【正文】 ent systems ? Be able to describe the benefits of a Bin system ? How to size (calculate) all the parameters for a Bin system 38 2Bin Replenishment Pull Improve 總結(jié) ? 知道箱補(bǔ)充系統(tǒng)的不同類型 ? 能夠描述一個(gè)箱系統(tǒng)的利益 ? 能夠去計(jì)算一個(gè)箱系統(tǒng)的所有參數(shù) 39 2Bin Replenishment Pull Measure Analyze Control Improve Lean Six Sigma APPENDIX 2Bin Replenishment Pull Measure Analyze Control Improve Lean Six Sigma 附錄 2箱補(bǔ)充拉系統(tǒng) Improve Instructions for Typical Card Triggered 2Bin Replenishment This process uses green and red cards to trigger replenishment。 ?訂單頻率 (OF) ? 如果訂單 /觸發(fā)信號(hào)的發(fā)放是按預(yù)定時(shí)間（如：并不是每天，而是每周一次） ? 2箱系統(tǒng)是不需要用訂單頻率的。 ? 當(dāng)?shù)谝幌溆猛炅撕?，在補(bǔ)充 /重新裝料時(shí)，第二箱取代第一箱的位置繼續(xù)滿足使用。 ? 有兩個(gè)主要的補(bǔ)充地點(diǎn)：線旁和使用點(diǎn) 11 2Bin Replenishment Pull Improve Benefits of 2Bin Replenishment ? Organized and overall cleaner appearance of stored materials ? Reduced frequency of orders submitted to the stockroom/vendor ? Reduced number of trips for resupply ? Better management of inventory on the shop floor ? More predictable inventory costs ? Improve employee productivity by: ? Eliminating part/supply shortages at the pointofuse ? Reduce time wasted by personnel/supervision retrieving supplies/inventory from the stockroom and/or vendors ? Eliminate lost or misplaced material ? 2Bin Replenishment can be used for office/safety supplies, production inventory, production supplies – even at home! 12 2Bin Replenishment Pull Improve 2箱補(bǔ)充拉系統(tǒng)的好處 ? 存儲(chǔ)的材料外觀非常清潔和有條理 ? 提交給庫(kù)房 /供應(yīng)商的頻率減少 ? 重復(fù)供應(yīng)的差錯(cuò)數(shù)量減少了 ? 現(xiàn)場(chǎng)庫(kù)存的管理更好 ? 庫(kù)存成本更具有預(yù)測(cè)性 ? 提高員工生產(chǎn)率 : ?排除在使用點(diǎn)的零件 /供應(yīng)短缺 ?減少由于人員 /管理等，從庫(kù)房和 /或供應(yīng)商重新找回供應(yīng) /庫(kù)存的時(shí)間浪費(fèi) ?排除材料的丟失或放錯(cuò)地方 ? 2箱補(bǔ)充可以被使用在辦公室，安全供應(yīng)，生產(chǎn)庫(kù)存，生產(chǎn)供應(yīng) —甚至在家里 ! 13 2Bin Replenishment Pull Improve When to Use 2Bin Replenishment Pull ? Repetitive product offering/process ? Relatively consistent demand/volume (low variability) ? Part/supply shortages are a consistent/costly problem ? Part/supply inventory costs are ―out of control‖ due to: ? Lost or misplaced parts/supplies ? Lack of issue/dispersal discipline or control 14 2Bin Replenishment Pull Improve 何時(shí)使用 2箱補(bǔ)充拉系統(tǒng) ? 重復(fù)的產(chǎn)品供應(yīng) /流程 ? 重復(fù)穩(wěn)定的需求 (底變異 ) ? 零件 /供應(yīng)短缺是常事，且是一個(gè)代價(jià)很大的問(wèn)題 ? 零件 /供應(yīng)庫(kù)存成本是失控的，由于： ? 零件 /供應(yīng)品丟失或放錯(cuò)地方 ? 缺乏投料 /分發(fā)的一致性或控制 15 2Bin Replenishment Pull Improve What Is a Bin? ? Doesn’t necessarily look like a ―bin‖ ? Can be a standard plastic bin (Acrobin) ? Can also be the box/container the part/supply is shipped in (also called a ―standard pack‖ – purchasing definition) ? When the box/container method is used, a ―bin‖ can be one standard pack or several standard packs. Examples: ? 1 box of screws ? 2 boxes of screws ? 1 drum of oil ? 30 bags of connectors ? 1 roll of labels ? 4 tubes of sealant 16 2Bin Replenishment Pull Improve 一箱是什么 ? ? 這并不是說(shuō)一定要看上去像個(gè)“箱子” ? 它可以是一個(gè)標(biāo)準(zhǔn)的塑料箱 ? 它也可以是用于零件運(yùn)輸?shù)囊粋€(gè)盒子或容器 (也可以用采購(gòu)的定義被稱為一個(gè)“標(biāo)準(zhǔn)包 ‖ ) ? 當(dāng)盒子 /容器方式使用了后 , 一個(gè)“箱”可以是一個(gè)標(biāo)準(zhǔn)的包或幾個(gè)標(biāo)準(zhǔn)包。補(bǔ)充可以發(fā)生在每天、每班（或更多） ?盒子 /容器數(shù)量 ? 如果庫(kù)房或供應(yīng)商沒(méi)有列出運(yùn)輸數(shù)量的明細(xì)分類，那么箱數(shù)量可以設(shè)定為等于運(yùn)送零件 /供應(yīng)品的若干盒子 /容器數(shù)量 ?安全庫(kù)存 ? 一般來(lái)說(shuō)的設(shè)定為 1/2 max (LT, OF) * DMD, 否則根據(jù)獨(dú)立的情況來(lái)看 19 2Bin Replenishment Pull Improve Stock Room or Vendor 1 2 Full Bin/Card Move 1 to 2 when 2 is pulled, Send Trigger Use Components Empty Bin/Card PointOfUse (POU) Locations or WorkInProcess (WIP) 2Bin Replenishment (“LineSide” Stocking) ? Reduces part/supply shortages increasing productivity ? Facilitates WIP reduction ? Will result in significant productivity improvements in stock/supply room ? Reduces/eliminates stockroom impact on lot sizes ? May simplify inventory/cycle count processes LineSide Storage LT OF 2 SS/2D MDOF),LTmax(Quant ity Bin ???20 2Bin Replenishment Pull Improve 庫(kù)房或 供應(yīng)商 1 2 添滿的 箱 /卡 當(dāng) 2 被拉動(dòng)時(shí)，移動(dòng) 1 到 2 ， 發(fā)送觸發(fā)信號(hào) 使用的 部件 空的 箱 /卡 使用點(diǎn)位置 (POU) 或工作庫(kù)存 (WIP) 2箱補(bǔ)充 (“線旁” 庫(kù)存 ) ? 減少零件 /供應(yīng)品庫(kù)存，增加生產(chǎn)效率 ? 促進(jìn) WIP的降低 ? 將導(dǎo)致在庫(kù)房里的顯著的生產(chǎn)力提高 ? 降低 /消除庫(kù)房在批數(shù)量上的影響 ? 可以簡(jiǎn)單化存貨 /周轉(zhuǎn)的計(jì)算流程 線旁庫(kù)存 LT OF 2 SS/2 DMD OF) , LT max( 箱數(shù)量 ? ? ? 21 2Bin Replenishment Pull Improve Full Bin/Card Pull from 1 until empty, send trigger and pull from 2 until empty, send trigger, etc. Use Components Empty Bin/Card 2Bin Replenishment (“Pointof Use” Stocking) LT OF 1 SS/2D MDOF),LTmax(Quant ity Bin ???? 2Bin POU stocking is used when restocking is not an issue. Stock Room or Vendor PointOfUse (POU) Locations or WorkInProcess (WIP) 2 22 2Bin Replenishment Pull Improve 拉動(dòng)從 1開(kāi)始直到用完為止 , 發(fā)送觸發(fā)信號(hào)，然后拉動(dòng)從 2開(kāi)始直到用完為止，發(fā)送觸發(fā)信號(hào) , 等等 . 使用 部件 2箱補(bǔ)充 (“使用點(diǎn)” 庫(kù)存 ) LT OF 1 SS/2 DMD OF) , LT max( 箱數(shù)量 ? ? ? ? 當(dāng)重新備庫(kù)存不是一個(gè)問(wèn)題時(shí)，使用 2箱 POU 庫(kù)存 庫(kù)房或 供應(yīng)商 2 添滿的 箱 /卡 空的 箱 /卡 使用點(diǎn)位置 (POU) 或工作庫(kù)存 (WIP) 23 2Bin Replenishment Pull Improve 2Bin Replenishment Calculations ? Bin Quantity = Max(LT, OF) + SS/2 ? If replenishing in standard packs, Bin Quantity is rounded up to the nearest standard pack multiple ? Example: ? Calculate the Bin Quantity for the following (standard pack replenishment): ? Part Number: 40567 ? Description: Rubber Gloves ? Demand/Usage: 25 pairs/day ? Lead Time: 2 days (trigger stock/supply room replenishment) ? Order Frequency: N/A ? Box Quantity: 50 pairs ? Bin Quantity ? = [Max (2 days, N/A) * 25 pairs/day] + .5 * [Max (2 days, N/A) * 25 pairs/day] /2 ? = 63 pairs ? But we have to round up to the nearest standard pack, so: ? Bin Quantity = 100 pairs = 2 boxes 24 2Bin Replenishment Pull Improve 2箱補(bǔ)充的計(jì)算 ?箱數(shù)量 = Max(LT, OF) + SS/2 ? 如果是標(biāo)準(zhǔn)包的補(bǔ)充，箱數(shù)量應(yīng)該是近似于標(biāo)準(zhǔn)包的倍數(shù) ?舉例 : ? 計(jì)算下列數(shù)據(jù)的箱數(shù)量 (標(biāo)準(zhǔn)包補(bǔ)充 ): ?零件號(hào)碼 : 40567 ?描述 : 橡膠手套 ?需求 /用量 : 25 雙 /天 ?交貨時(shí)間 : 2 天 (觸發(fā) – 庫(kù)房 – 補(bǔ)充 ) ?訂單頻率 : 不適用 ?箱數(shù)量 : 50 雙 ? 箱數(shù)量 ? = [Max (2 天 , N/A) * 25 雙 /天 ] + .5 * [Max (2 天 , N/A) * 25 雙 /天 ] /2 ? = 63 雙 ? 但是 我們要取一個(gè)近似標(biāo)準(zhǔn)箱的數(shù)量，所以 : ?箱數(shù)量 = 100