優(yōu)化生產(chǎn)中的物流活動S

MaterialMovementinaLeanManufacturingOperation

優(yōu)化生產(chǎn)中的物流活動TotalSystemsDevelopment

全體系生產(chǎn)提高JIT生產(chǎn)(準(zhǔn)時,準(zhǔn)量生產(chǎn)):Whatismeantbytheterm,“Just-In-Time”?JIT生產(chǎn)意味著什么?DoesitmeanJITSupply?準(zhǔn)時,準(zhǔn)量供應(yīng)?DoesitmeanJITProduction?準(zhǔn)時,準(zhǔn)量生產(chǎn)?So,whatisJust-In-Time?

那么,什么是準(zhǔn)時準(zhǔn)量生產(chǎn)?Theconceptofproducingthenecessaryunitsinthenecessaryquantitiesatthenecessarytimeisdescribedbytheshort-phrase“Just-In-Time”.JIT生產(chǎn)是:在必需時間內(nèi)生產(chǎn)必需數(shù)量的必需部品的概念.Forexample….Inbuildingshoes:Thenecessarysubassembliesoftheproceedingprocess(uppersandbottoms)shouldarriveattheassemblylineatthetimeneededintheamountsneeded.舉例說明:在生產(chǎn)成品鞋的時候:制鞋所必需的部件(鞋幫和鞋底)要準(zhǔn)時,準(zhǔn)量,準(zhǔn)型號地到達(dá)制造車間.IfweachieveJIT:

如果我們做到準(zhǔn)時,準(zhǔn)量生產(chǎn):Unnecessaryinventorieswillbeeliminated.不必要的庫存就會消除Storesandwarehouseswillnotbeneeded.儲存區(qū)和倉庫也可以取消Materialcarryingcostswillbediminished.資材搬運成本降低However….TorelysolelyonacentralplanningapproachthatinstructstheproductionschedulestoallprocessessimultaneouslyisnotlikelytoresultinaJITprocessforalloperations.但是：單純地依賴計劃生產(chǎn)的方法,使所有工序同步生產(chǎn)，并不能完全實現(xiàn)所有環(huán)節(jié)的準(zhǔn)時，準(zhǔn)量生產(chǎn).TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每周生產(chǎn)計劃Typically,onecontroloperationreceivesthecustomers’ordersanddisseminatesschedules.

通常，生產(chǎn)控制部門接受客戶定單，然后制訂并傳達(dá)計劃.

ProductionControl生產(chǎn)控制TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每周生產(chǎn)計劃ProductionControl生產(chǎn)控制IIIIIITheproblemcomeswhenachangeismadeeitherbecausetheorderchangesorequipmentbreaksdown.

但是當(dāng)定單有變化或設(shè)備出現(xiàn)問題的時候，就會發(fā)生一些問題：庫存庫存庫存庫存Theresultisexcessinventory…

結(jié)果是導(dǎo)致過多的庫存……withintheplantasWork-In-Process…在本車間工序內(nèi)積壓過多的庫存…supplierssendinginpartsthatarenotneeded…上一道工序發(fā)來的并不需要的部件Additionally另外,Weneedextrafloorspacetostorethematerial.我們需要額外的空間來堆放材料Needexpeditorstosatisfythechangesinschedule.需要人力和時間投入來改變生產(chǎn)計劃Runovertimetomakeuppartsthatwenowneed.用加班時間來生產(chǎn)現(xiàn)在所需部件Toyotarethoughthowtocommunicateschedules.豐田公司對對調(diào)整生產(chǎn)產(chǎn)計劃做了了改進(jìn):Toyotadiscoveredadifferentwaytomanagetheirschedule,豐田使用不不同的方法法來制訂調(diào)調(diào)整生產(chǎn)計計劃Theystoppedtryingtoguesswhatthecustomerwillwant.他們并不去去猜想客戶戶的需求Instead相反..Eachdepartmenthadinstalledasmallinventoryofeachproduct.每個車間都都保持少量量的庫存Downstreamprocessescometothesupplyingdepartmentsandtakewhatitneeds.下一道工序序到上一道道工序去取取他們所需需部件Thisallowstheprocessesupstreamtosimplyreplacewhatwastaken.這樣,上一一工序只要要補(bǔ)充被取取走的部件件即可.TheToyotaProductionSystemTPS豐田體系…….Islikelytobethemoststudiedanddiscussedoperationsprogramintheworld.是極可能被被全世界研研究和討論論的體系NumerousbooksandpapershavebeenwrittenaboutTPS.出版了很多多關(guān)于TPS的書籍和其其它資料ManyhavecometocharacterizeTPSas“l(fā)eanproduction”orNOS.許多人認(rèn)為為豐田體系系(TPS)實際上就代代表優(yōu)化生生產(chǎn)或NOSLeanManufacturing(NOS)NOS優(yōu)化生產(chǎn)Regardlessofanyauthor’’sopinionorrational,allagreethatthefoundationofleanmanufacturing(NOS)isthecontinualpursuittoeliminatewaste.盡管大家的的觀點有些些不一樣,但所有人人都認(rèn)為NOS的基礎(chǔ)是持持續(xù)不斷地地減少浪費費Wasteisdefinedasanythingthatconsumesresourcesortime,butdoesnotaddvaluetotheproduct.浪費是任何何耗費資源源或時間,但不增加加產(chǎn)品價值值的活動ExcessInventoryisWaste多余的庫存存是一種浪浪費Excessinventoryhidesproblems多余的庫存存會隱藏一一些問題SeaofInventory大量庫存RawMaterial

原資材FinishedGoods

成品LongTransportation過長運輸時間VendorDelivery

供應(yīng)商運送Absenteeism缺勤Commun-icationProblemPoorScheduling計劃不力MachineBreakdown設(shè)備停機(jī)QualityProblems質(zhì)量問題LineImbalance線內(nèi)不平衡衡LongSet-UpTime過長調(diào)整時時間LackofHouse-Keeping倉儲管理問問題溝通問題OurgoalformaterialsmanagementinNOSNOS資材管理的的目標(biāo)Theidealstateisasmoothflowofmaterialsthroughoutourownfactory理想的狀態(tài)態(tài)是物料在在整個工廠廠內(nèi)順暢的的流動.Wewanttotietogetherprocessesthatareseparatedbylargephysicaldistances.使那些有一一定距離而而相對分離離的生產(chǎn)流流程緊密結(jié)結(jié)合起來Weneedtoimprovecommunicationinregardstomaterialmovement.在物流方面面要加強(qiáng)各各工序間的的溝通ThePushSystem”推動“生產(chǎn)產(chǎn)體系Intraditionalmanufacturing,variousproductionschedulesarereleasedtoallprocesses;componentmakingandassembly.在傳統(tǒng)的生生產(chǎn)中,各各種生產(chǎn)計計劃被傳達(dá)達(dá)到各個工工序,部件件生產(chǎn)和組組裝部門.ThePushSystem(cont.)”推動“Thesepart-makingprocessesproducethepartsinaccordancetotheirschedulesandtransportthepartstothenextprocess.部件生產(chǎn)產(chǎn)部門按按照收到到的計劃劃生產(chǎn)并并把成品品部件運運送到下下一道工工序.ThePushSystem(cont.)”推動“Thismethodmakesitdifficulttopromptlyadapttochanges.這種方法法使生產(chǎn)產(chǎn)很難迅迅速對變變化作出出反應(yīng)Eachproductionschedulemustbechangedateachprocesssimultaneously.每個工序序的生產(chǎn)產(chǎn)計劃都都必需同同時變化化以適應(yīng)應(yīng)同步生生產(chǎn)ThePushSystem(cont.)”推動”TheResult導(dǎo)致:Thecompanymustholdextrainventoryamongallprocesses.公司不得得不在各各個工序序保持額額外的庫庫存Thiscreatesanimbalanceofstockbetweenprocesses.各工序間間的庫存存達(dá)不到到平衡ThePullSystem“拉動”生生產(chǎn)體系系Incontrast,inaPULLSYSTEM,eachprocesswillwithdrawthepartsitneedsfromtheproceedingprocess.相反,““拉動動”生產(chǎn)產(chǎn)體系要要求各個個工序僅僅需從上上一道工工序提取取自己所所需要的的部件.BA“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市SupplyingProcess供應(yīng)工序序CustomerProcess客戶工序序“生產(chǎn)””指示板板“拒收””指示板板ThePullSystem(cont.)”拉動”體體系Sinceonlythefinal-assemblyprocesscanaccuratelyknowthenecessarytimingandquantityofpartsrequired,theyaretheonlyonestoreceiveaschedule.因為只有有制造準(zhǔn)準(zhǔn)確地了了解所需需時間和和部件數(shù)數(shù)量,以以只要制制造收到到生產(chǎn)計計劃即可可.AssemblyStock-fit準(zhǔn)備Stitching縫紉Assembly制造Shipping裝船WeeklySchedule每周生產(chǎn)產(chǎn)計劃FinalAssemblyreceivesascheduleandpullsfromtheMarketPlace.StitchingandStock-fitreplenishestheMarketPlace.制造接受受生產(chǎn)計計劃,并并借助““供應(yīng)超超市”拉拉動生產(chǎn)產(chǎn).縫紉紉和準(zhǔn)備備向“供供應(yīng)超市市”補(bǔ)充充部件.ProductionControl生產(chǎn)控制制ThePullSystem(cont.)”拉動”體體系Withtheschedule,thefinal-assemblygoestothesupplyingdepartmentsandwithdrawswhatpartsareneeded.根據(jù)生產(chǎn)計劃劃,制造到供供應(yīng)車間去提提取所需部件件.ThePullSystem(cont.)”拉動“生產(chǎn)Theprecedingoperationthenproducesthereplacementsofthepartswithdrawnbythesubsequentprocess.這樣,前一道道工序開始生生產(chǎn)被下一道道工序提走的的部件以補(bǔ)充充所需.BAssembly制造Stitching縫紉A“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市“生產(chǎn)”指示示板“拒收”指示示板Markets“供應(yīng)超市”Marketsarethestoragelocationsforallthepartspriortogoingtothenextoperation.“供應(yīng)超市”是是為下一道工工序儲存所需需各種部件的的區(qū)域.Marketssimplyareorganizedcollectionsofpurchasedpartsandwork-in-process.組建“供應(yīng)超超市”只是為為了搜集購買買的部件和線線上的庫存.Ifpartsarealreadystoredinyourplant,thenyoucanconstructmarkets.如果工廠內(nèi)有有儲存部件,那就可以設(shè)設(shè)置此體系.CautionsaboutMarkets關(guān)于“超市體體系”的警告告:Don’tgetcaughtupinotherpeople’’sphilosophy.不要受別的觀觀點的影響:Marketsdonothavetobelocatednexttothereceivingdocks.超市不一定要要靠近部件接接受區(qū)Marketsdonothavetobelargeinsize.規(guī)模不一定很很大Youcanhaveseveralmini-marketsifspaceisdifficulttoget.若空間不夠,可設(shè)多個分分散的小超市市.Useyourowncommonsense運用自己的常常識來解決問問題!RulesfordevelopingMarkets設(shè)立“超市””的規(guī)則:Haveastoragelocationforeverypart.為每一部件設(shè)設(shè)立儲存區(qū)Determinethemaximumofanyonepartthatwillbestored.為任一需儲存存部件設(shè)立最最大庫存標(biāo)準(zhǔn)準(zhǔn)Provideadequatestoragespace.提供合適的儲儲存區(qū)域Safetyisapriority.要優(yōu)先考慮安安全因素.LessonsLearnedaboutMarkets設(shè)立超市需注注意的幾點:Haveanoverflowspotandameanstomonitor.設(shè)立庫存限制制和監(jiān)控方法法Trytoreservespacesforfutureparts.提前考慮，為為以后的部件件留出儲存空空間Preferably,donotstorethesamepartinmorethanonelocation.同一部件最好好儲存在一個個區(qū)域Makesureaislewayscanaccommodateforklifts.保證過道可容容納或通行搬搬運工具.Determinecustomerdemand確定客戶需求求Takttimeisareferencenumberthatgivesyouasenseforthepaceatwhicheachprocessneedstobeproducing.TAKT節(jié)拍時間為了了解并調(diào)整各各個工序的生生產(chǎn)速度提供供參考依據(jù)Tocalculatetakttime,dividetheavailabletimebythecustomerdemand.用可利用的生生產(chǎn)時間除以以客戶需求量量，即為節(jié)拍時間間.Forourplant對我們公司來來說:Oneshiftisninehoursthereisone60-minutelunch9小時一個班次次,其中有1個小時的就就餐休息時間間Work-time工作時間8Hrs.X60min/hr=480minutes8小時X60=480分鐘480minutespershiftThereis28,800secondspershift480分鐘每個班次次,即28,800秒每每個班次Customerdemand客戶需求Thecustomerneeds2,000pairseachday.客戶每天需要要2,000足鞋WeworkoneshifteachdayinAssembly,6daysperweek.制造車間每天天一個班次,每周工作6天Customerdemandis客戶的需求是是:2,000Pairs/28,800sec2,000足/28,800秒秒or1PAIRevery14.4seconds或每14.4秒需要產(chǎn)一一足鞋Marketsetupsandlocations供應(yīng)超市準(zhǔn)備備和位置選定定Locatespacewithintheplantthatcanbeusedasamarket(s).選定公司可作作為超市的位位置Minimizethenumberofmarkets.Ifmaybenecessarytostartwithseveralsmallones,latertocombineintoone.盡量減少超市市的數(shù)量,若若有必要可先先設(shè)立幾個小小的超市,以以后再合并成成大的超市.Manpowerandequipmentneeded人員和設(shè)備要要求PartsaredeliveredtothelinebyMaterialHandlersusinghand-carts.搬運人員用手手推車將部件件運到生產(chǎn)線線TheMaterialHandlerhasadesignatedroutethatcoversallthestationshe(orshe)isresponsiblefor.搬運人員按照照指定的運輸輸路線負(fù)責(zé)自自己的工作區(qū)區(qū)域Hedeliversallpartsneededonthatdeliverycycle,retrievesallemptycontainers搬運人員必須須循環(huán)搬運所所需部件,并并取回空的部部件箱Training培訓(xùn)Thepeoplewhoareaffectedbythenewsystemneedtounderstandwhythecompanyhasimplementedtheprogram.新體系所涉及及到的人員需需要懂得為什什么公司實施施此體系Thosewhoaretosupportitmustunderstandhowitworks.支持新體系的的人員需懂得得體系是怎樣樣運作的Allpeoplemustreceiveadequatetraininginorderforthesystemtobebothrobustandsuccessful.所有相關(guān)人員員需接受培訓(xùn)訓(xùn)以保證新體體系的運作效效率和成功。。超市Training(continued)培訓(xùn)Rememberwhotheaudienceis:Productionworkershavelittleregardforhowmanyturnstheinventorymakes……Materialhandlerswillnotseeinventoryreductionasabenefit….記住誰誰是培培訓(xùn)對對象：：那些對對庫存存的影影響不不太關(guān)關(guān)心的的生產(chǎn)產(chǎn)者……看不到到減少少庫存存會帶帶來收收益的的資材材管理理者……Training(continued)培訓(xùn)Designyourtrainingprogram(s)usingtheknowledgeyouwillgaininthesystem’sdevelopment.運用你你在實實施NOS的過程程中得得到的的經(jīng)驗驗來設(shè)設(shè)計培培訓(xùn)內(nèi)內(nèi)容，，Keepitsimple.使培訓(xùn)訓(xùn)內(nèi)容容簡潔潔易懂懂，Giveyourselfenoughtimetohandlethetoughquestions.Respectthepeople’’sconcerns.用足夠夠的時時間來來解決決比較較棘手手的問問題，，尊重重別人人的意意見。。ResultsofaPullSystem生產(chǎn)拉拉動體體系的的結(jié)果果Inoperationswheretheimplementationhasbeensuccessful,boththemanagementandworkforcebelievetheworkenvironmenttobe““enhanced””在拉動動體系系取得得成功功的那那些環(huán)環(huán)節(jié),無論論是管管理層層還是是工人人都會會認(rèn)為為他們們的工工作環(huán)環(huán)境正正在改改善。。ResultsofaPullSystem生產(chǎn)拉拉動體體系的的結(jié)果果Wheretherehasbeenlittleefforttomakethesystemwork,theplanttypicallyhasshortagesandmissesdeliverywindows.若工廠廠沒有有努力力去實實現(xiàn)拉拉動生生產(chǎn)，，就會會出現(xiàn)現(xiàn)部件件投入入不足足和不不能按按照生生產(chǎn)需需要來來搬運運部件件。9、靜夜四無鄰鄰，荒居舊業(yè)業(yè)貧。。1月-231月-23Saturday,January7,202310、雨中黃葉葉樹，燈下下白頭人。。。17:58:4717:58:4717:581/7/20235:58:47PM11、以我獨獨沈久，，愧君相相見頻。。。1月-2317:58:4717:58Jan-2307-Jan-2312、故人江海海別，幾度度隔山川。。。17:58:4717:58:4717:58Saturday,January7,202313、乍見翻翻疑夢，，相悲各各問年。。。1月-231月-2317:58:4817:58:48January7,202314、他鄉(xiāng)鄉(xiāng)生白白發(fā)，，舊國國見青青山。。。07一一月月20235:58:48下下午17:58:481月-2315、比不了得得就不比，，得不到的的就不要。。。。一月235:58下下午1月-2317:58January7,202316、行動出成果果，工作出財財富。。2023/1/717:58:4817:58:4807January202317、做前，能能夠環(huán)視四四周；做時時，你只能能或者最好好沿著以腳腳為起點的的射線向前前。。5:58:48下下午5:58下下午17:58:481月-239、沒沒有有失失敗敗，，只只有有暫暫時時停停止止成成功功??！。。1月月-231月月-23Saturday,January7,202310、很多多事情情努力力了未未必有有結(jié)果果，但但是不不努力力卻什什么改改變也也沒有有。。。17:58:4817:58:4817:581/7/20235:58:48PM11、成功功就是是日復(fù)復(fù)一日日那一一點點點小小小努力力的積積累。。。1月-2317:58:4817:58Jan-2307-Jan-2312、世間成事，，不求其絕對對圓滿，留一一份不足，可可得無限完美美。。17:58:4817:58:4817:58Saturday,January7,202313、不知知香積積寺，，數(shù)里里入云云峰。。。1月-231月-2317:58:4817:58:48January7,2