，共42頁。Step2:SupermarketSizing第二步：62ThePlanforEveryPart(PFEP)answers:單個(gè)零件方案解答了：Howisthepartpurchased?零件如何進(jìn)展采購？Whoproducesthispart?誰生產(chǎn)這個(gè)零件？Howisitpackaged?零件如何包裝？Howisthepartreceived?零件如何收貨？Whereisitstored?在哪里儲(chǔ)存？Whereisitspointofuse?在哪里使用？Howisitdeliveredtopointofuse?如何交付到使用點(diǎn)?Step2:SupermarketSizing第二步：超市大小第21頁，共42頁。ThePlanforEveryPart(PFEP)63SamplePFEPData數(shù)據(jù)的案例PartNumber物料編號(hào)Thenumberusedtoidentifythematerialsatthissite在工廠內(nèi)物料的識(shí)別編號(hào)Description描述Commonnameofmaterial物料的通用名稱Dailyusage每天用量Averagequantityofmaterialusedperday物料每天是平均使用量PointofUse使用點(diǎn)Processorareawherethematerialisconsumed物料在哪個(gè)工序進(jìn)行消耗PointofStorage儲(chǔ)存點(diǎn)Addressorlocationwherematerialisstored物料存儲(chǔ)的地址Orderfrequency訂單頻率Howoftenthematerialisorderedfromthesupplier下物料訂單的頻率Suppliername供應(yīng)商N(yùn)ameofthesupplierofmaterial零件供應(yīng)商的名稱Suppliercity供應(yīng)商城市Citywherethesupplierofthismaterialislocated零件供應(yīng)商所在城市Supplierregion供應(yīng)商地區(qū)Prefecture,state,district,orprovincewheresupplierislocated零件供應(yīng)商所在區(qū)域Suppliercountry供應(yīng)商國家Countrywheresupplierislocated供應(yīng)商所在的國家Containertype包裝箱類型Typeofthecontainerusedforthismaterial物料使用的周轉(zhuǎn)箱類型Containerweight包裝箱重量Howmuchanemptycontainerweighs空箱的重量Weightperpart零件單重Howmuchoneunitofthismaterialweighs單個(gè)零件的重量Totalpkg.weight整箱重量Weightofafullcontainerofthismaterial物料滿箱的總重PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫第22頁，共42頁。SamplePFEPData數(shù)據(jù)的案例PartNum64Containerlength周轉(zhuǎn)箱長度Lengthordepthofcontainer周轉(zhuǎn)箱的長度或深度Containerwidth周轉(zhuǎn)箱的寬度Widthofcontainer周轉(zhuǎn)箱的寬度Containerheight周轉(zhuǎn)箱高度Heightofcontainer周轉(zhuǎn)箱的高度Useperassembly每個(gè)產(chǎn)品的用量Quantityofmaterialusedforonefinishedproduct零件在單個(gè)成品中的用量Hourlyusage每小時(shí)的使用量Maximumquantityofmaterialsconsumedperhour每小時(shí)最大是使用量Standardcontainerquantity標(biāo)準(zhǔn)的周轉(zhuǎn)箱數(shù)量Quantityofmaterialinonefullcontainer滿箱中的零件數(shù)量Hourlycontainerusage每小時(shí)的周轉(zhuǎn)箱用量Maximumquantityofcontainersconsumedperhour每小時(shí)周轉(zhuǎn)箱的最大使用量Shipmentsize送貨的批量大小Standardshipmentsize(inusagedays)標(biāo)準(zhǔn)的出貨大小Carrier貨運(yùn)公司Nameoftransportationservicecompany運(yùn)輸服務(wù)公司的名稱Timeintransit運(yùn)輸時(shí)間Traveltimefromsuppliertosite(indays)從供應(yīng)商處到工廠的時(shí)間（天數(shù)）Kanbanquantity看板數(shù)量Quantityofkanbancardsorpullsignalsinsystem拉動(dòng)信號(hào)系統(tǒng)中看板卡的數(shù)量Supplierquality供應(yīng)商質(zhì)量Performanceratingforquality(percentage)質(zhì)量的成績（百分比）Supplierdelivery供應(yīng)商交付Performanceratingfordelivery(percentage)出貨的成績（百分比）SamplePFEPData數(shù)據(jù)的案例PFEP(PlanforEveryPart)PFEP數(shù)據(jù)庫第23頁，共42頁。Containerlength周轉(zhuǎn)箱長度Lengthor65PFEPDatabasePFEP數(shù)據(jù)庫PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫第24頁，共42頁。PFEPDatabasePFEP數(shù)據(jù)庫PFEP(Pla66Foreachpartnumberinthesupermarket:在超市中的每個(gè)零件編號(hào)：Whatistheaveragedailyusage?平均每天用量是多少？Whatistheincomingshipmentsize(daysusage)?來料出貨的大小〔多少天的用量〕？Howmuchbufferisrequired(daysusage)?需要的緩沖庫存〔多少天的用量〕？PFEP(PlanforEveryPart)DatabasePFEP數(shù)據(jù)庫第25頁，共42頁。Foreachpartnumberinthesu67PlannedMaximumInventory方案的最大庫存=Dailyusage每天用量xShipmentsizeindays’usage出貨的大小〔多少天的用量〕xDays’usagepurchasedpartssafetystock〔采購件平安庫存使用的天數(shù)〕Safetystock:平安庫存：Howmanydaysinventorydoweneedtoguardagainst…我們需要多少天的庫存來保障Supplierissues?供給商問題？Transportationissues?運(yùn)輸問題Internalissues?內(nèi)部問題？DeterminingBufferSize定義緩沖庫存的大小第26頁，共42頁。PlannedMaximumInventory方案的最大68MaximumCon