如何縮短制造周期二

如何縮短制造周期二第1頁/共26頁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/OrderParts第2頁/共26頁ShortLeadTime

縮短制造周期學(xué)完縮短制造周期內(nèi)容，將會：明白縮短制造周期對客戶響應(yīng)及減少成本的重要性了解縮短制造周期的相關(guān)概念了解控制物料進入及在工廠內(nèi)流動的精益物料管理系統(tǒng)第3頁/共26頁純粹的精益物流系統(tǒng)是從供應(yīng)商最后的增殖產(chǎn)品到客戶的開始使用期間，沒有等待、儲存量、雙重處理、多余庫存。ShortLeadTimeStrategy縮短制造周期策略Supplier(供應(yīng)商)Plant(工廠)

PointofUse開始使用ReceiveCustomerOrder

接收定單ProduceVehicle生產(chǎn)手機DeliverVehicle交付產(chǎn)品ReceivePayment收到付款第4頁/共26頁Themovementofmaterialintherightquantity,attherighttime,totherightlocation,withtherightequipment,usingtheshortestleadtimeandlowestpossiblecostforbothsupplierandcustomer.在最短的時間內(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?shù)臅r間里把合適的數(shù)量用恰當?shù)墓ぞ哌\送到一定的地點的流動。LeanMaterialFlowDefinition

精益物流定義第5頁/共26頁1)PartsOrdering

定購零件2)Suppliers

供應(yīng)商3)Packaging

包裝4)Transport

運輸5)Receiving

接收6)Temp.Stores臨時倉庫7)MaterialPullSystem物料拉動系統(tǒng)8)AssemblyLine生產(chǎn)線LeanMaterialsManagement

精益物料管理第6頁/共26頁FullFullFullFullEmptyEmptyOperator(操作工)PartPresentation(零件擺設(shè))Conveyance(運輸)Staging(分段運輸)Receive/Unload(接收/卸貨)Transportation(運輸)Suppliers(供應(yīng)商)LOWESTTOTALCOST最低成本REDUCELEADTIMEPLANFOREVERYPARTLeanMaterialFlow:GuidingPrinciples

精益物流：指導(dǎo)原則SAFE(安全)Highvalue

added(高增殖生產(chǎn))Compression（壓）Part

Presentation

（介紹）SmallLotBulkSequenced/Repack（計、序列）Ergonomic

Space(空間)Organization(組織)FIFO(先進先出)Method（方式）Frequency(頻率)Communicatin(交流)WindowReceiving(窗口接收)Equipment(裝置)Frequency(頻率)

DirectShip(直接運輸）100%Tracked(100%跟蹤)Responsive(響應(yīng))OnTime(及時)Right

Quantity(數(shù)量)To

Specifications(合適規(guī)格)第7頁/共26頁1.VehicleSchedules制造計劃生產(chǎn)計劃應(yīng)均衡各個階段的生產(chǎn)需求。百分百地在交付日期交貨。整個生產(chǎn)部門都應(yīng)該了解制造狀態(tài)。支持減少手機交付時間和各種生產(chǎn)限制。CustomerOrder客戶定單：WhencanIgetmymobilephone?(什么時候可以交付?)143256ProductionPlan第8頁/共26頁2.PartsOrdering:IndividualParts

訂購：個件Partorderbaseduponaprojectedvehiclebuildschedule零件訂購要以設(shè)定的生產(chǎn)計劃為基礎(chǔ)Order=(PartsNeeded)-(PartsHave)

訂單=(需要零件)-(現(xiàn)有零件)PickUpDocument

訂購文件Deliveryquantityandtiminginstructionspershipment每次運輸?shù)臄?shù)量及時限CCIPlantDeliverySupplierPickUpDocumentPickUpDocumentPlantLinesideOperation第9頁/共26頁3.SupplyBase(供應(yīng)基地)在CCI工廠附近為對制造周期有特殊要求的零件設(shè)立的基地（通常是些定序的分裝件）(按先后需求排序是合格供應(yīng)商的職責):------在送到生產(chǎn)線之前供應(yīng)商擁有庫存供應(yīng)數(shù)量最低化:零件或分裝件的單一供應(yīng)點總供應(yīng)基地的最小化（供應(yīng)商數(shù)量）

基于總材料傳送成本決定貨源第10頁/共26頁4-1.TransportationandReceiving

運輸與接收每天運送頻率預(yù)警：貨車司機在供應(yīng)商處檢查貨物貨物不符時協(xié)商Suppliers(供應(yīng)商)MON.-8:00amTUE.-8:00amWED.-8:00amTHU.-8:00amFRI.-8:00amCBA第11頁/共26頁4-1.TransportationandReceiving運輸與接收LeadLogisticsProvider(LLP):On-sitesinglepointofcontactforplant.(現(xiàn)場單一聯(lián)系)Routeplanningandscheduling.(路線計劃與安排)Visualroute/dockboard.(目視化路線/接收板)PlantReceiving:工廠接收Visualboard(目視化欄板)-Canlookatboardandseewhatishappening(看欄板就可以知道情況)Scheduled，

daily/weekly日/周計劃-Whenmaterialwillarriveatplant(什么時候零件能到達工廠)Levelunloadplan(平衡卸貨計劃)PlantLLPTransportationRouteBoardxx#1#2#3#4RouteTime第12頁/共26頁定義：不直接把材料從供應(yīng)商處運送到線旁，而是暫時將其集中存放的區(qū)域。目的：組織控制不直接由供應(yīng)商送到生產(chǎn)線的材料庫存量、產(chǎn)量和物流4-2.CentralMaterialArea(集中材料區(qū)域)第13頁/共26頁4-2.CentralMaterialArea(集中材料區(qū)域)第14頁/共26頁KeyConcepts(主要概念):Organizebybulk/cartontoseparateequipment&minimizespacerequirements(用大箱或紙箱裝零件來隔離設(shè)備，減少空間需求)1locationperpartnumber(一個零件一個存放點)Minimizespace(空間最小化)Minimizedeliverylead-time(運送時間最小化)4-2.CentralMaterialArea(集中材料區(qū)域)KeyBenefits(主要益處):Optimizespace,manpower&equipment(優(yōu)化空間、人員及設(shè)備)Min.impactofproductionpullfluctuations(減少生產(chǎn)拉動波動的影響)SupportF.I.F.O.(支持先進先出)第15頁/共26頁Definition

(定義):Amethodofmaterialreplenishmentbasedonconsumption,authorizedbytheuser,whosendsasignaltomanufacture,ship,ordeliveryaproductataspecifictime,place,andquantity.

(使用者認可的，通過向生產(chǎn)、運輸部門發(fā)出信號，要求在一定時間內(nèi)在具體地方運送定量產(chǎn)品的一種補充消耗物料的方法。)AflexibletoolthatenablesJust-in-Time.

(一個能確保JIT的靈活工具)Connectsoperationstomaterialsupply.(連接生產(chǎn)與材料供給.)

5.InternalPull/Delivery(內(nèi)部拉動/運送)第16頁/共26頁5-1.TypesofInternalPullSystems

(內(nèi)部物流的拉動系統(tǒng)的種類)EmptyContainerPullProcess(空箱拉動系統(tǒng))PullCardProcess(卡片拉動系統(tǒng))ElectronicPullSystem(EPS)(電子拉動系統(tǒng))“Nothingmoveswithoutapullsignal(無信號無拉動).”第17頁/共26頁PullCardProcess(卡片拉動系統(tǒng)):Description(定義):

Amaterialpullsystemthatusescardstocommunicatereplenishmentrequirements(使用卡片來傳遞供貨信息的物流拉動系統(tǒng))(投遞卡片)(掃描卡片)(運送材料）第18頁/共26頁EPSProcess(EPS系統(tǒng)):(材料需求)(電子識別)(材料提取，分運）(材料運送)(交貨結(jié)束)第19頁/共26頁EmptyContainerPullProcess(空箱拉動系統(tǒng))Using

LocationReplenishProductionTeamMember生產(chǎn)人員PushOutPushInEMPTYFULL第20頁/共26頁Simpledesign(簡單設(shè)計)Designtoenablemultiplepartnumbersperdelivery

(能夠每次多零件運送的設(shè)計)Standardizeequipmentandcomponentsthroughouttheplant(numberoftypes,hitches,chassis)(整個工廠設(shè)備及零件標準化（種類、栓、底盤的數(shù)目）)Designformanualmanipulation(pushandpull).(人工操作（推或拉）的設(shè)計)6.MobileEquipment

(運輸設(shè)備):NOYESExample(實例):LinesideDelivery(線旁運送)第21頁/共26頁DollyExamples(手推車實例)Bulkcontainerdollybase(Standard)(大箱手推車基座)(標準)SwivelTurntableBase(旋轉(zhuǎn)轉(zhuǎn)盤基座)第22頁/共26頁7.PartPresentation

(零件展示）Returnablecontainers(回收空箱)Oneortwohoursusagepercontainer(每個箱一到兩小時的用量)Hand-carriedorhand-manageable(dolly)(手提或手推)Easypartpick(容易提取)Properpartslabeling(合適的標簽)Stackable(層疊)Simpledesign(設(shè)計簡單)PartPresentation(零件擺設(shè)):WithinWorkstation(在工位內(nèi))Withinarm’sreachatpointofinstallation(安裝點在手臂可及處)Lessthan5feetinheight(lineofsight)(高度低于5英尺)HandManageable(人工操作)5feetPartASmallLotContainer(小裝箱)Bringthepartstotheoperator(零件運送到操作工身旁)第23頁/共26頁

零件展示實例能夠人力或自動移動裝螺絲螺栓的圍兜減少運動浪費小件包裝第24頁/共26頁LeanMaterialFlow