如何縮短產(chǎn)品制造周期

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Thispresentationfocusesonleanmaterialflowanditsimpactonreducingleadtime.

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

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

明白SLT對客戶響應(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)品到客戶的開始使用期間，沒有等待、儲存量、雙重處理、多余庫存。ShortLeadTimeStrategySLT策略Supplier(供應(yīng)商)Plant(工廠)

PointofUse開始使用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)送到一定的地點的流動。LeanMaterialFlowDefinition

精益物流定義1)PartsOrdering

定購零件2)Suppliers

供應(yīng)商3)Packaging

包裝4)Transport

運(yùn)輸5)Receiving

接收6)Temp.Stores臨時倉庫7)MaterialPullSystem物料拉動系統(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)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:

1.VehicleScheduling制造計劃2.PartOrdering訂購零件3.SupplyBase供應(yīng)基地4.Transportation&Receiving運(yùn)輸與接收5.InternalPullSystems內(nèi)部拉動系統(tǒng)6.MobileEquipment移動設(shè)備7.PartPresentation零件擺放

Tools工具：PlanforEveryPart每個零件計劃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(拉動系統(tǒng))LevelBuildPattern(均衡生產(chǎn)模式)FrequentDelivery(????)MultiplePartNumbers/Delivery

(??????/??)MinimalInventory(????)GMPlantPartPartPartABCPlantProductionQtyTime1.VehicleSchedulingProcessOverview

制造安排觀測*CustomerOrders客戶訂購+*Non-SoldOrders非賣計劃

PlantProductionPlan工廠生產(chǎn)計劃Customer

客戶ProduceVehicles生產(chǎn)階段

Dealers賣方/Marketing銷售DeliverFinishedVehicles

交付成品*CustomerOrders客戶訂購:SoldVehicles銷售車輛*Non-SoldOrders非賣計劃:Dealer/RegionOrders(Nospecifiedcustomer)

賣方/區(qū)域訂購（無明確客戶）

1-1.VehicleSchedules制造計劃ThePlantProductionPlanlevelsvehiclerequirementsacrosstheproductionperiod生產(chǎn)計劃應(yīng)均衡各個階段的生產(chǎn)需求。100%Customerdeliverydatecompliance百分百地在交付日期交貨。Vehiclebuildstatusisknownthroughoutthemanufacturingprocess.

整個生產(chǎn)部門都應(yīng)該了解制造狀態(tài)。Supportreducedvehicledeliveryleadtime&manufacturingrestrictions.

支持減少車輛交付時間和各種生產(chǎn)限制。VehicleBuildPattern樣板車:

CustomerOrder客戶定單：WhencanIgetmyvehicle()?(什么時候可以交付車子?)143256PlantProductionPlan2

Non-sunroof1Sunroof2.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(yùn)輸?shù)臄?shù)量及時限GMPlantDeliverySupplierPickUpDocumentPickUpDocumentPlantLinesideOperation2-1.PartsOrdering:Sub-AssemblyParts

(零件訂購：分裝件)Asthevehiclepassesasetpointintheproductionprocess,asignalisgeneratedandsenttothesupplybaserequestingpartsrequiredforthatvehicle.生產(chǎn)過程中，當(dāng)生產(chǎn)車輛超出一定點時，生成一個信號通知供應(yīng)商對該車的零件需求。BroadcastSignal

(廣播信號)7:008:009:00SEQ#1(8:00a.m.)SEQ#2(8:01a.m.)SupplierInSequence(Seat)3.SupplyBase(供應(yīng)基地)CloseproximitytotheGMPlantforspecificpartsperdeliverylead-timeneeds(typicallythesearesequencedsub-assemblies).

在GA車間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）Sequencingrequirementsaretheresponsibilityoftheawardedsupplier

(按先后需求排序是合格供應(yīng)商的職責(zé)):Supplierownstheinventoryuntilthelatestpointpossibleinthemanufacturingprocess.

(在送到生產(chǎn)線之前供應(yīng)商擁有庫存)Minimizesupplypoints(供應(yīng)數(shù)量最低化):Singlesupplypointperpartorsub-assembly.(零件或分裝件的單一供應(yīng)點）Minimizethetotalsupplierbase(amountofsuppliers).

（總供應(yīng)基地的最小化（供應(yīng)商數(shù)量））SourcingdecisionsarebasedontheTotalMaterialPipelineCosts

(基于總材料傳送成本決定貨源）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Pre-Scheduledpickupanddeliverywindowtimes.

(事先計劃好接收與交付的間隔時間)Multiplesupplier/partpickupspertruck.

(增加每次裝載的供應(yīng)商/零件接收)Dailyshippingfrequency.

(每天運(yùn)送頻率)EarlyWarning:Truckdriverscheckfreightatsupplierlocation.

(預(yù)警：貨車司機(jī)在供應(yīng)商處檢查貨物)Exception-basedcommunications.

(貨物不符時協(xié)商)80%Highcubeutilization(liquid).

(80%的立方利用率（液體）)LeadLogisticsProviderassinglepointofcontactfortheplant.(精益物流供應(yīng)者作為工廠單一聯(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(dá)工廠)Levelunloadplan(平衡卸貨計劃)PlantLLPTransportationRouteBoardxx#1#2#3#4RouteTimeDefinition:Acentralizedtemporarystorageareaforpartsnotbeingdelivereddirectlyfromsuppliertolineside.定義：不直接把材料從供應(yīng)商處運(yùn)送到線旁，而是暫時將其集中存放的區(qū)域。Purpose:ToOrganize&ControlInventoryLevels,Throughput&FlowforMaterialsnotdelivereddirectlyfromsuppliertopointofuse.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)4-2.CentralMaterialArea(集中材料區(qū)域)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)MinimizeCMAspace(CMA空間最小化)Minimizedeliverylead-time(運(yùn)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)SupportsPullSystemRoutes(支持拉動系統(tǒng)路線)SupportF.I.F.O.(支持先進(jìn)先出)Definition

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

(使用者認(rèn)可的，通過向生產(chǎn)、運(yùn)輸部門發(fā)出信號，要求在一定時間內(nèi)在具體地方運(yùn)送定量產(chǎn)品的一種補(bǔ)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(yùn)送)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).”ProductionPullProcess(生產(chǎn)拉動系統(tǒng))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)(CMA收集卡片）(運(yùn)送材料）EPSProcess(EPS系統(tǒng)):(材料需求)(電子識別)(材料提取，分運(yùn)）(材料運(yùn)送)(交貨結(jié)束)EmptyContainerPullProcess(空箱拉動系統(tǒng))Using

LocationReplenishProductionTeamMember生產(chǎn)人員PushOutPushInEMPTYFULLProductionPullProcess(生產(chǎn)拉動系統(tǒng))BroadcastPoint(RFID廣播）VehicleLocation&MGOPartData(車輛存放點及MGO零件數(shù)據(jù))Automatedpullsystemordersmaterialbasedonactualvehiclepartconsumption(自動拉動系統(tǒng)零件訂購以實際消耗為根據(jù))Simpledesign(簡單設(shè)計)Designtoenablemultiplepartnumbersperdelivery

(能夠每次多零件運(yùn)送的設(shè)計)Standardizeequipmentandcomponentsthroughouttheplant(numberoftypes,hitches,chassis)(整個工廠設(shè)備及零件標(biāo)準(zhǔn)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(yùn)輸設(shè)備):NOYESExle(實例):LinesideDelivery(線旁運(yùn)送)DollyExles(手推車實例)Bulkcontainerdollybase(Standard)(大箱手推車基座)(標(biāo)準(zhǔn))SwivelTurntableBase(旋轉(zhuǎn)轉(zhuǎn)盤基座)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)Ergonomicallyapproved(size,grippoints)

(通過人機(jī)工程認(rèn)證)（大小、把手）Minimaldunnage(partisalloperatorneeds!)

(最小限制的隔板（這是所有操作者需要的部分）)Easypartpick(容易提取)Properpartslabeling(合適的標(biāo)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(yùn)送到操作工身旁)PartPresentationExle

(零件展示實例)LineTrackingDevice(流水線跟蹤儀器)Apron(圍兜)Canmovewithcarrierormanually(能夠人力或自動移動)ApronforFastenersandTools(裝螺絲螺栓的圍兜)Eliminateswasteofmotion(減少運(yùn)動浪費(fèi))SmallLotPartsandContainers(小件包裝)LeanMaterialFlow

(精益物流)WeakMaterialFlow(欠缺物流)IdealMaterialFlow

(理想物流)

LackofVisualManagementTechniques(缺乏目視化管理)

SinglePart/ContainerDeliveryPerTrip(每次單一零件/單箱配送)MaterialPushedtoSubsequentLocation(零件推動到其他地點)

MaterialDictatesLengthofProductionO