如何縮短產(chǎn)品制造周期

ShortLeadTime

縮短制造周期

GMS員工參與標(biāo)準(zhǔn)化制造質(zhì)量縮短制造周期持續(xù)改進(jìn)32

GMSContinuousImprovementBuilt-In

QualityShortLead

TimePeople

InvolvementStandardizationShortLeadTime縮短制造周期Healthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessControlled

ExternalTransportationManufacturing

Process

ValidationProduct

Quality

StandardsQuality

System

ManagementScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementValuesVision/MissionShopFloor

ManagementInternalPull/DeliveryAndon

ConceptProblem

SolvingSimple

Process

FlowIn-Process

Control&VerificationStandardized

WorkSmallLot

PackagingTemporary

Material

StorageQuality

Feedback/

Feed-forwardVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

Maintenance

FixedPeriod

Ordering

System/OrderPartsPresentationFocus

展示的重點(diǎn)Thispresentationfocusesonleanmaterialflowanditsimpactonreducingleadtime.

側(cè)重于精益的物料流程，以及其對(duì)縮短過(guò)渡周期的作用FullFullFullFullEmptyEmptyShortLeadTime

縮短制造周期UponCompletionofThisModuleParticipantsWill學(xué)完SLT內(nèi)容，將會(huì)：UnderstandtheImportanceofShortLeadTimeforCustomerResponsivenessandCost.

明白SLT對(duì)客戶響應(yīng)及減少成本的重要性。BeFamiliarWiththeConceptsWhichContributetoShortLeadTime.

了解SLT的相關(guān)概念。BeIntroducedtotheLeanMaterialsManagementSystemsWhichControltheMaterialFlowIntoandWithinthePlant.

了解控制物料進(jìn)入及在工廠內(nèi)流動(dòng)的精益物料管理系統(tǒng)。ThePurestFormofLeanMaterialFlowisfromthesupplier’sLastValueAddedOperationtothecustomer’sPointofUsewithNoWaiting,Storage,DoubleHandling,orExcessInventory.純粹的精益物流系統(tǒng)是從供應(yīng)商最后的增殖產(chǎn)品到客戶的開(kāi)始使用期間，沒(méi)有等待、儲(chǔ)存量、雙重處理、多余庫(kù)存。ShortLeadTimeStrategySLT策略Supplier(供應(yīng)商)Plant(工廠)

PointofUse開(kāi)始使用ReceiveCustomerOrder

接收定單ProduceVehicle生產(chǎn)車輛DeliverVehicle交付產(chǎn)品ReceivePayment收到付款Themovementofmaterialintherightquantity,attherighttime,totherightlocation,withtherightequipment,usingtheshortestleadtimeandlowestpossiblecostforbothsupplierandcustomer.在最短的時(shí)間內(nèi)，供應(yīng)商與客戶雙方最少的成本損耗條件下，物料在適當(dāng)?shù)臅r(shí)間里把合適的數(shù)量用恰當(dāng)?shù)墓ぞ哌\(yùn)送到一定的地點(diǎn)的流動(dòng)。LeanMaterialFlowDefinition

精益物流定義1)PartsOrdering

定購(gòu)零件2)Suppliers

供應(yīng)商3)Packaging

包裝4)Transport

運(yùn)輸5)Receiving

接收6)Temp.Stores臨時(shí)倉(cāng)庫(kù)7)MaterialPullSystem物料拉動(dòng)系統(tǒng)8)AssemblyLine生產(chǎn)線LeanMaterialsManagement

精益物料管理FullFullFullFullEmptyEmptyOperator(操作工)PartPresentation(零件擺設(shè))Conveyance(運(yùn)輸)Staging(分段運(yùn)輸)Receive/Unload(接收/卸貨)Transportation(運(yùn)輸)Suppliers(供應(yīng)商)LOWESTTOTALCOST最低成本REDUCELEADTIME(??????)PLANFOREVERYPART(?????????)LeanMaterialFlow:GuidingPrinciples

精益物流：指導(dǎo)原則SAFE(安全)Highvalue

added(高增殖生產(chǎn))CompressionPart

Presentation

SmallLot#1BulkSequenced/Repack

Ergonomic

Space(空間)Organization(組織)FIFO(先進(jìn)先出)Method（方式）Frequency(頻率)Commun-ication(交流)WindowReceiving(窗口接收)Equipment

(裝置)Frequency(頻率)MilkRuns

DirectShip(直接運(yùn)輸）100%Tracked(100%跟蹤)Responsive(響應(yīng))OnTime(及時(shí))Right

Quantity(數(shù)量)To

Specifications(合適規(guī)格)(??)GuidingPrinciples

指導(dǎo)原則Make/receivefrequentdeliveries.

接收頻率Usesmalllotcontainers.使用小件包裝UsetheFirstInFirstOut(FIFO)process.先進(jìn)先出程序Eliminatewaste.減少浪費(fèi)LeanMaterialFlowModel精益物流典型FocusAreas重點(diǎn):

1.VehicleScheduling制造計(jì)劃2.PartOrdering訂購(gòu)零件3.SupplyBase供應(yīng)基地4.Transportation&Receiving運(yùn)輸與接收5.InternalPullSystems內(nèi)部拉動(dòng)系統(tǒng)6.MobileEquipment移動(dòng)設(shè)備7.PartPresentation零件擺放

Tools工具：PlanforEveryPart每個(gè)零件計(jì)劃StandardizedWork標(biāo)準(zhǔn)化工作SmallLotPackaging

小件包裝LevelSchedules進(jìn)展階段VisualManagement目視化管理

MinimumnumberofsupplypointsSupplyBasePullsystems(拉動(dòng)系統(tǒng))LevelBuildPattern(均衡生產(chǎn)模式)FrequentDelivery(????)MultiplePartNumbers/Delivery

(??????/??)MinimalInventory(????)GMPlantPartPartPartABCPlantProductionQtyTime1.VehicleSchedulingProcessOverview制造安排觀觀測(cè)*CustomerOrders客戶訂購(gòu)+*Non-SoldOrders非賣計(jì)劃PlantProductionPlan工廠生產(chǎn)計(jì)劃Customer客戶ProduceVehicles生產(chǎn)階段Dealers賣方/Marketing銷售DeliverFinishedVehicles交付成成品*CustomerOrders客戶訂訂購(gòu):SoldVehicles銷售車車輛*Non-SoldOrders非賣計(jì)計(jì)劃:Dealer/RegionOrders(Nospecifiedcustomer)賣方/區(qū)域域訂購(gòu)購(gòu)（無(wú)無(wú)明確確客戶戶）1-1.VehicleSchedules制造計(jì)計(jì)劃ThePlantProductionPlanlevelsvehiclerequirementsacrosstheproductionperiod生產(chǎn)計(jì)計(jì)劃應(yīng)應(yīng)均衡衡各個(gè)個(gè)階段段的生生產(chǎn)需需求。。100%Customerdeliverydatecompliance百分百百地在在交付付日期期交貨貨。Vehiclebuildstatusisknownthroughoutthemanufacturingprocess.整個(gè)生生產(chǎn)部部門都都應(yīng)該該了解解制造造狀態(tài)態(tài)。Supportreducedvehicledeliveryleadtime&manufacturingrestrictions.支持減減少車車輛交交付時(shí)時(shí)間和和各種種生產(chǎn)產(chǎn)限制制。VehicleBuildPattern樣板車車:CustomerOrder客戶定單：WhencanIgetmyvehicle()?(什么時(shí)候可以交付車子?)143256PlantProductionPlan2Non-sunroof1Sunroof2.PartsOrdering:IndividualParts訂購(gòu)：：個(gè)件件Partorderbaseduponaprojectedvehiclebuildschedule零件訂訂購(gòu)要要以設(shè)設(shè)定的的生產(chǎn)產(chǎn)計(jì)劃劃為基基礎(chǔ)Order=(PartsNeeded)-(PartsHave)訂單=(需要零零件)-(現(xiàn)有零零件)PickUpDocument訂購(gòu)文文件Deliveryquantityandtiminginstructionspershipment每次運(yùn)運(yùn)輸?shù)牡臄?shù)量量及時(shí)時(shí)限GMPlantDeliverySupplierPickUpDocumentPickUpDocumentPlantLinesideOperation2-1.PartsOrdering:Sub-AssemblyParts(零件訂訂購(gòu)：：分裝裝件)Asthevehiclepassesasetpointintheproductionprocess,asignalisgeneratedandsenttothesupplybaserequestingpartsrequiredforthatvehicle.生產(chǎn)過(guò)過(guò)程中中，當(dāng)當(dāng)生產(chǎn)產(chǎn)車輛輛超出出一定定點(diǎn)時(shí)時(shí)，生生成一一個(gè)信信號(hào)通通知供供應(yīng)商商對(duì)該該車的的零件件需求求。BroadcastSignal(廣播信信號(hào))7:008:009:00SEQ#1(8:00a.m.)SEQ#2(8:01a.m.)SupplierInSequence(Seat)3.SupplyBase(供應(yīng)基基地)CloseproximitytotheGMPlantforspecificpartsperdeliverylead-timeneeds(typicallythesearesequencedsub-assemblies).在GA車間附附近為為對(duì)制制造周周期有有特殊殊要求求的零零件設(shè)設(shè)立的的基地地（通通常是是些定定序的的分裝裝件））Sequencingrequirementsaretheresponsibilityoftheawardedsupplier(按先后后需求求排序序是合合格供供應(yīng)商商的職職責(zé)):Supplierownstheinventoryuntilthelatestpointpossibleinthemanufacturingprocess.(在送到到生產(chǎn)產(chǎn)線之之前供供應(yīng)商商擁有有庫(kù)存存)Minimizesupplypoints(供應(yīng)數(shù)數(shù)量最最低化化):Singlesupplypointperpartorsub-assembly.(零件或或分裝裝件的的單一一供應(yīng)應(yīng)點(diǎn)））Minimizethetotalsupplierbase(amountofsuppliers).（總供應(yīng)基基地的的最小化化（供供應(yīng)商商數(shù)量量）））SourcingdecisionsarebasedontheTotalMaterialPipelineCosts(基于總材料料傳送成本本決定貨源源）MilkRun10-11p.m.SUPPLIERA8-9a.m.SUPPLIERB10-11a.m.SUPPLIERC2-3p.m.SUPPLIERD5-6p.m.OurPlant4.Transportation(運(yùn)輸)Direct(直運(yùn))SUPPLIERASUPPLIERBSUPPLIERCOurPlantLOCSUPPLIERASUPPLIERBSUPPLIERCOurPlantLogisticsOptimizationCenter(物流優(yōu)化中心)4-1.TransportationandReceiving運(yùn)輸與接收收Pre-Scheduledpickupanddeliverywindowtimes.(事先計(jì)劃好好接收與交交付的間隔隔時(shí)間)Multiplesupplier/partpickupspertruck.(增加每次裝裝載的供應(yīng)應(yīng)商/零件件接收)Dailyshippingfrequency.(每天運(yùn)送頻頻率)EarlyWarning:Truckdriverscheckfreightatsupplierlocation.(預(yù)警：貨車車司機(jī)在供供應(yīng)商處檢檢查貨物)Exception-basedcommunications.(貨物不符時(shí)時(shí)協(xié)商)80%Highcubeutilization(liquid).(80%的立方利用用率（液體體）)LeadLogisticsProviderassinglepointofcontactfortheplant.(精益物流供供應(yīng)者作為為工廠單一一聯(lián)系人)Suppliers(供應(yīng)商)MON.-8:00amTUE.-8:00amWED.-8:00amTHU.-8:00amFRI.-8:00amCBA4-1.TransportationandReceiving運(yùn)輸與接收收LeadLogisticsProvider(LLP):On-sitesinglepointofcontactforplant.(現(xiàn)場(chǎng)單一聯(lián)聯(lián)系)Routeplanningandscheduling.(路線計(jì)劃與與安排)Visualroute/dockboard.(目視化路線線/接收板板)PlantReceiving:工廠接收Visualboard(目視化欄板板)-Canlookatboardandseewhatishappening(看欄板就可可以知道情情況)Scheduled，daily/weekly日/周計(jì)劃劃-Whenmaterialwillarriveatplant(什么時(shí)候零零件能到達(dá)達(dá)工廠)Levelunloadplan(平衡卸貨計(jì)計(jì)劃)PlantLLPTransportationRouteBoardxx#1#2#3#4RouteTimeDefinition:Acentralizedtemporarystorageareaforpartsnotbeingdelivereddirectlyfromsuppliertolineside.定義：不直直接把材料料從供應(yīng)商商處運(yùn)送到到線旁，而而是暫時(shí)將將其集中存存放的區(qū)域域。Purpose:ToOrganize&ControlInventoryLevels,Throughput&FlowforMaterialsnotdelivereddirectlyfromsuppliertopointofuse.目的：組織織控制不直直接由供應(yīng)應(yīng)商送到生生產(chǎn)線的材材料庫(kù)存量量、產(chǎn)量和和物物流4-2.CentralMaterialArea(集中材料區(qū)區(qū)域)4-2.CentralMaterialArea(集中材料區(qū)區(qū)域)KeyConcepts(主要概念):Organizebybulk/cartontoseparateequipment&minimizespacerequirements(用大箱或紙紙箱裝零件件來(lái)隔離設(shè)設(shè)備，減少少空間需求求)1locationperpartnumber(一個(gè)零件一一個(gè)存放點(diǎn)點(diǎn))MinimizeCMAspace(CMA空間最小化化)Minimizedeliverylead-time(運(yùn)送時(shí)間最最小化)4-2.CentralMaterialArea(集中材料區(qū)區(qū)域)KeyBenefits(主要益處):Optimizespace,manpower&equipment(優(yōu)化空間、、人員及設(shè)設(shè)備)Min.impactofproductionpullfluctuations(減少生產(chǎn)拉拉動(dòng)波動(dòng)的的影響)SupportsPullSystemRoutes(支持拉動(dòng)系系統(tǒng)路線)SupportF.I.F.O.(支持先進(jìn)先先出)Definition(定義):Amethodofmaterialreplenishmentbasedonconsumption,authorizedbytheuser,whosendsasignaltomanufacture,ship,ordeliveryaproductataspecifictime,place,andquantity.(使用者認(rèn)可可的，通過(guò)過(guò)向生產(chǎn)、、運(yùn)輸部門門發(fā)出信號(hào)號(hào)，要求在在一定時(shí)間間內(nèi)在具體體地方運(yùn)送送定量產(chǎn)品品的一種補(bǔ)補(bǔ)充消耗物物料的方法法。)AflexibletoolthatenablesJust-in-Time.(一個(gè)能確保保JIT的靈活工具具)Connectsoperationstomaterialsupply.(連接生產(chǎn)與與材料供給給.)5.InternalPull/Delivery(內(nèi)部拉動(dòng)/運(yùn)送)5-1.TypesofInternalPullSystems(內(nèi)部物流的的拉動(dòng)系統(tǒng)統(tǒng)的種類)EmptyContainerPullProcess(空箱拉動(dòng)系系統(tǒng))PullCardProcess(卡片拉動(dòng)系系統(tǒng))ElectronicPullSystem(EPS)(電子拉動(dòng)系系統(tǒng))“Nothingmoveswithoutapullsignal(無(wú)信號(hào)無(wú)拉拉動(dòng)).”ProductionPullProcess(生產(chǎn)拉動(dòng)系系統(tǒng))PullCardProcess(卡片拉動(dòng)系系統(tǒng)):Description(定義):Amaterialpullsystemthatusescardstocommunicatereplenishmentrequirements(使用卡片來(lái)來(lái)傳遞供貨貨信息的物物流拉動(dòng)系系統(tǒng))(投遞卡片)(掃描卡片)(CMA收集卡片））(運(yùn)送材料））EPSProcess(EPS系統(tǒng)):(材料需求)(電子識(shí)別)(材料提取，，分運(yùn)）(材料運(yùn)送)(交貨結(jié)束)EmptyContainerPullProcess(空箱拉動(dòng)系系統(tǒng))UsingLocationReplenishProductionTeamMember生產(chǎn)人員PushOutPushInEMPTYFULLProductionPullProcess(生產(chǎn)拉動(dòng)系系統(tǒng))BroadcastPoint(RFID廣播）VehicleLocation&MGOPartData(車輛存放放點(diǎn)及MGO零件數(shù)據(jù)據(jù))Automatedpullsystemordersmaterialbasedonactualvehiclepartconsumption(自動(dòng)拉動(dòng)動(dòng)系統(tǒng)零零件訂購(gòu)購(gòu)以實(shí)際際消耗為為根據(jù))Simpledesign(簡(jiǎn)單設(shè)計(jì)計(jì))Designtoenablemultiplepartnumbersperdelivery(能夠每次次多零件件運(yùn)送的的設(shè)計(jì))Standardizeequipmentandcomponentsthroughouttheplant(numberoftypes,hitches,chassis)(整個(gè)工廠廠設(shè)備及及零件標(biāo)標(biāo)準(zhǔn)化（（種類、、栓、底底盤的數(shù)數(shù)目）)Designformanualmanipulation(pushandpull).(人工操作作（推或或拉）的的設(shè)計(jì))6.MobileEquipment(運(yùn)輸設(shè)備備):NOYESExample(實(shí)例):LinesideDelivery(線旁運(yùn)送送)DollyExamples(手推車實(shí)實(shí)例)Bulkcontainerdollybase(Standard)(大箱手推推車基座座)(標(biāo)準(zhǔn))SwivelTurntableBase(旋轉(zhuǎn)轉(zhuǎn)盤盤基座)7.PartPresentation(零件展示示）Returnablecontainers(回收空箱箱)Oneortwohoursusagepercontainer(每個(gè)箱一一到兩小小時(shí)的用用量)Hand-carriedorhand-manageable(dolly)(手提或手手推)Ergonomicallyapproved(size,grippoints)(通過(guò)人機(jī)機(jī)工程認(rèn)認(rèn)證)（大小、、把手））Minimaldunnage(partisalloperatorneeds!)(最小限制制的隔板板（這是是所有操操作者需需要的部部分）)Easypartpick(容易提取取)Properpartslabeling(合適的標(biāo)標(biāo)簽)Stackable(層疊)Simpledesign(設(shè)計(jì)簡(jiǎn)單單)PartPresentation(零件擺設(shè)設(shè)):WithinWorkstation(在工位內(nèi)內(nèi))Withinarm’sreachatpointofinstallation(安裝點(diǎn)在在手臂可可及處)Lessthan5feetinheight(lineofsight)(高度低于于5英尺尺)HandManageable(人工操作作)5feetPartASmallLotContainer(小裝箱)Bringthepartstotheoperator(零件運(yùn)送送到操作作工身旁旁)PartPresentationExample(零件展示示實(shí)例)LineTrackingDevice(流水線跟跟蹤儀器器)Apron(圍兜)Canmovewithcarrierormanually(能夠人力力或自動(dòng)動(dòng)移動(dòng))ApronforFastenersandTools(裝螺絲螺螺栓的圍圍兜)Eliminateswasteofmotion(減少運(yùn)動(dòng)動(dòng)浪費(fèi))SmallLotPartsandContainers(小件包裝裝)LeanMaterialFlow(精益物流流)WeakMaterialFlow(欠缺物流流)IdealMaterialFlow(理想物流流)LackofVisualManagementTechniques(缺乏目視視化管理理)SinglePart/ContainerDeliveryPerTrip(每次單一一零件/單箱配配送)MaterialPushedtoSubsequentLocation(零件推動(dòng)動(dòng)到其他他地點(diǎn))MaterialDictatesLengthofProductionOperator’sFootPrint(材料指示示生產(chǎn))EmptyMaterialLocations(空箱回收收地點(diǎn))IdleMaterialOperators(閑置的材材料員)HeavyPullCardLoss(拉動(dòng)卡的的巨大損損失)ManySmallCMAs(7-11Concept)(太多CMA(7-11概念))VisualManagement(目視化管管理)MultipleDeliveriesperPartNumber(每次同一一零件的的多箱配配送)EstablishedInventoryLevels(確定的庫(kù)庫(kù)存量)PartsScheduledviaPullSignal(Kanban,Broadcast)(拉動(dòng)信號(hào)號(hào)對(duì)應(yīng)相相應(yīng)零件件看板、、廣播））)ReducedLeadtime(SupplierCo-location)(減少制造造周期（（供應(yīng)商商共同地地點(diǎn))DriverChecksatSupplierDock(司機(jī)在供應(yīng)商商處驗(yàn)貨)Point-of-Use/Direct-to-LineDelivery(使用節(jié)點(diǎn)/直直接到線運(yùn)送送)LowCost,FlexibleEquipment(低成本，靈活活的設(shè)備)HowdoesShortLeadTimeApplytoOtherGMSPrinciples?(SLT與其他GMS原則關(guān)系)Built-In-Quality(制造質(zhì)量):Rightpartattherightstationattherighttime(合適的時(shí)間、、一定的工位位、適當(dāng)?shù)牧懔慵?Returnablecontainersprotectpart(空箱回收保護(hù)護(hù)零件)PeopleInvolvement(員工參與):Shopfloorinvolvementinplanningandexecutingleanmaterialflow(員工參與計(jì)劃劃及實(shí)施精益益物流)Standardization(標(biāo)準(zhǔn)化):Scheduledpick-upsanddeliveries(計(jì)劃好的接收收與運(yùn)送)Leanpartpresentationtotheoperator(操作工精益的的零件擺放)Standardizedroutes(標(biāo)準(zhǔn)路線)ContinuousImprovement(持續(xù)改進(jìn)):Visualmanagementinallareasofleanmaterialflowallowforcontinuousimprovement(各個(gè)領(lǐng)域精益益物流的目視視化管理促進(jìn)進(jìn)不斷改進(jìn))GM-GMS(員工參與)(標(biāo)準(zhǔn)化)(制造質(zhì)量)(縮短制造周期期)(持續(xù)改進(jìn))9、靜夜四四無(wú)鄰，，荒居舊舊業(yè)貧。。。12月-2212月-22Friday,December23,202210、雨中黃葉樹(shù)樹(shù)，燈下白頭頭人。。23:17:0023:17:0023:1712/23/202211:17:00PM11、以我我獨(dú)沈沈久，，愧君君相見(jiàn)見(jiàn)頻。。。12月月-2223:17:0023:17Dec-2223-Dec-2212、故人人江海海別，，幾度度隔山山川。。。23:17:0023:17:0023:17Friday,December23,202213、乍乍見(jiàn)見(jiàn)翻翻疑疑夢(mèng)夢(mèng)，，相相悲悲各各問(wèn)問(wèn)年年。。。。12月月-2212月月-2223:17:0023:17:00December23,202214、他鄉(xiāng)生生白發(fā)，，舊國(guó)見(jiàn)見(jiàn)青山。。。23十十二月202211:17:00下下午23:17:0012月-2215、比不了了得就不不比，得得不到的的就不要要。。。。十二月2211:17下下午12月-2223:17December23,202216、行動(dòng)出成成果，工作作出財(cái)富。。。2022/12/2323:17:0023:17:0023December202217、做前，能能夠環(huán)視四四周；做時(shí)時(shí)，你只能能或者最好好沿著以腳腳為起點(diǎn)的的射線向前前。。11:17:00下下午11:17下午23:17:0012月-229、沒(méi)有失敗敗，只有暫暫時(shí)停止成成功！。12月-2212月-22Friday,December23,202210、很多事情情努力了未未必有結(jié)果果，但是不不努力卻什什么改變也也沒(méi)有。。。23:17:0023:17:0023:1712/23/202211:17:00PM11、成功就是日日復(fù)一日那一一點(diǎn)點(diǎn)小小努努力的積累。。。12月-2223:17:0023:17Dec-222