江森精益生產(chǎn)制造系統(tǒng)下半部課件

ALeanSimulation

江森精益制造系統(tǒng)PartTwo第二部分ALeanSimulation

江森精益制造系統(tǒng)PartLeanSim_Part2_SHW_E_Sep2003.ppt2SystemDevelopment

系統(tǒng)開(kāi)發(fā)ControllingInventoryandImprovingOperations庫(kù)存管理和改善運(yùn)作LeanSim_Part2_SHW_E_Sep2003.LeanasaSystem

精益制造系統(tǒng)AllLeanManufacturingProcessesMustBeViewedByTheLeadershipAsATotalSystem管理層必須視所有的精益制造過(guò)程為一完整的系統(tǒng)LeanasaSystem

精益制造系統(tǒng)AllLeaLeanSim_Part2_SHW_E_Sep2003.ppt4ValueStreamMapping:

MaterialandInformationFlow

價(jià)值流程圖:

物料和信息流程Graphicallyplotcurrentstateofmaterialandinformationflowatthemanufacturingsite用圖解來(lái)描述生產(chǎn)場(chǎng)地的物料和信息流程現(xiàn)狀Evaluatetheinventorylocationsandstatus對(duì)庫(kù)存場(chǎng)地和現(xiàn)狀進(jìn)行評(píng)估Plotafuturestateformaterialandinformationflowusingguidequestions用引導(dǎo)問(wèn)題繪制未來(lái)的物料和信息流程圖Planthetransitiontofuturestate制定未來(lái)的過(guò)濾計(jì)劃LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt5CurrentStateMap:LeanSimulationGameRawmaterialsSuppliersNUTMANUF.

C/T=3.5secondC/O=15secYield=99%1workerEPE=4weeks

IC/T=7.5secondsC/O=NoneYield=100%1workerEPE=weekBOLT

HardeningPAINTCURE

(NUTS)SteelBalls15days5days15daysASSEMBLYC/T=6seconds

C/O=NoneYield=95%1workerEPE=4weeksC/T=30secondsC/O=02workersYield=98%EPE=4WeeksSHIPPINGStaging80linkages/mo-40silver-20gold-20blackTray10Pieces2shiftsWeeklydelivery1XWeekMRP15daysWeeklyFaxDailyShipScheduleDailyOrderIINutsIWeeklyScheduleDailyPltsBolts5days5daysRawbolts10daysPacificSteelCo.PacificSteelCo.PacificSteelCo.CUSTOMERPRODUCTIONCONTROL90/60/30dayForecasts6-weekForecast7sec15daysProductionLeadTime=55days(3300sec)ValueAddedTime=64sec.(<1day)10days15days15days15sec12sec30secConcurrentworkaddlongestlead-timeLeanSim_Part2_SHW_E_Sep2003.原料供應(yīng)商螺母生產(chǎn)

C/T=3.5秒C/O=15秒產(chǎn)量=99%1個(gè)工人EPE=4周

IC/T=7.5秒C/O=無(wú)產(chǎn)量=100%1個(gè)工人EPE=周螺釘加固油漆處理

(螺母)鋼珠15天5天15天裝配C/T=6秒

C/O=無(wú)產(chǎn)量=95%1個(gè)工人EPE=4周C/T=30秒C/O=02個(gè)工人產(chǎn)量=98%EPE=4周發(fā)貨分段運(yùn)輸80個(gè)連桿/mo-40銀色-20金色-20黑色托盤(pán)10件2班每周交貨1X周生產(chǎn)控制MRP90/60/30天預(yù)測(cè)

目前的狀態(tài)圖:精益模擬游戲客戶15天6周預(yù)測(cè)PacificSteelCo.PacificSteelCo.太平洋鋼鐵公司每周傳真每日裝貨時(shí)間表每日訂購(gòu)II螺母I7秒15天生產(chǎn)前置時(shí)間

=55天(3300秒)增加值時(shí)間=64秒.(<1天)5天10天15天15天15秒12秒30秒每周時(shí)間表同時(shí)工作會(huì)造成前置時(shí)間最長(zhǎng)每天Plts螺釘5天5天粗制螺釘10天原料供應(yīng)商螺母C/T=3.5秒C/O=15秒產(chǎn)量LeanSim_Part2_SHW_E_Sep2003.ppt7

RawmaterialsSuppliersNUTMANUF.

C/T=3.5secondC/O=15secYield=99%1workerEPE=4weeks

IC/T=7.5secondsC/O=NoneYield=100%1workerEPE=weekBOLT

HardeningPAINTCURE

(NUTS)SteelBalls15days5days15daysASSEMBLYC/T=6seconds

C/O=NoneYield=95%1workerEPE=4weeksC/T=30secondsC/O=02workersYield=98%EPE=4WeeksSHIPPINGStaging80linkages/mo-40silver-20gold-20blackTray10Pieces2shiftsWeeklydelivery1XWeekPRODUCTIONCONTROLMRP90/60/30dayForecastsCurrentStateMap:LeanSimulationGameCUSTOMER15days6-weekForecastPacificSteelCo.PacificSteelCo.PacificSteelCo.WeeklyFaxDailyShipScheduleDailyOrderIRawbolts10daysINutsIWeeklyScheduleDailyPltsBolts5days5daysSupplierLoop供應(yīng)商回路PacemakerLoop進(jìn)度決策回路AssemblyLoop裝配回路BatchPaintLoop成批油漆回路CustomerLoop客戶回路7sec15daysProductionLeadTime=55days(3300sec)ValueAddedTime=64sec.(<1day)10days15days15days15sec12sec30secConcurrentworkaddlongestlead-timeLeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt8RawmaterialsSuppliersNUTMANUF.

C/T=3.5secondC/O=15secYield=99%1workerEPE=4weeks

IC/T=7.5secondsC/O=NoneYield=100%1workerEPE=weekBOLT

HardeningPAINTCURE

(NUTS)SteelBalls15days5days15daysASSEMBLYC/T=6seconds

C/O=NoneYield=95%1workerEPE=4weeksC/T=30secondsC/O=02workersYield=98%EPE=4WeeksSHIPPINGStaging80linkages/mo-40silver-20gold-20blackTray10Pieces2shiftsWeeklydelivery1XWeekPRODUCTIONCONTROLMRP90/60/30dayForecastsCUSTOMER15days6-weekForecastPacificSteelCo.PacificSteelCo.PacificSteelCo.WeeklyFaxDailyShipScheduleDailyOrderIRawbolts10daysINutsIWeeklyScheduleDailyPltsBolts5days5daysQCOKaizenKanbanLevelLoadErrorproof5SConstraintMgt.TPMPullSystemsStd.WorkSixSigmaCurrentStateMap:LeanSimulationGame7sec15daysProductionLeadTime=55days(3300sec)ValueAddedTime=64sec.(<1day)5days10days15days15days15sec12sec30secConcurrentworkaddlongestlead-timeLeanSim_Part2_SHW_E_Sep2003.原料供應(yīng)商螺母生產(chǎn)

C/T=3.5秒C/O=15秒產(chǎn)量=99%1個(gè)工人EPE=4周

IC/T=7.5秒C/O=無(wú)產(chǎn)量=100%1工人EPE=周螺釘加固油漆處理

(螺母)鋼珠15天5天15天裝配C/T=6秒

C/O=無(wú)產(chǎn)量=95%1個(gè)工人EPE=4周C/T=30秒C/O=02個(gè)工人產(chǎn)量=98%EPE=4周發(fā)貨分段運(yùn)輸80個(gè)連桿/mo-40銀色-20金色-20黑色托盤(pán)10件2班每周交貨1X周生產(chǎn)管理MRP90/60/30天預(yù)測(cè)目前的狀態(tài)圖:精益模擬游戲客戶15天6周預(yù)測(cè)PacificSteelCo.PacificSteelCo.太平洋鋼鐵公司每周傳真每日裝貨時(shí)間表每日定貨I粗制螺釘10天I螺母I7秒15天生產(chǎn)前置時(shí)間=55天(3300秒)增加值時(shí)間=64秒.(<1天)5天10天15天15天15秒12秒30秒每周時(shí)間表工作和最長(zhǎng)的前置時(shí)間每天Plts螺釘5天5天QCO改善看板平衡工作量防錯(cuò)5S制約管理TPM拉動(dòng)系統(tǒng)標(biāo)準(zhǔn)化作業(yè)6西格瑪原料供應(yīng)商螺母C/T=3.5秒C/O=15秒產(chǎn)量LeanSim_Part2_SHW_E_Sep2003.ppt10KeyQuestionsfor

Future-StateDesign

構(gòu)思未來(lái)狀態(tài)的關(guān)鍵問(wèn)題Whatisthetakttime什么是節(jié)拍時(shí)間？Buildtosupermarketortoshipping設(shè)置超市或貨運(yùn)環(huán)節(jié)Wherecanyouusecontinuousflowprocessing你在什么地方可以采用持續(xù)的流程處理方法Wherewillyouneedtousesupermarketpullsystems你在什么地方將要采用超市拉動(dòng)系統(tǒng)Atwhatsinglepointintheproductionchainwillyouhavethepacemakerprocess你在生產(chǎn)鏈的哪個(gè)點(diǎn)上設(shè)置進(jìn)度決策過(guò)程Howwillyoulevelthemixatthepacemaker你怎樣調(diào)節(jié)牽涉到很多環(huán)節(jié)的進(jìn)度決策程序Whatincrementofworkwillyoureleaseandtakeawayatthepacemakerprocess在進(jìn)度決策過(guò)程中你會(huì)削減哪方面增加的工作Whatimprovementswillbenecessaryforthefuture要實(shí)現(xiàn)未來(lái)的狀態(tài)圖,哪些方面必須加以改進(jìn)ToyotaDNAapplieshere豐田DNA應(yīng)用于此LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt11RawmaterialsSuppliers80linkages/mo-40silver-20gold-20black1piececapable1shiftsCUSTOMERPRODUCTIONCONTROLLevelProduction6-weekForecastPacificSteelCo.PacificSteelCo.PacificSteelCo.NutMfg.BatchPaintLineBoltHrd./Assy.OXOXHeijunka2days(Conveyance)DailyshipMilkrundaily90/60/30dayForecastsWeeklyFirmOrder.75daysBufferSafetyPaintedNuts

RawNutsRawBallsPlatesC/T=3.5sec.C/O=5sec.1shift1person95%UptimeEPE=Day95%UptimeT/T=15sec.C/T=15.sec.1shift2people97%UptimeC/T=6secC/O=0min.1shift1person95%YieldEPE=DayEPE=Day2days.5daysRe-orderboardFutureStateMap:LeanSimulationGameSupermarket5days7sec5daysProductionLeadTime=8.75days(525sec)ValueAddedTime=64sec.(<1day)2days2day.75days12sec45secSupermarket5daysLeanSim_Part2_SHW_E_Sep2003.原料供應(yīng)商80l個(gè)連桿/mo-40銀色-20金色-20黑色能容納1件1班未來(lái)的狀態(tài)圖:精益模擬游戲客戶生產(chǎn)控制平衡生產(chǎn)6周預(yù)測(cè)PacificSteelCo.PacificSteelCo.太平洋鋼鐵公司7秒5天生產(chǎn)前置時(shí)間=8.75天(525秒)增加值時(shí)間=64秒.(<1天)2天2天.75天12秒45秒螺母生產(chǎn)成批油漆鏈螺釘加固/裝配.OXOX平準(zhǔn)化2天(運(yùn)輸)每日發(fā)貨每日貨運(yùn)90/60/30天預(yù)測(cè)每周確定定貨.75天緩沖庫(kù)存安全庫(kù)存已油漆過(guò)的螺母粗制螺母粗制珠料超市托盤(pán)C/T=3.5秒.C/O=5秒.1班1人95%UptimeEPE=天95%正常運(yùn)行時(shí)間T/T=15秒C/T=15.秒1班2人97%正常運(yùn)行時(shí)間C/T=6秒C/O=0分鐘.1班1人95%產(chǎn)量EPE=天EPE=天2天5天.5天再定購(gòu)板原料供應(yīng)商80l個(gè)連桿/mo未來(lái)的狀態(tài)圖:精益模擬游戲客LeanSim_Part2_SHW_E_Sep2003.ppt13BuildingBlocksofJust-In-Time

建造即時(shí)生產(chǎn)方式的格局ProductionatthePaceoftheCustomerWithMinimalInventoryRequirements在保持最小庫(kù)存量的要求下,以客戶的需求速度進(jìn)行生產(chǎn)Just-InTime及時(shí)制生產(chǎn)ContinuousflowProcessing持續(xù)的流程處理方法

PullSystem(Kanban)拉動(dòng)系統(tǒng)(看板)

TaktTime節(jié)拍時(shí)間

LevelScheduledProduction平衡生產(chǎn)進(jìn)度LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt14PullSystems

拉動(dòng)系統(tǒng)在你已實(shí)現(xiàn)了穩(wěn)定性這一目標(biāo)之后AfteryouhaveachievedStability遵循ERQ方法FollowERQmethodology標(biāo)準(zhǔn)實(shí)施到位并且可預(yù)見(jiàn)到改進(jìn)之處Thestandardsareinplaceandpredictableallowingimprovements在不能“流動(dòng)”之處實(shí)施“拉動(dòng)”P(pán)ullwhereyoucannotflowLeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt15

CategoriesofKanban看板的分類Instruction指示W(wǎng)ithdrawal提取型Kanban看板ProductionKanban(nonlotproduction)生產(chǎn)看板

(非批量生產(chǎn))TriangleKanban(forlotproduction)三角看板(用于批量生產(chǎn))InterprocessKanban進(jìn)程看板SupplierKanban供應(yīng)商看板LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt16KanbanTypes

看板的類型store儲(chǔ)存ProceedingProcess加工過(guò)程FollowingProcess接下來(lái)的過(guò)程ProductionInstructionKanban生產(chǎn)指示看板WithdrawalKanban提取型看板

NewProduct新產(chǎn)品NeededProduct所需產(chǎn)品LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt17DevelopFormat

開(kāi)發(fā)格式SUPPLIER:供應(yīng)商:STOCKLOCATION:庫(kù)存地點(diǎn):D#(part#)DESCRIPTION:描述:BOXQUANTITY箱的數(shù)量KANBANNO.看板號(hào)LINEADDRESS生產(chǎn)線地址LINELOCATION生產(chǎn)線地點(diǎn)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt18PreparationsforKanban

看板的準(zhǔn)備工作 PlantLayout工廠布局AislesID’dAlphanumeric通道應(yīng)用字母數(shù)字標(biāo)識(shí)WorkcellIDwithindividualmateriallocationsdefined工作單元標(biāo)識(shí)，帶有規(guī)定的物料地點(diǎn)說(shuō)明Methodforattachinganddetachingthekanbancard添加和取下看板卡的方法Methodfortrackingkanbancards看板卡的追蹤方法VisualManagement目視管理CentralMarkets中心市場(chǎng)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt19KANBANMAYIHAVESOMEPARTS,PLEASE?我能取些零件嗎?Itisa“FixedTimeRandomQuantity”route.它是一條“固定時(shí)間內(nèi)的取用數(shù)量隨意”的線路(方法).Providesmaterialsbasedonconsumption.它根據(jù)消費(fèi)量來(lái)提供材料.Everythinghasadesignatedlocationforsimplicity.為了簡(jiǎn)化,所有東西都有一指定地點(diǎn).Customercanfocusontheirqualitybecausematerialstheyneedarealwaysthere.因?yàn)樗璧脑峡偸怯斜ＷC,客戶會(huì)更注重產(chǎn)品的質(zhì)量.Welldefinedsystemforeaseofimprovement.規(guī)定明確的系統(tǒng)也便于改進(jìn).Supportsthetotalpullsystemandmayprovideinstructiontoits’supplier.支持整個(gè)拉動(dòng)系統(tǒng)并可能為供應(yīng)商提供相關(guān)信息.WithdrawalKanbanandConveyance:TheActiontoWithdrawal提取型看板和運(yùn)輸:提取的作用LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt20InstructionKanban

指示型看板明確指出所要生產(chǎn)的產(chǎn)品ClearInstructionsonwhattoProduce指明優(yōu)先順序SetsPriority設(shè)定期望值EstablishesExpectations簡(jiǎn)單并且看得見(jiàn)CanbesimpleandvisualLeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt21

InstructionKanbanPART#11066DESCRIPTION:COLOR:QUANTITY:ASSOC/DATE/SHIFTJE12/20/951stCYHOUSINGRH30DescriptionGOLDNUTSLotSize10pcs.2TotesTrigger0

TotesRunTime40sec.PART

NUMBERDESCRIPTIONRHF-SERIESPRIVSVSQUANTITY15MACHINE13ZONE3TIMENEEDEDREORDERPOSITION:REORDERPOINT:53420123456789101112(Dolly)123(Pallet)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt22

指示型看板零件編號(hào)#11066描述:顏色數(shù)量ASSOC/日期/班JE12/20/951stCYHOUSINGRH30描述金色螺母批量大小10pcs.2Totes觸發(fā)0

揀貨箱運(yùn)行時(shí)間40sec.零件編號(hào)

描述RHF-SERIESPRIVSVS數(shù)量15機(jī)器13區(qū)域3TI所需REORDERPOSITION:REORDERPOINT:53420零件編號(hào)11023數(shù)量.=50(Card)3.123456789101112手推車123(托盤(pán)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt23LineA

A生產(chǎn)線LineSideInventory生產(chǎn)線旁邊的存貨PressSupermarket推動(dòng)超市PRECEDINGPROCESS前面的過(guò)程SUBSEQUENTPROCESS接下來(lái)的過(guò)程

Thanks!謝謝!Press推動(dòng)看板MAYIHAVESOMEPARTS,PLEASE?我能取用一些零件嗎?WithdrawalandInstructionKanbanasPartoftheSystem提取和作為系統(tǒng)一部分的看板指令FTVQFQVTLeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt24WhyChangeover?為什么要切換?

Time時(shí)間

Inventorylevel庫(kù)存水平Averageinventorylevels平均的庫(kù)存水平Differenceinaverageinventorylevelwithmorechangeovers因更多的切換帶來(lái)的不同的平均庫(kù)存水平Themorewechangeover,themoreourinventorylevelsdecrease.Thishelpsaccomplishourgoalofwasteelimination.切換越多,我們的庫(kù)存水平就越降低.這有助于實(shí)現(xiàn)消除浪費(fèi)的目標(biāo).Change變化LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt25KeyPointsofReplenishmentRoutes

補(bǔ)貨線路的關(guān)鍵點(diǎn)Enoughofallmaterialsstoredatlinetocoverdemandofareplenishmentcycle線上貯存各種足量的原料以滿足補(bǔ)給周期的需求Emptypackagingreturn空包裝箱返回Dedicatedlocationsforeachcomponent為每個(gè)元件指定地點(diǎn)Mistakeproofedtopreventerrors采取防錯(cuò)Changefrompart“A”to“B”inlessthanacycle,QuickChangeOver(QCO)在不到一個(gè)周期的時(shí)間里從零件”A”轉(zhuǎn)換成零件”B”,完成快速切換(QCO)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt26JITElement-ContinuousFlowProcessing

即時(shí)生產(chǎn)的要素–持續(xù)的流程處理BatchProcessing批量處理10minutes

10分鐘10minutes

10分鐘10minutes

10分鐘TotalBatchAprocessingtime:30minutes批量處理的總時(shí)間:30分鐘ContinuousFlowProcessing持續(xù)的流程處理TotalBatchAprocessingtime:12minutes

Only3minutesfor1stpart批量處理的總時(shí)間:12分鐘

第一批零件僅用了3分鐘Productrequiresthreeprocessesthattakeoneminuteeach產(chǎn)品要求進(jìn)行三道工序處理,每道工序需1分鐘Processingfirstbatchinbatchesof10requires30minutes處理10批中的第一批需要30分鐘Processingfirst“batch”one-at-a-timerequiresonly12minutes按一次一個(gè)處理第一批僅需12分鐘LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt27Heijunka-LevelScheduling

平準(zhǔn)化–平衡進(jìn)度安排

CloselyMirrorsCustomerDemand,ThePaceoftheCustomer非常如實(shí)地反映出客戶的需求及進(jìn)度OptimizesOperations實(shí)行最優(yōu)化操作PreventsOverProduction防止過(guò)量生產(chǎn)MaximizesChangeOverOpportunities盡可能多地利用快速切換機(jī)會(huì)QuickChangeOver(QCO)快速切換(QCO)Batchofonecapabilities,smallerpackaging一批相同容量的小包裝箱Materialchangewithinacycle在一個(gè)周期時(shí)間內(nèi)完成原料切換LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt28Levelproduction,eliminatespeaksandvalleys平衡生產(chǎn),消除生產(chǎn)量大幅波動(dòng)的現(xiàn)象（波峰和波谷）.Evenlypacedlaborforce.平衡地設(shè)置勞動(dòng)力.LevelshipmentsfromSuppliers.平衡供應(yīng)商的發(fā)貨.Minimizedinter-processstockandhandling將進(jìn)程中的庫(kù)存及處理降到最低Heijunka-LevelSchedulingOutcome

平準(zhǔn)化–平衡進(jìn)度的結(jié)果LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt29Conclusions

結(jié)論 JCMS是我們工廠運(yùn)作的方式JCMSisthewaywerunourplants

JCMS有助于降低各項(xiàng)成本JCMSwillhelpreduceourcostsJCMS有助于我們保持競(jìng)爭(zhēng)力JCMSwillhelpkeepuscompetitiveJCMS有助于我們不斷超越客戶日益增加的期望JCMSwillhelpusexceedourcustomersincreasingexpectationsLeanSim_Part2_SHW_E_Sep2003.ALeanSimulation

江森精益制造系統(tǒng)PartTwo第二部分ALeanSimulation

江森精益制造系統(tǒng)PartLeanSim_Part2_SHW_E_Sep2003.ppt31SystemDevelopment

系統(tǒng)開(kāi)發(fā)ControllingInventoryandImprovingOperations庫(kù)存管理和改善運(yùn)作LeanSim_Part2_SHW_E_Sep2003.LeanasaSystem

精益制造系統(tǒng)AllLeanManufacturingProcessesMustBeViewedByTheLeadershipAsATotalSystem管理層必須視所有的精益制造過(guò)程為一完整的系統(tǒng)LeanasaSystem

精益制造系統(tǒng)AllLeaLeanSim_Part2_SHW_E_Sep2003.ppt33ValueStreamMapping:

MaterialandInformationFlow

價(jià)值流程圖:

物料和信息流程Graphicallyplotcurrentstateofmaterialandinformationflowatthemanufacturingsite用圖解來(lái)描述生產(chǎn)場(chǎng)地的物料和信息流程現(xiàn)狀Evaluatetheinventorylocationsandstatus對(duì)庫(kù)存場(chǎng)地和現(xiàn)狀進(jìn)行評(píng)估Plotafuturestateformaterialandinformationflowusingguidequestions用引導(dǎo)問(wèn)題繪制未來(lái)的物料和信息流程圖Planthetransitiontofuturestate制定未來(lái)的過(guò)濾計(jì)劃LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt34CurrentStateMap:LeanSimulationGameRawmaterialsSuppliersNUTMANUF.

C/T=3.5secondC/O=15secYield=99%1workerEPE=4weeks

IC/T=7.5secondsC/O=NoneYield=100%1workerEPE=weekBOLT

HardeningPAINTCURE

(NUTS)SteelBalls15days5days15daysASSEMBLYC/T=6seconds

C/O=NoneYield=95%1workerEPE=4weeksC/T=30secondsC/O=02workersYield=98%EPE=4WeeksSHIPPINGStaging80linkages/mo-40silver-20gold-20blackTray10Pieces2shiftsWeeklydelivery1XWeekMRP15daysWeeklyFaxDailyShipScheduleDailyOrderIINutsIWeeklyScheduleDailyPltsBolts5days5daysRawbolts10daysPacificSteelCo.PacificSteelCo.PacificSteelCo.CUSTOMERPRODUCTIONCONTROL90/60/30dayForecasts6-weekForecast7sec15daysProductionLeadTime=55days(3300sec)ValueAddedTime=64sec.(<1day)10days15days15days15sec12sec30secConcurrentworkaddlongestlead-timeLeanSim_Part2_SHW_E_Sep2003.原料供應(yīng)商螺母生產(chǎn)

C/T=3.5秒C/O=15秒產(chǎn)量=99%1個(gè)工人EPE=4周

IC/T=7.5秒C/O=無(wú)產(chǎn)量=100%1個(gè)工人EPE=周螺釘加固油漆處理

(螺母)鋼珠15天5天15天裝配C/T=6秒

C/O=無(wú)產(chǎn)量=95%1個(gè)工人EPE=4周C/T=30秒C/O=02個(gè)工人產(chǎn)量=98%EPE=4周發(fā)貨分段運(yùn)輸80個(gè)連桿/mo-40銀色-20金色-20黑色托盤(pán)10件2班每周交貨1X周生產(chǎn)控制MRP90/60/30天預(yù)測(cè)

目前的狀態(tài)圖:精益模擬游戲客戶15天6周預(yù)測(cè)PacificSteelCo.PacificSteelCo.太平洋鋼鐵公司每周傳真每日裝貨時(shí)間表每日訂購(gòu)II螺母I7秒15天生產(chǎn)前置時(shí)間

=55天(3300秒)增加值時(shí)間=64秒.(<1天)5天10天15天15天15秒12秒30秒每周時(shí)間表同時(shí)工作會(huì)造成前置時(shí)間最長(zhǎng)每天Plts螺釘5天5天粗制螺釘10天原料供應(yīng)商螺母C/T=3.5秒C/O=15秒產(chǎn)量LeanSim_Part2_SHW_E_Sep2003.ppt36

RawmaterialsSuppliersNUTMANUF.

C/T=3.5secondC/O=15secYield=99%1workerEPE=4weeks

IC/T=7.5secondsC/O=NoneYield=100%1workerEPE=weekBOLT

HardeningPAINTCURE

(NUTS)SteelBalls15days5days15daysASSEMBLYC/T=6seconds

C/O=NoneYield=95%1workerEPE=4weeksC/T=30secondsC/O=02workersYield=98%EPE=4WeeksSHIPPINGStaging80linkages/mo-40silver-20gold-20blackTray10Pieces2shiftsWeeklydelivery1XWeekPRODUCTIONCONTROLMRP90/60/30dayForecastsCurrentStateMap:LeanSimulationGameCUSTOMER15days6-weekForecastPacificSteelCo.PacificSteelCo.PacificSteelCo.WeeklyFaxDailyShipScheduleDailyOrderIRawbolts10daysINutsIWeeklyScheduleDailyPltsBolts5days5daysSupplierLoop供應(yīng)商回路PacemakerLoop進(jìn)度決策回路AssemblyLoop裝配回路BatchPaintLoop成批油漆回路CustomerLoop客戶回路7sec15daysProductionLeadTime=55days(3300sec)ValueAddedTime=64sec.(<1day)10days15days15days15sec12sec30secConcurrentworkaddlongestlead-timeLeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt37RawmaterialsSuppliersNUTMANUF.

C/T=3.5secondC/O=15secYield=99%1workerEPE=4weeks

IC/T=7.5secondsC/O=NoneYield=100%1workerEPE=weekBOLT

HardeningPAINTCURE

(NUTS)SteelBalls15days5days15daysASSEMBLYC/T=6seconds

C/O=NoneYield=95%1workerEPE=4weeksC/T=30secondsC/O=02workersYield=98%EPE=4WeeksSHIPPINGStaging80linkages/mo-40silver-20gold-20blackTray10Pieces2shiftsWeeklydelivery1XWeekPRODUCTIONCONTROLMRP90/60/30dayForecastsCUSTOMER15days6-weekForecastPacificSteelCo.PacificSteelCo.PacificSteelCo.WeeklyFaxDailyShipScheduleDailyOrderIRawbolts10daysINutsIWeeklyScheduleDailyPltsBolts5days5daysQCOKaizenKanbanLevelLoadErrorproof5SConstraintMgt.TPMPullSystemsStd.WorkSixSigmaCurrentStateMap:LeanSimulationGame7sec15daysProductionLeadTime=55days(3300sec)ValueAddedTime=64sec.(<1day)5days10days15days15days15sec12sec30secConcurrentworkaddlongestlead-timeLeanSim_Part2_SHW_E_Sep2003.原料供應(yīng)商螺母生產(chǎn)

C/T=3.5秒C/O=15秒產(chǎn)量=99%1個(gè)工人EPE=4周

IC/T=7.5秒C/O=無(wú)產(chǎn)量=100%1工人EPE=周螺釘加固油漆處理

(螺母)鋼珠15天5天15天裝配C/T=6秒

C/O=無(wú)產(chǎn)量=95%1個(gè)工人EPE=4周C/T=30秒C/O=02個(gè)工人產(chǎn)量=98%EPE=4周發(fā)貨分段運(yùn)輸80個(gè)連桿/mo-40銀色-20金色-20黑色托盤(pán)10件2班每周交貨1X周生產(chǎn)管理MRP90/60/30天預(yù)測(cè)目前的狀態(tài)圖:精益模擬游戲客戶15天6周預(yù)測(cè)PacificSteelCo.PacificSteelCo.太平洋鋼鐵公司每周傳真每日裝貨時(shí)間表每日定貨I粗制螺釘10天I螺母I7秒15天生產(chǎn)前置時(shí)間=55天(3300秒)增加值時(shí)間=64秒.(<1天)5天10天15天15天15秒12秒30秒每周時(shí)間表工作和最長(zhǎng)的前置時(shí)間每天Plts螺釘5天5天QCO改善看板平衡工作量防錯(cuò)5S制約管理TPM拉動(dòng)系統(tǒng)標(biāo)準(zhǔn)化作業(yè)6西格瑪原料供應(yīng)商螺母C/T=3.5秒C/O=15秒產(chǎn)量LeanSim_Part2_SHW_E_Sep2003.ppt39KeyQuestionsfor

Future-StateDesign

構(gòu)思未來(lái)狀態(tài)的關(guān)鍵問(wèn)題Whatisthetakttime什么是節(jié)拍時(shí)間？Buildtosupermarketortoshipping設(shè)置超市或貨運(yùn)環(huán)節(jié)Wherecanyouusecontinuousflowprocessing你在什么地方可以采用持續(xù)的流程處理方法Wherewillyouneedtousesupermarketpullsystems你在什么地方將要采用超市拉動(dòng)系統(tǒng)Atwhatsinglepointintheproductionchainwillyouhavethepacemakerprocess你在生產(chǎn)鏈的哪個(gè)點(diǎn)上設(shè)置進(jìn)度決策過(guò)程Howwillyoulevelthemixatthepacemaker你怎樣調(diào)節(jié)牽涉到很多環(huán)節(jié)的進(jìn)度決策程序Whatincrementofworkwillyoureleaseandtakeawayatthepacemakerprocess在進(jìn)度決策過(guò)程中你會(huì)削減哪方面增加的工作Whatimprovementswillbenecessaryforthefuture要實(shí)現(xiàn)未來(lái)的狀態(tài)圖,哪些方面必須加以改進(jìn)ToyotaDNAapplieshere豐田DNA應(yīng)用于此LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt40RawmaterialsSuppliers80linkages/mo-40silver-20gold-20black1piececapable1shiftsCUSTOMERPRODUCTIONCONTROLLevelProduction6-weekForecastPacificSteelCo.PacificSteelCo.PacificSteelCo.NutMfg.BatchPaintLineBoltHrd./Assy.OXOXHeijunka2days(Conveyance)DailyshipMilkrundaily90/60/30dayForecastsWeeklyFirmOrder.75daysBufferSafetyPaintedNuts

RawNutsRawBallsPlatesC/T=3.5sec.C/O=5sec.1shift1person95%UptimeEPE=Day95%UptimeT/T=15sec.C/T=15.sec.1shift2people97%UptimeC/T=6secC/O=0min.1shift1person95%YieldEPE=DayEPE=Day2days.5daysRe-orderboardFutureStateMap:LeanSimulationGameSupermarket5days7sec5daysProductionLeadTime=8.75days(525sec)ValueAddedTime=64sec.(<1day)2days2day.75days12sec45secSupermarket5daysLeanSim_Part2_SHW_E_Sep2003.原料供應(yīng)商80l個(gè)連桿/mo-40銀色-20金色-20黑色能容納1件1班未來(lái)的狀態(tài)圖:精益模擬游戲客戶生產(chǎn)控制平衡生產(chǎn)6周預(yù)測(cè)PacificSteelCo.PacificSteelCo.太平洋鋼鐵公司7秒5天生產(chǎn)前置時(shí)間=8.75天(525秒)增加值時(shí)間=64秒.(<1天)2天2天.75天12秒45秒螺母生產(chǎn)成批油漆鏈螺釘加固/裝配.OXOX平準(zhǔn)化2天(運(yùn)輸)每日發(fā)貨每日貨運(yùn)90/60/30天預(yù)測(cè)每周確定定貨.75天緩沖庫(kù)存安全庫(kù)存已油漆過(guò)的螺母粗制螺母粗制珠料超市托盤(pán)C/T=3.5秒.C/O=5秒.1班1人95%UptimeEPE=天95%正常運(yùn)行時(shí)間T/T=15秒C/T=15.秒1班2人97%正常運(yùn)行時(shí)間C/T=6秒C/O=0分鐘.1班1人95%產(chǎn)量EPE=天EPE=天2天5天.5天再定購(gòu)板原料供應(yīng)商80l個(gè)連桿/mo未來(lái)的狀態(tài)圖:精益模擬游戲客LeanSim_Part2_SHW_E_Sep2003.ppt42BuildingBlocksofJust-In-Time

建造即時(shí)生產(chǎn)方式的格局ProductionatthePaceoftheCustomerWithMinimalInventoryRequirements在保持最小庫(kù)存量的要求下,以客戶的需求速度進(jìn)行生產(chǎn)Just-InTime及時(shí)制生產(chǎn)ContinuousflowProcessing持續(xù)的流程處理方法

PullSystem(Kanban)拉動(dòng)系統(tǒng)(看板)

TaktTime節(jié)拍時(shí)間

LevelScheduledProduction平衡生產(chǎn)進(jìn)度LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt43PullSystems

拉動(dòng)系統(tǒng)在你已實(shí)現(xiàn)了穩(wěn)定性這一目標(biāo)之后AfteryouhaveachievedStability遵循ERQ方法FollowERQmethodology標(biāo)準(zhǔn)實(shí)施到位并且可預(yù)見(jiàn)到改進(jìn)之處Thestandardsareinplaceandpredictableallowingimprovements在不能“流動(dòng)”之處實(shí)施“拉動(dòng)”P(pán)ullwhereyoucannotflowLeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt44

CategoriesofKanban看板的分類Instruction指示W(wǎng)ithdrawal提取型Kanban看板ProductionKanban(nonlotproduction)生產(chǎn)看板

(非批量生產(chǎn))TriangleKanban(forlotproduction)三角看板(用于批量生產(chǎn))InterprocessKanban進(jìn)程看板SupplierKanban供應(yīng)商看板LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt45KanbanTypes

看板的類型store儲(chǔ)存ProceedingProcess加工過(guò)程FollowingProcess接下來(lái)的過(guò)程ProductionInstructionKanban生產(chǎn)指示看板WithdrawalKanban提取型看板

NewProduct新產(chǎn)品NeededProduct所需產(chǎn)品LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt46DevelopFormat

開(kāi)發(fā)格式SUPPLIER:供應(yīng)商:STOCKLOCATION:庫(kù)存地點(diǎn):D#(part#)DESCRIPTION:描述:BOXQUANTITY箱的數(shù)量KANBANNO.看板號(hào)LINEADDRESS生產(chǎn)線地址LINELOCATION生產(chǎn)線地點(diǎn)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt47PreparationsforKanban

看板的準(zhǔn)備工作 PlantLayout工廠布局AislesID’dAlphanumeric通道應(yīng)用字母數(shù)字標(biāo)識(shí)WorkcellIDwithindividualmateriallocationsdefined工作單元標(biāo)識(shí)，帶有規(guī)定的物料地點(diǎn)說(shuō)明Methodforattachinganddetachingthekanbancard添加和取下看板卡的方法Methodfortrackingkanbancards看板卡的追蹤方法VisualManagement目視管理CentralMarkets中心市場(chǎng)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt48KANBANMAYIHAVESOMEPARTS,PLEASE?我能取些零件嗎?Itisa“FixedTimeRandomQuantity”route.它是一條“固定時(shí)間內(nèi)的取用數(shù)量隨意”的線路(方法).Providesmaterialsbasedonconsumption.它根據(jù)消費(fèi)量來(lái)提供材料.Everythinghasadesignatedlocationforsimplicity.為了簡(jiǎn)化,所有東西都有一指定地點(diǎn).Customercanfocusontheirqualitybecausematerialstheyneedarealwaysthere.因?yàn)樗璧脑峡偸怯斜ＷC,客戶會(huì)更注重產(chǎn)品的質(zhì)量.Welldefinedsystemforeaseofimprovement.規(guī)定明確的系統(tǒng)也便于改進(jìn).Supportsthetotalpullsystemandmayprovideinstructiontoits’supplier.支持整個(gè)拉動(dòng)系統(tǒng)并可能為供應(yīng)商提供相關(guān)信息.WithdrawalKanbanandConveyance:TheActiontoWithdrawal提取型看板和運(yùn)輸:提取的作用LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt49InstructionKanban

指示型看板明確指出所要生產(chǎn)的產(chǎn)品ClearInstructionsonwhattoProduce指明優(yōu)先順序SetsPriority設(shè)定期望值EstablishesExpectations簡(jiǎn)單并且看得見(jiàn)CanbesimpleandvisualLeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt50

InstructionKanbanPART#11066DESCRIPTION:COLOR:QUANTITY:ASSOC/DATE/SHIFTJE12/20/951stCYHOUSINGRH30DescriptionGOLDNUTSLotSize10pcs.2TotesTrigger0

TotesRunTime40sec.PART

NUMBERDESCRIPTIONRHF-SERIESPRIVSVSQUANTITY15MACHINE13ZONE3TIMENEEDEDREORDERPOSITION:REORDERPOINT:53420123456789101112(Dolly)123(Pallet)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt51

指示型看板零件編號(hào)#11066描述:顏色數(shù)量ASSOC/日期/班JE12/20/951stCYHOUSINGRH30描述金色螺母批量大小10pcs.2Totes觸發(fā)0

揀貨箱運(yùn)行時(shí)間40sec.零件編號(hào)

描述RHF-SERIESPRIVSVS數(shù)量15機(jī)器13區(qū)域3TI所需REORDERPOSITION:REORDERPOINT:53420零件編號(hào)11023數(shù)量.=50(Card)3.123456789101112手推車123(托盤(pán)LeanSim_Part2_SHW_E_Sep2003.LeanSim_Part2_SHW_E_Sep2003.ppt52LineA

A生產(chǎn)線LineSideInventory生產(chǎn)線旁邊的存貨PressSupermarket推動(dòng)