【正文】 andard WIP for each station is 1pc. 改善前，插件拉的制程 WIP=9 pcs。 ? However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and bottle neck 然而，在完全達(dá)到標(biāo)準(zhǔn) WIP數(shù)量前，你需要經(jīng)過(guò)不同的階段了解制程中的浪費(fèi)和瓶頸。 Scenario 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec 情節(jié) 2：如果正反面產(chǎn)品同時(shí)在一條生產(chǎn)線生產(chǎn)，節(jié)拍時(shí)間則為一半， 48秒。 sec 2792 ,0001,58 4,00 0pcs 792 ,000s 360 0 x days 20 x Hou rs 22 Deman d Custome r Time AvailableTime Takt????客戶(hù)需求有效時(shí)間6 How to start the Takt Time Calculation Based On Product and Process Design怎樣根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Step 2: Calculate Process Takt time Based on Product and Process Design 第二步：根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Based on Step 1, Takt Time is 2 second to produce 1 pcs. 根據(jù)步驟 1，節(jié)拍時(shí)間是每 2 秒生產(chǎn) 1 件產(chǎn)品。 Type 3 : Standard Work (also called as Work Standard) to support task carried out once signal is triggered. 類(lèi)型 3：標(biāo)準(zhǔn)作業(yè)（也叫做作業(yè)標(biāo)準(zhǔn)）適用于當(dāng)信號(hào)產(chǎn)生時(shí)才去執(zhí)行相應(yīng)任務(wù)的作業(yè)方式 。 庫(kù)存減半 ? Productivity : X 2 生產(chǎn)效率翻倍 ? Lead Time : X 189。 生產(chǎn)周期減半 ? Scrap : X 1/10 報(bào)廢降低 90% ? Space : X 189。 No Std Work means no Kaizen … Std Work is the Mother of all Kaizen 沒(méi)有標(biāo)準(zhǔn)作業(yè)就沒(méi)有改善 …… 標(biāo)準(zhǔn)作業(yè)是改善之母 5 How to start the Takt Time Calculation Based On Customer Demand 怎樣根據(jù)客戶(hù)需求計(jì)算節(jié)拍時(shí)間 ? Step 1: Calculate Takt time Based on Customer Demand 第一步：根據(jù)客戶(hù)需求計(jì)算節(jié)拍時(shí)間 ? Example 例如 : ? Customer Demand per Month 792K. Working hour per day is 22 hours, 20 days a month. 客戶(hù)每月需求量是 792K。 7 How to start the Takt Time Calculation Based On Product and Process Design怎樣根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Scenario 1: Product design is 6 pcs per one PCB panel. The Process Takt Time will be every 12 second a panel. Besides, your process design is using a pallet to place 4 panels, then your Process Takt Time is 48 second a pallet. If 2 line running, process Takt time will be 96 sec. 情節(jié) 1：產(chǎn)品設(shè)計(jì)為每塊 PCB板由 6 塊小板組成，節(jié)拍時(shí)間是每塊 PCB板 12 秒 。 As such the Process Takt Time Calculation as following: 制程節(jié)拍時(shí)間計(jì)算如下： = Takt Time X Product Up x Process Up X Number of Line = 2 sec X 6 products per panel X 4 Panel per pallet X 2 Lines = 96 sec 8 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Various types of WIP in our manufacturing process 生產(chǎn)過(guò)程中存在各種類(lèi)型的 WIP 1. Standard WIP 標(biāo)準(zhǔn) WIP 2. Process WIP 制程 WIP 3. Process To Process WIP 制程與制程間 WIP 4. Station To Station WIP 工位與工位間 WIP 9 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP ? WIP means INVENTORY. INVENTORY is Basically ‘bad’. WIP就是庫(kù)存。 Key Note from Sensei: 老師的重要提示： ? To understand the above WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解 WIP定義，你需要去到現(xiàn)場(chǎng)在工作中實(shí)踐正確的 WIP數(shù)量。改善后插件拉制程WIP=3pcs。計(jì)算如下： Takt Time = 30sec Changeover Time = 5 min 30sec Process A Process B pcs 10sec 3060sec x 5min WIPPTP 　???15 Takt Time 節(jié)拍時(shí)間 Cycle time Takt time ( 1 Station Process ) C/TTakt Time (1個(gè)工位） Cycle time than takt for single process (2 same stations needed) C/TTakt (需要2個(gè)相同工位 ) TAKT Time = 20s 10 20 30 40 Machine/Process A : St. 1 Machine/Process A : St. 2 Note注 : CT TT : No additional Machine/Man needed 不需要額外的機(jī)器 /人員 CT TT : Additional Machine/Man needed 需要額外的機(jī)器 /人員 It can be used to calculate 節(jié) 拍 時(shí)間 可以 計(jì) 算 ? Total Operators needed 員 工需求數(shù)量 ? Total machines needed 機(jī)器需求數(shù)量 ? Standard WIP needed Etc 標(biāo) 準(zhǔn) WIP需求數(shù)量，等 16 1) Is the Takt time visible (with counter and triggering point)? 節(jié)拍時(shí)間可以直觀地看出來(lái)嗎？有沒(méi)有借助工具 (計(jì)數(shù)器和觸發(fā)機(jī)制 ) 。s not meet ―傳送帶 ‖的 4個(gè)功能， 如果不符合以下條件則不能使用 ―傳送帶 ‖ ? Function as a Pace Setter ( Takt Manufacturing ) 節(jié)拍調(diào)節(jié)器（節(jié)拍生產(chǎn)） b) Function as a Value adding work station ( Value being added as it moves) 增 值工位 （ 傳送帶移動(dòng)時(shí)產(chǎn)品可以增值，如在傳送帶上作業(yè) ） c) Function as a Jidoka ( Stop every abnormal ) 自?xún)P化 （ 異常時(shí)停止作業(yè)） d) Function as a transportation mode ( 5% of the function ) 傳送作用 （只占 5%的功能） 22 Layout 布局 1) Insure the short walking distance. 確保產(chǎn)線行走距離短 . 2) Do you have 3 TEI implemented on your line? 產(chǎn)線有沒(méi)有對(duì)物品實(shí)施三定原則 ? a) Fix place 定點(diǎn) b) Fix things 定位 /定物 c) Fix qty 定量 3) Is the safety aisle easily accessed by the operator? 安全通道是否易于員工通過(guò) ? 4) Are there trash bins inside the cell? 單元生產(chǎn)線內(nèi)有沒(méi)有垃圾箱 ? 5) Do you have cell concept implemented on your line? 有沒(méi)有在生產(chǎn)線上應(yīng)用單元生產(chǎn)的概念 . 23 Layout ( continue ) 布局 (續(xù)頁(yè) ) 6) The operator movement in a cell : is it counter clock wise(1) or clockwise(0). Counter clock wise is remended 操作員在 單元 內(nèi)的移動(dòng)是逆時(shí)針還是順時(shí)針 (逆時(shí)針為佳 ) 7) The gap in a cell : is it wider(0) or narrower(1) (narrower remended). 單元 內(nèi)工站間的間距合適的嗎 ?寬 (0) 還是窄 (1) (推薦用窄 ). 8) Is the station made of crefoam material and is it on the wheel for flexible movement? 工作臺(tái)是由復(fù)合管做成的嗎 ?是否有滑輪易于移動(dòng)呢 ? 9) The flow of a layout must be like a single stroke, no zigzag. 產(chǎn)線布局的流向必須是單行程的，而不是彎曲交錯(cuò)的 。 17) Do you have mean test ? challenge the current state (Potential Problem Analysis) 有運(yùn)用均值檢驗(yàn)嗎 ? –對(duì)現(xiàn)狀進(jìn)行尋根究底 (分析潛在的問(wèn)題 ) 18) Do you use 5 Why analysis to understand the root cause? 有沒(méi)有運(yùn)用 5個(gè)為什么來(lái)分析根本原因？ 19) Landscape concept – View from all angles (the mountain) ,Search for the truth (the forest), Look/Focus (the tree), See and fix it (the branch) 全局概念 全方位 遠(yuǎn)看 (山 )，尋找真相 近觀 (森林 )，細(xì)看 (樹(shù) )，深究并解決問(wèn)題 (枝干 ) 30 One Piece Flow 單件流 1) One piece flow 單件流 2) Are the line visibility clear for the supervisor? ? Takt counter? Line flow? 對(duì)于管理者來(lái)說(shuō)，產(chǎn)線狀況可視化嗎？有標(biāo)準(zhǔn) WIP?節(jié)拍計(jì)數(shù)器？產(chǎn)線是流動(dòng)的嗎？ 3) One piece flow which like as the eggs inside the chicken should be one by one flow ,but not in parallel. 單件流就像母雞肚里的雞蛋一樣是一個(gè)一個(gè)下蛋的，而不是一起下出來(lái)的。 7) The layout of ― Y‖ is better than the layout ― I I I ‖ series ―Y‖型布局比 ―I I I