看板系統的教案

看板系統的教案第1頁/共121頁ObjectivesofthisModule這個模塊的目的Participantswillbeableto:參與者能夠：

NamethetypesofKanbanandtheiruses說出看板種類的名稱及用法Describethestepsincirculatingkanban描述看板循環(huán)中的步驟CalculateKanbanquantities,計算看板數量Namethe6prerequisitesofKanban說出6中看板必要條件DescribetherelationshipofKanbanandproductionsmoothing(heijunka)描述看板與平穩(wěn)生產的關系EvaluatethereadinesstoimplementKanbansystem評估實施看板系統是否準備就緒Followthestepstodesignandsetupacompletepullsystemwithinavaluestream在價值流中根據步驟設計以個完整的拉動系統第2頁/共121頁Topics主題Section1:WhatisKanban?什么是看板？Section2:Two-cardKanbanSystems2張看板卡系統Section3:KanbanCalculation看板的計算Section4:ManagingtheKanbanSystem管理看板系統Section5:KanbanSystemImplementation看板系統的實施第3頁/共121頁JargonBuster專業(yè)術語Kanban看板Supermarket超市ProductionInstructionKanban生產指示看板WithdrawalKanban取料看板Supplier供應商SignalKanban信號看板Safetystock安全庫存Bufferstock緩沖庫存JargonBusterKanban?2-bin?Supermarket?第4頁/共121頁Section1Topics第1章主題WhatisKanban?什么是看板？Definitionsiskanban看板的定義Functionsofkanban看板的功能Formsofkanban看板的形式第5頁/共121頁WhatisKanban?什么是看板Atoolofthepullsystem拉動系統的工具Asignalthatauthorizesproductionormovement(withdrawal)ofitems授權生產或移動物料的信號Theactualcard,containerorphysicalsignalitself實物卡，周轉箱或者實際的信號Avisualmethodofcontrollingworkflow,inventedinthedaysbeforeIT一個目視化的控制生產流的方法，在IT之前發(fā)明Thesystemthatuseskanban這個系統使用看板第6頁/共121頁WhatisaKanbanSystem什么是看板系統Kanbanisasimpleandeffectivemethodforvisuallycontrollingmaterialflow看板是一個針對目視化管理物料流的簡單高效的方法Thekanbansystemitselfisfullofwastesuchashandling,inventoryandprocessing看板體系本身也是充滿了浪費,例如物料搬運，庫存及操作Kanbanistheacknowledgementofthefailuretoimplementonepieceflow看板承認不能實現單件流的表現第7頁/共121頁WhatisKanban?什么是看板“See”“board”“Signboard”suchasyouseeinfrontofastore“信號板”例如在庫存前看到的第8頁/共121頁WhatdoesKanbanDo?看板能做什么？Setslimits設定限制Kanbanislikecurrency–youcannotbuypartswithoutpayingforthem!看板就像貨幣—你不能在沒有付錢的情況下買東西Nothingismadeormovedwithoutakanban在沒有看板的情況不生產或者移動物料Makesproblemsvisible讓問題可視化Kanban=inventory=waste看板=庫存=浪費第9頁/共121頁TheTwoFunctionsofKanban看板的2種功能Instructprocessestoproduce指示工序進行生產Limitsoverproduction限制過量生產Instructmaterialhandlerstomoveproduct指示物料員運送產品Withdrawalfromupstreambydownstreamprocess下工序從上工序取料第10頁/共121頁Inapushsystemtherearemanyandcomplexproductionandtransportinstructions在一個推動系統中有很多復雜的生產及運輸指示。Triggeredbypreviousprocess(producer)=push通過上一個工序來觸發(fā)（生產者）=推動TheTwoFunctionsofKanban看板的2種功能第11頁/共121頁ProductionKanbanWithdrawalKanbanHeijunkaBoxInapullsystemthereareafewsimpleproductionandtransportinstructions在一個拉動體系中只有1個簡單的生產及運輸指示Triggeredbynextprocess(customer)=pull通過下工序（客戶）來觸發(fā)=拉動TheTwoFunctionsofKanban看板的2種功能第12頁/共121頁FormsofKanban看板的形式Akanbancanbe:看板能夠表現為Classic“twocard”system(usesproductionandwithdrawalcards)經典的“2種卡”系統（使用生產及取料看板）“Onecard”systemusesoneofthefollowing“看板”系統使用以下的方式Card卡片Triangularplates三角板Containers周轉箱Carts推車Coloredballs不用顏色的球Electronicsignal電子信號Oranythingthatconveysonlythenecessaryinformation.或者其他人能能夠轉換必要信息的工具第13頁/共121頁FormsofKanban看板的形式Containerorsimpledevices周轉箱或簡單的裝置Cardorinformation-bearingtoken卡片或象征性的信息Electronic電子的Easetoimplement容易實施High高Medium中Low低Visibility目視化Medium中High高Low/Medium*低/中Easeofupkeep容易維護Low低Medium中High高Bestused…但是用于…forsteadydemanditemsincloseproximity穩(wěn)定需求的零件及容易接近的地方…whenprerequisitesconditionsaremet當必要條件都滿足…aftermasteringcardkanban在熟練紙質看板后*Pureelectronicsignalsareinvisible,e-kanbancombinedwithprintedcardsorvideomonitorsaremediumorhighvisibility單純的電子信號時無形的，電子看板與紙質的看板合并或者視頻監(jiān)控是中等或高能見度第14頁/共121頁“OneCard”KanbanSignalExamples“卡片”看板信號的例子第15頁/共121頁Full1of3Full2of3Full3of3Full1of3Full2of3Full3of3DonotproduceEmpty2of3Empty1of3Full3of3Full1of3Full2of3Full3of3DonotproduceEmpty1of3Empty2of3Empty3of3Full1of3Full2of3Full3of3Fill4binsEmpty1of3Empty2of3Empty3of3Empty1of3Full2of3Full3of3Fill4binsEmpty1of3Empty2of3Empty3of3Empty1of3Empty2of3Full3of3Fill4binsEmpty1of3Empty2of3Empty3of3Empty1of3Empty2of3Empty3of3Empty1of3Full2of3DonotproduceFull3of3Full1of3Full2of3Full3of3“EmptySpace”Kanban“空的空間”看板第16頁/共121頁ContainersorSimpleDevices周轉箱或簡單的裝置The2-binsystem（2箱系統）Twobinswithanequalamountofgoodsandinformationaboutthecontainedgoods(name,location,quantity)areprepared準備好的兩箱與同等數量的商品和信息所包含的貨物（名稱，位置，數量）的制備Partsaretakenfromthefirstbin零件從第一箱中拿取Whenthefirstbinisemptyitisthesignaltoreplenishtwomorebins當第一桶是空的，這是補充兩箱的信號Thesecondbinslidesforwardintopositionofuse第二箱向前滑動到使用位置Materialhandlerreplenishestwobinswithinagreedlead-time(beforeallpartsareconsumed)物料員在約定的交貨時間內補充第2箱（在所有零件都被消耗前）“Pleasereplenish”12345第17頁/共121頁ContainersorSimpleDevices周轉箱或簡單的裝置Limitationsofcontainer/devicekanban周轉箱或簡單裝置的局限性Visibility:lineofsightonly,asdevicestypicallydonottravel(exceptcarts,etc.)目視化：唯一的視線，作為設備通常不移動（除推車，等）Quantity:alargenumberofdeviceswillbeneededtosupporthighmix,lowvolumeproduction數量：大量的設備需求來支持多品種，小批量生產Flexibility:thecosttomakeormodifydevicesishighcomparedtoprintedcards靈活性：相對于印刷卡制作或修改設備成本高第18頁/共121頁KanbanCards看板卡Akanbancard:看板卡：Isthemostcommonandbestknownsignalingmethod是最常見的和最知名的信號方法Travelswiththepartsbetweensupplierandcustomerprocesses(fromdownstreamtoupstream)與零件一起在供應商和客戶的過程之間移動。（從下游向上游）Containsinformation(humanandmachinereadable)suchas包含的信息(人和機器能識別)例如：Partnameandnumber零件名及編號Supplierprocessname供應工序名Packoutquantity包裝數量Deliveryaddress運送地址Storageaddress儲存地址Withdrawalfrequency補料頻率第19頁/共121頁KanbanCards看板卡Akanbancard:看板卡Differsmostsignificantlywith2-bininthatthecardispulledassoonasthefirstpartistaken與2箱系統最顯著不同是當第一個零件被拿取后立即拉動Canbeeithera“move”ora“make”signalfordedicated,first-infirstoutlines以指“移動”或“制造”的專用信號，先進先出Mosttypicallyusestwotypesofcards:thewithdrawalkanbanandproductioninstructionkanban通常使用兩種類型的卡：領取看板和生產指令看板第20頁/共121頁Two-cardKanbanCycles2張看板卡循環(huán)ProducerProcess生產工序ConsumerProcess使用工序Materialhandler“move”loop物料員移動物料循環(huán)Responsibleforwithdrawalcardsandmaterialmovement用于取料卡及物料移動Operator“make”loop員工生產循環(huán)Responsibleforproductioncardsandmakingthings用于生產看板卡及生產產品第21頁/共121頁Section2Topics第2部分主題Two-cardKanbanSystems2種卡看板系統Typesofkanban看板的類型Productioninstructionkanban生產指示看板Signalkanban信號看板Lotmakingboard批量生產板Withdrawalkanban取料看板Supplierkanban供應商看板Kanbancycles看板循環(huán)第22頁/共121頁TypesofKanban看板的類型Kanban看板Productioninstructionkanban生產指示看板Withdrawalkanban取料看板In-processkanban在制看板Signalkanban信號看板Supplierkanban供應商看板Inter-processkanban內部工序看板第23頁/共121頁PartNumber產品的名稱PartDescription產品的描述SupplierProcessName&Location供應的工序名稱及地址ConsumerProcessName&Location使用的工序名稱及地址QuantityPerContainer每箱數量NumberofCardsinSystem片的數量(E.g.1of3)BasicCardDesign基本的卡片設計第24頁/共121頁InformationonaKanbanCard看板卡上的信息Theaction(make,move,etc.)行動（制造，移動）Partnumber物料名稱Partdescription物料描述Thesupplier(orprocess)name供應商（工序）名稱Quantity數量Containerquantity周轉箱數量Thesourcelocation物料存儲的地址Thedeliverylocation物料運送地址Thetimingoftheaction(kanbancycle)行動的時間（看板循環(huán)時間）Etc.等等。第25頁/共121頁ProductionInstructionCardExample

生產指示卡案例Machining機器finishedgoodsSupermarket成品超市Supplier：供應商Machiningcell#11機器#11Location：地址B2V7Part#：Partdescription：GyromotorhousingQuantity數量

：12ProductionLine：生產線：Sub-assemblyCell#8半制品組裝#8Location：地址AssemblyDept.裝配部25210Pointofuseinformation使用點信息Productinformation產品信息Supplierprocessinformation供應工序信息第26頁/共121頁ProductionInstructionKanban生產指示看板LotforlotChangeovertimesarenotanissue換型時間不存在問題Canbeproduced“l(fā)otforlot”asneeded根據需要進行批量生產Quantityincontainerissetbypaceofcustomerwithdrawal周轉箱內的數量根據客戶取料的節(jié)拍設定Productionkanbanalwaysstayswiththeproducer(circulatesinternally)生產看板往往在生產處（內部循環(huán)）Removecard(trigger)whenfirstpartisremovedfromcontainer當第一個零件沖周轉箱中拿取時拆下看板卡（觸發(fā)）。第27頁/共121頁ProductionInstructionCard:In-process生產指示卡：工序內ProducerProcessDownstreamprocessuseswithdrawalkanbantopullmaterial下游工序使用補料看板卡來拉動物料Productioninstructioncardisremoved生產指示看板卡被觸發(fā)Teamleadercollectscardsfrompostandplacesthemonkanbanboardasinstructiontoproduce組長收集看板卡并公布在看板板上用于指示生產Operatorattachesproductioninstructioncardmaterialcontainer,removeswithdrawalcardandplacesitinpost,beginsproductionasinstructedbykanban操作員將生產指示卡附在物料周轉箱上，拆下補料看板，并開始按照看板指示進行生產。3214第28頁/共121頁KanbaninaBatchProcess批量生產工序的看板Therearethreeprimarymethodsforlinkingkanbantoabatchprocess有3個初級的方法將看板與批量生產工序鏈接起來Signalkanbanatreorderpoint信號看板Patternproduction模式生產Lotmakingboard批量生產板第29頁/共121頁ProductionInstruction:SignalKanban生產指示：信號看板Signalcard(triangle)placestheorder信號卡（3角）下訂單Materialcard(rectangle)instructsrawmaterialpreparation物料卡（矩形）指示原材料準備Fixedquantity,variabletimeonly數量固定，時間可變Normallyusedwhentheset-uptimeistoolongtomaintainsinglepieceorsmalllots通常情況下用于設立時間太長以至于不能保證單件或者小批量Signalposition=reorderpoint信號位置=下訂單點Reorderquantity=productionlotsize

訂購數量=生產批量大小Lotsizeisgreaterthanusagequantity批量大小大于用量數量第30頁/共121頁SignalKanbanExample信號看板案例PartNumber零件號23-8765ContainerQty.包裝數量50OrderPoint訂單點7StoreLocation儲存位置13-B-8LotSize批量大小25LineNo.生產線11第31頁/共121頁Withdrawalkanban取料看板Productionkanban(materialpreparation)生產看板Signalkanban信號看板SignalKanban信號看板Withdrawalkanban取料看板LotproductionprocessSignalKanban信號看板1432第32頁/共121頁PatternProduction模式生產Followingafixedsequence(pattern)ofproductionthatisrepeated按照一個重復的固定的生產順序ABCDEFGABCDEFGABCDEFGetc.Optimizedaroundchangeoverdifficulty(e.g.colorchangefromlightertodarker)優(yōu)化換型的難度（例如：顏色從淡到深）Patternreplenishmentcycledeterminessupermarketinventorylevel(e.g.1daypattern=1daysupplyofstock)模式的補料循環(huán)時間定義了超市庫存的水平（例如：1天模式=1天的庫存）第33頁/共121頁ABCDEFFGGAVisualWheelforPatternProduction

模式生產的目視化轉盤第34頁/共121頁PatternProduction模式生產Advantagesofpatternproduction模式生產的優(yōu)勢Simplemethod–maynotrequirekanban簡單的方法-也許不需要看板Predictablechangeoversequence可預見的換模順序Batchsizeallowsbufferforvariability批量大小考慮緩沖及變化性Disadvantagesofpatternproduction模式生產的劣勢Fixedsequencecannotbechanged固定不能更改的順序Hidesproblems–lessneedtoreducechangeovertimes隱藏了問題—減少了換模時間減少的必要性。Requiresperiodicreanalysisofthedemandpattern要求預先對生產需求的模式進行分析第35頁/共121頁Part#ReorderPointLine訂購點Minimizeschangeoversbyrunningthesamepartnumbersasabatch批量生產相同的品號來減少換模時間Whenthearrivingkanbancrossesthereorderpoint,thosepartsmustbeproducednext當收到的看板卡超過訂貨點，這些零件必須馬上進行生產LotMakingBoard批量生產板A01A02B01B02B03B04C01C02C03Triggered!觸發(fā)Producequantityspecifiedonthe5cards生產數量設定為5張卡=productioninstructionkanbancards生產指示看板卡第36頁/共121頁LotMaking批量生產Advantagesoflotmakingboards批量生產板的優(yōu)勢Morefrequentinformationflowbacktotheproducerprocess(comparedtosignalkanban)VisuallydisplaysinventoryconsumptionratesProblemscanbeseenearlierDisadvantagesoflotmakingboards批量生產板的劣勢Accuracyofboarddependsonhowquicklykanbancardsarereturnedotheboard批量板的準確性基于看板卡能夠多快的返回批量板Createsatemptationtobuildahead(beforetriggerpointisreached)創(chuàng)建一個誘惑點在生產前（在觸發(fā)點到達前）第37頁/共121頁WithdrawalKanban補料看板Internal–circulatesbetweenprocesseswithinasite內部—在工廠內部的不同工序間循環(huán)External–circulatesbetweencustomerandsuppliersites外部—在客戶及供應商之間循環(huán)第38頁/共121頁Pointofuseinformation使用點信息Productinformation生產信息SourceDept.MoldingMachine#:IM-P9Q2Location:地址R1K09BPartdescription:零件描述LowerbasinQuantity數量:10Kanbancard:3of9看板卡：3of9Operation工序30Deliverylocation:運送地址Subassemblycell#2半制品生產線#2Part#零件號：M-8532Upstreamprocess上游工序Inter-processWithdrawalKanban

內部工序補料看板卡第39頁/共121頁Supplier(Withdrawal)Kanban供應商（取料）看板Travelsbetweentwodifferentcompanies–customerandsupplier在2加不同的公司間移動—客戶與供應商Cardcontainspart-specificinformationforbothcompanies(partnumber,location,etc.)卡片包含零件在兩家公司特定的信息（零件編號，地址等）Eachkanbancardservesasacommerciallybindingorderbasedonblanketpurchaseorderspecifyingvariousterms每個看板卡服務于一個基于特定不同時期的空白訂單第40頁/共121頁SupplierKanbanCirculation供應商看板循環(huán)32145Finishedgoodssupermarket成品超市Supplier供應商Supplierkanbanareremovedfromcontainerwhenthefirstpartisusedandplacedinpost當第一個零件被使用時將供應商看板從周轉箱上取出Kanbancardsarecollectedfromthepostatasettimeanddeliveredtosortingmachine看板卡被收集并公布定期被公布及送至相應的機器Sortedkanbancardsareplacedinsupplier’sslot分類過的看板卡放置在對應的供應商的槽內。Supplierpicksupkanbanatthewhentheyarrivetomakeadelivery當供應商抵達及送貨時取回看板卡Supplierkanbanaresortedanddistributedtoshippingareas分類后的供應商看板分發(fā)到出貨區(qū)域Kanbanarematchedwithpartsandpreparedaccordingtospecifieddeliverycycle看板卡與相應的物料對應起來根據特定的交貨循環(huán)準備好Partsaredeliveredfromthesuppliertothereceivingareortheline供應商將零件交付到收貨區(qū)域或生產線。67第41頁/共121頁SupplierKanbanCirculation供應商看板循環(huán)KanbansflowingbetweencustomersandsuppliersarepartofexistingtheframeworkofblanketPOsanddonotneedtopassthroughsalesorpurchasingorganizations客戶與供應商之間的看板流程是現有的空白訂單的架構，不需要通過銷售及采購組織。Thekanbancardsdopassthroughsortingcentermanagedbyproductioncontrol生產控制部門通過挑選中心來管理看板卡第42頁/共121頁SupplierKanbanSystemExample供應商看板案例Toyotafinalassemblyplant豐田成品組裝工廠15,000vehiclespermonth15000輛車/月1,200employees1200名員工Allsupplierpartsarecontrolledbykanban所有的供應商零件通過看板進行管理Sortinganddistributioncenterforwithdrawalkanbancards(suppliertransport)用于挑選及分發(fā)補料看板卡的中心（供應商運輸）Twofulltimeproductioncontrolpeople2個全日制的生產管理人員第43頁/共121頁SupplierKanbanCardExample供應商看板卡案例Pointofuseinformation使用點信息Productinformation產品信息Suppliercode:03-952Supplier:SuperiorMachineSupplierlocation:321IndustryRdIndustry,USAPartdescription:CrankshaftQuantity:8Kanbancycle:1-4-2Receivingdock:4Supermarketlocation:B3-K-12Part#：D-7632Supplierinformation供應商信息Deliverytiming第44頁/共121頁SupplierKanbanCycles供應商看板循環(huán)Themeaningof“1-4-2”onexamplecard:案例上“1-4-2”的意思1=partsonthecardwillbedeliveredwithinonedayofthecardbeingpulled1=在卡上將在一天內被交付的零件4=asupplier’struckwilldeliverthesepartstothesupplierfourtimesperday供應商的卡車將會將這些零件每天4次交付到供應商2=thiskanbancardwillreturnnotonthenexttruckbutonthe2ndtruckarriving2=這張看板卡將不會在下一輛卡車上返回，但是會在第二輛卡車返回第45頁/共121頁KanbanDeliveryCycles1:4:2“Period”周期Inoneday在一天內“Frequency”頻率Makefourdeliveries4次交付“Lag”遲延Andthesepartsmustcomebacktwodeliveriesaftersupplierkanbanissent這些零件在看板卡發(fā)出后的2次交貨后返回SupplierKanbanCycles供應商看板循環(huán)第46頁/共121頁Customer客戶Supplier供應商SupplierKanbanCycles供應商看板循環(huán)Day11stshift2ndshiftPickupPickupPickupPickupDeliveryDeliveryDeliveryDeliveryPickupPickupDeliveryDelivery1:4:21day1天4deliveries4次交付2truckslater2次交付后后BroadcastKanban廣播看板第47頁/共121頁CommunicatingSupplierKanban溝通供應商看板ForecastKanban預測看板Electronicsignalsentoutseveralhoursinadvanceofphysicalcardsbasedonsetschedulefromdailyorweeklybuildplan根據每天及每周的計劃在實物卡發(fā)出前的幾個小時發(fā)出電子信號Usedforshortlead-timematerials,suchaswhensuppliersareonsamecampus用于生產時間短的物料，例如當供應在相同的區(qū)域Adjustmentscanbemadequicklybasedonactualusage可以根據實際的用量快速的進行調整第48頁/共121頁CommunicatingSupplierKanban溝通供應商看板BroadcastKanban廣播看板Electronicsignalsentoutseveralhoursinadvanceofphysicalcardsbasedonactualusage根據實際的使用量在實物卡發(fā)出前的幾個小時發(fā)出電子信號Usedforlongerlead-timematerials用于生產時間長的物料Safetystockmayormaynotbeconsumed–“plannedpull”canbecomepush安全庫存可能不會被使用，“計劃的拉動”成為推動第49頁/共121頁Section3Topics第3章主題KanbanCalculation看板計算Thevariables變量Kanbanquantitycalculation看板數量計算Signalpointcalculation信號點計算Threetypesofstock3種庫存類型Calculationexercises計算練習Tips提示第50頁/共121頁KanbanSystemParameters看板系統的參數Kanbancalculationdetermines看板計算決定于Howmanypartsareneededinthesystem系統中需要多少零件Formandcirculationofkanban形式及看板的循環(huán)Howmanysignalsareneededinthesystem系統中需要多少信號Totalcardsornon-cardsignals所有的卡及非卡的信號Totalcontainers所有的周轉箱Whenreplenishmentwillhappen補料發(fā)生于Specifiedonthekanbancardorsignal看板卡或信號中特定的時間第51頁/共121頁KanbanCalculationVariables看板計算的變量Allkanbancards所有的看板卡AD=AveragedailydemandAD=每天平均需求RT=ReplenishmentleadtimeRT=補料的時間SF=SafetyfactorSF=安全因素CQ=ContainerquantityCQ=包裝數量Signalkanbanonly信號看板僅僅MD=MonthlydemandMD=每月需求CO/M=ChangeoverspermonthCO/M=每月換模次數第52頁/共121頁AverageDailyDemand(AD)每天平均需求Assumesproductionsmoothing(heijunka)hasbeendonewithaveragedmixandvolumes假設生產已經平穩(wěn)化（平均的種類及生產量）Mayallowforupto10%bufferstockinADbasedonstandarddeviation基于標準偏差允許每天需求量有最高10%的緩沖量Calculatedemandstandarddeviationbasedontimewindowforaveraging(heijunka)基于平均的時間窗口計算需求的標準偏差FrequencyofrecalcultionofADisbasedontimewindowforaveraging基于平均的時間窗口來決定重新計算每天平均需求的頻率。第53頁/共121頁ReplenishmentTime(RT)補料時間Theamountoftimefromordersignaltocompletionofthereplenishmentofmaterialfromsupplyprocesstopointofuse完成訂單信號到完成物料從供應流程到使用點的補料時間。Maybelessthanlead-timewhenpullinggoodsfromfinishedgoodssupermarket(insteadofmanufacturing)當從成品超市拉動物料時的時間將短于生產時間Includes…包括。。。Timetodeliversignal發(fā)出信號的時間Timetoreceivesignal收到信號的時間Waitingtime等待的時間Timetobuild(orpullfromsupermarket)生產的時間（或從超市拉動的時間）Transporttimedownstream下游運輸的時間Timetodeliverpointofuse運送到使用點的時間第54頁/共121頁SafetyFactor(SF)安全因素Failurefactorstakenintoaccount:應考慮的失敗因素Downtime停工時間Qualitylosses質量損失Delaysintransportation運輸造成的延遲Weatherdelays氣候造成的延遲Laborstoppages停工Etc.等第55頁/共121頁SafetyFactor(SF)安全因數CalculationTips計算提示Expressthesumofsafetyfactorsasa%oftotaldemand使用所有需求的百分比的合計來表達Downtime=5%停機=5%Defects=3%壞品=3%Deliverydelays=2%交付延遲=2%Total=5%+3%+2%=10%匯總=5%+3%+2%=10%Thenconvertintodecimal(E.g.10%=0.10)然后轉換成小數點（例如：10%=0.10）SF=(1+0.10)=1.1SF=（1+0.10）第56頁/共121頁SafetyFactor(SF)安全因素Tips:提示Beginwithmorethanenoughtocoverformaterialoutages開始時準備較多的物料損耗Thesafetyfactormaybearbitraryatfirst,butaccuracymustcontinuouslyimprove安全因素開始時可能隨意，但是準確性需要持續(xù)進行改進Continuouslyimprovethefailurefactorstoreducethesafetyfactoryandstocklevels不斷的改善實效因素來減少安全庫存。第57頁/共121頁Pullsystemassumption:everythinginproductionandlogisticswillworkasplanned拉動系統假設：所有的生產及物流將按照計劃完成Averagingofdemandandmix(heijunka)需求被均衡化Predictabledeliverytiming(kruns)可預測的交貨時間Inrealityproblemshappen現實的問題發(fā)生Thebufferstockandsafetyfactorarecountermeasurestovariation緩沖庫存及安全因素是針對變差的對策ThreeTypesofStock3種庫存類型第58頁/共121頁Cyclestock循環(huán)庫存Bufferstock緩沖庫存Safetystock安全庫存Averagedailydemand平均每天需求

×Replenishmenttime補料時間Cycle循環(huán)+Demandvariationas%ofCyclestock需求的變差作為%的循環(huán)庫存Buffer緩沖+SafetyFactoras%of｛Cyclestock+Bufferstock｝安全因素作為%（循環(huán)庫存+緩沖庫存）Safety安全=Inventory庫存Averagedailydemand(AD)每天的平均需求Replenishmenttime(RT)補料時間ThreeTypesofStock3種庫存類型Time→第59頁/共121頁Name名稱Definition定義Formula公式Factors因素CycleStock循環(huán)庫存Inventoryneededtocovernormaldemand庫存來滿足正常需求Averagedailydemandxlead-timetoreplenish(days)平均每天需求X補料時間（天）Averagedemand平均需求Replenishmentlead-time補料時間BufferStock緩沖庫存Inventoryneededtocovercustomervariation庫存需要滿足客戶變差Demandvariation*/CycleStock需求變差/循環(huán)庫存Forecasterrors預測錯誤MRPwhipMRP鞭子效用Demandswings需求振幅Servicepolicy服務政策SafetyStock**安全庫存Inventoryneededtocoverinternallosses庫存來滿足內部的損耗PartsLost/(CycleStock+BufferStock)零件損失/(循環(huán)庫存+緩沖庫存)Poorquality差質量Downtime停工時間*Basedonstandarddeviation–nomorethan10%基于標準偏差—不超過10%**Worstcasepieceslossduetoscrap,rework,downtime,latedelivery,etc.基于報廢，返工，停機，晚交付等最差的情況ThreeTypesofStock3種庫存類型第60頁/共121頁KanbanQuantityCalculation看板數量計算Forin-processorinter-processkanban:工序看板或者工序內看板:ADx(RT)x(1+SF)#ofKanbanCards看板卡數量=CQ第61頁/共121頁KanbanCalculationExercise看板計算練習Model型號AverageDailyDemand平均每天需求ReplenishmentTime補料時間SafetyFactor安全因素ContainerQuantity包裝數量A10018%20B2025%20C4537%40HowmanykanbancardsdoweneedforA?ForB?ForC?ABC物料各需要多少看板卡？第62頁/共121頁KanbanQuantityCalculation看板數量計算Forsignalkanban:信號看板MD#ofKanbanCards看板卡數量=CO/MCQ+[ADx(1+SF)]第63頁/共121頁KanbanCalculationExercise看板計算練習Model型號AverageDailyDemand平均每天需求ReplenishmentTime補料時間SafetyFactor安全因素ContainerQuantity包裝數量Model型號D501,20035%50E3570013%30F451,00036%40HowmanysignalkanbancardsdoweneedforD?ForE?ForF?DEF物料各需要多少看板卡？第64頁/共121頁KanbanQuantityCalculation看板數量計算Positionofpullsignal,forsignalkanban:拉動信號的位置，針對信號看板ADx(RT)x(1+SF)PositionofSignal信號的位置=CQSignalkanbanisusedwhentheupstreamprocessproducesinbatchduetolongchangeovertimesandthereforecannotrespondtoeachkanbancardasapullsignal.信號看板用于當上游工序因為較長的換模時間進行批量生產因此不能夠回應每一張單獨的看板卡及拉動信號第65頁/共121頁KanbanCalculationExercise看板計算練習Model型號AverageDailyDemand平均每天需求ReplenishmentTime補料時間SafetyFactor安全因素ContainerQuantity包裝數量D5015%50E3523%30F4516%40WhatisthepositionofthepullsignalforD?ForE?ForF?DEF零件拉動信號的位置在哪里？第66頁/共121頁KanbanQuantityCalculation看板數量計算Forsupplierkanban:供應商看板ADCQa(c+1)#ofKanbanCards看板卡數量=[b+(SFx)]xa,b,carekanbancyclevariablesA,b,c是看板循環(huán)的變差1b第67頁/共121頁KanbanCalculationExercise看板計算練習Model型號AverageDailyDemand平均每天需求ReplenishmentTime補料時間SafetyFactor安全因素ContainerQuantity包裝數量A1001:4:210%20B201:3:28%20C451:3:315%40HowmanysupplierkanbancardsdoweneedforA?ForB?ForC?ABC零件需求的看板卡數量第68頁/共121頁KanbanQuantityCalculation看板數量計算Calculationtips計算提示RoundUPwhencalculatingthekanbancardquantity(e.g.23.4=24cards)當計算看板卡數量時向上圓整RoundUPwhencalculatingthesignalposition(e.g.16.3=17thcontainer)當計算信號位置識向上圓整第69頁/共121頁KanbanSystemTip看板系統提示Improveallvariables(todifferingdegrees)tooptimizethekanbansystem,e.g.:改善所有的變差來優(yōu)化看板系統AD=minimizevariationthroughsalesandoperationsplanning,andreviewingservicepolicies通過銷售，生產計劃，重新檢查服務政策來最小化變差RT=improveinternalprocessesorsupplierprocessestoshortentime通過改進內部流程或供應商流程來縮短時間SF=improvequality,processreliability,deliveryreliability提高質量，過程可靠性，運輸可靠性CQ=usesmallercontainerstoincreasefrequencyofinformation(order)flowanddeliveries使用小的周轉箱來增加信息流及交付的頻率第70頁/共121頁Section4Topics第4章主題ManagingtheKanbanSystem管理看板系統The6prerequisites6個必要條件The6goldenrules6條金科玉律Kanbancirculationsteps看板循環(huán)步驟Integrationwiththeplanningsystem與計劃系統進行整合第71頁/共121頁WhatDoesitMeantoManagetheKanbanSystem?這對管理看板系統的意義？Implementthe6Prerequisitesfirst首先實施6個必要條件Buildafoundationofstabilitydemand創(chuàng)造一個需求平穩(wěn)的基礎Buildprocesscapabilityandresponsiveness創(chuàng)造制程能力及應答Followthe6GoldenRules按照6條金科玉律Trainandpracticeuntilitbecomessecondnature培訓及練習直到成為第2個本性Materialconveyancesystemsupportsthepullsystem物料勻速系統支持拉動系統Integratewiththeplanningsystem與計劃系統進行整合Responsibilityforadd/removalofcardsbasedondemandandcapabilitychanges負責根據需求及產能的變更來增加或減少看板卡Thekanbancardsreplaceotherpaperinstructions–thesystemmustfailifkanbancardsgomissing看板卡替代其他的紙質指示—當看板卡丟失時系統一定會失效。第72頁/共121頁The6PrerequisitesofKanbanSystems看板系統的6個必要條件Stableandpredictabledemand平穩(wěn)及可預測的需求HeijunkaSmalllotsizesthroughquickchangeover通過快速換模時間小的生產批量Informationlinkedtomaterial信息與物料鏈接Defect-freedelivery無缺陷的交付Attachkanbancontainer看板附在周轉箱上Continuousimprovementdiscipline持續(xù)改進記律6Sdiscipline6s紀律Usekanbantoexposeandproblems使用看板來暴露問題第73頁/共121頁Heijunka=Averagingofbothproductionvolumeandmix生產種類及生產量平均化WITHOUTheijunka,thekanbansystemwillhave:沒有均衡化,看板系統將會：Excessresourcestorespondtodemandswings,需要多余的資源來應對需求的振幅Excessinventorylevels(settingkanbancardquantityatmaximumdemand),or需要多余的庫存（根據最大的需求來設置看板卡數量）Theneedtoconstantlyadjustkanbanquantitiesandmaterialsinprocessupanddowntomatchdemand不斷的需要調整看板數量及WIP數量來滿足需求KanbanPrerequisite#1:Heijunka看板必要條件#1RefertoActivity4.1tolearnmoreaboutheijunka第74頁/共121頁HeijunkaBoxProductionKanbanWithdrawalKanbanFinishedGoodsSupermarketKanbanPrerequisite#1:Heijunka看板必要條件#2:均衡化生產第75頁/共121頁g=Kanbancard看板卡KanbanBoardDate11-3-2003Time/ProductABCD8AM–9AMg9AM–10AMg10AM–11AMg11AM–12PMgg1PM–2PMg2PM–3PMg3PM–4PMg4PM–5PMggKanbanBoardDate11-3-2003Time/ProductABCD8AM–9AMg9AM–10AMg10AM–11AMg11AM–12PMg1PM–2PMg2PM–3PMg3PM–4PMgg4PM–5PMggHeijunka:1cycle/day1個循環(huán)/天Heijunka:2cycles/day2個循環(huán)/天KanbanPrerequisite#1:Heijunka看板必要條件#1：均衡化生產第76頁/共121頁Minimizeset-uptimesandotherfactorsthatincreaselotsize最小化開機時間及其他因素來提高批量大小Prerequisite#2:SmallLotProduction必要條件#2：小批量生產WITHOUTsmalllotsizes,thekanbansystemwillhave:沒有小批量生產，看板系統將：Morekanbancardsduetolongreplenishmentleadtimescausedbylargebatchsizes,因為大的批量造成的補料時間長則需要多的看板

Off-linestorageareasforpartsnotneededinthekanbansystem(overproduction),and線外的存儲區(qū)域不在看板系統內（過量生產）Lessresponsivenesstodownstreamchangesincustomerpull,resultinginmoreinventoryan