【正文】 ? How Can a Shop Resource This ?生產(chǎn)車間怎樣規(guī)劃? How Can the Supply Chain Cope ?供應鏈怎樣應付? What if the Supply Chain is Global ?如果是全球供應鏈又怎樣HeijunkaHeijunka均衡化生產(chǎn)6LEAN TO EXCELLENCEProductionControl產(chǎn)量控制Pacemaker Sets the Pace for Upstream Processes節(jié)拍器設(shè)置在上游制程? Single Scheduling Point單個計劃控制點? Down Stream Processes Occur as a Flow下游流程化More leveled production更多均衡化生產(chǎn)Pacemaker節(jié)拍控制點Finished Goods Supermarket 成品超市Customer Demand客戶需求Customer客戶Kanban Post看板位Withdrawal (Pull)拉動Withdrawal (Pull)拉動Heijunka均衡化生產(chǎn)7LEAN TO EXCELLENCE均衡 投入指引8LEAN TO EXCELLENCEPurpose:目的目的 To provide guidelines for developing the method and tools for levelloading (or levelscheduling) the shop floor. 提供均衡投入（均衡計劃）生產(chǎn)的方法和工具的指引Key Elements of Levelscheduling 均衡計劃的主要基礎(chǔ)均衡計劃的主要基礎(chǔ)n Production units are stratified according to planned sales volume n 產(chǎn)品分類按計劃銷售量n The production sequence bines Build To Order (BTO) and Customer Forecastn 生產(chǎn)順序結(jié)合按訂單生產(chǎn)和客戶預測n Sequence is designed to achieve the bined TAKT time for all itemsn 生產(chǎn)順序結(jié)合了各個項目的節(jié)拍時間n Eliminating production rate variance is required to achieve TAKT timen 消除生產(chǎn)率差異是達到節(jié)拍時間的要求n Build only high volume products to FG supermarket based on business model n 根據(jù)生意模式建立大批量產(chǎn)品的成品超市n Lower volume items are only sequenced with firm orders 低產(chǎn)量產(chǎn)品排產(chǎn)只根據(jù)確定的訂單n Hold ponents in Raw Materials supermarket only for low volume 項目n Fill orders first from FG, second WIP, third sequence them (attach the order to the production plan)n 訂單填充首先從成品，其次在制品 第三就要排序它們（生產(chǎn)計劃聯(lián)系訂單）均衡投入指引9LEAN TO EXCELLENCESales Production HeijunkaIt is natural that the customer’s demand is not always same. To satisfy them, you need to pull and manufacture the product by leveling both volume and types.*客戶的需求總是不同的，這是很自然的，為了讓客戶滿意，你需要通過均衡產(chǎn)量和品種來拉動和制造產(chǎn)品* Shingijutsu Corp.均衡的 概念10LEAN TO EXCELLENCE3 Types of Plan 3種計劃i. Frozen: 100% fix, No change allowed 凍結(jié)： 100%確定，不允許任何更改。凍結(jié) 計劃11LEAN TO EXCELLENCERelationship between Schedule visibility and manufacturing lead time計劃的可見度和制造期限的關(guān)系Forecast預測SemiFrozen半凍結(jié)Frozen凍結(jié)Week 12Week 11Week 10Week 9Week 8Week 7Week 6Week 5Week 4Week 3Week 2Week 1Lead time 1/ ? Schedule Visibility and Accuracy交貨時間 1/ ? 計劃的可見度和準確性Lead time increase ? Schedule visibility and accuracy reduced交貨時間增加 ?計劃的可見度和準確性降低Visibility and accuracy reduced可見度和準確性降低凍結(jié) 計劃12LEAN TO EXCELLENCE順序 生產(chǎn)指引13LEAN TO EXCELLENCENeed to Determine . . .需要決定How Much 2 systems per dayWhat Kind 15 pcs of System A 5 pcs of System BWhen 5 of G, 2 of R, 5 of G,2 of R, 5 of G, 1 of RTAKT節(jié)拍時間Level Load Mix均衡化混合Level LoadSequence順序均衡化If we are making Systems. . . 如果我們正在生產(chǎn)產(chǎn)品QuarterlyWeeklyWeekly Frequency頻率Takt Time節(jié)拍時間 = Available Time可用時間Demand/Customer Forecast 客戶需求Assumptions假設(shè) :1) Machine Breakdown = 0 hour機器故障 =0小時2) Setup Change = 0 hour設(shè)置轉(zhuǎn)換 =0小時3) Defect Rate = 0%不良率 =0%Quick Example5 – 2 – 5 – 2 – 5 – 1 A BABBA A A A A B BAA A AA BA A A AA ABB A B順序 ：決定生產(chǎn)數(shù)量和節(jié)拍時間14LEAN TO EXCELLENCE順序：決定生產(chǎn)數(shù)量和節(jié)拍時間CSetting the production sequence of multiple Types設(shè)置多種類型的生產(chǎn)順序48 units1440 unitsTotal units min12 units360 unitsSystem 3 min12 units360 unitsSystem 2 min24 units720 unitsSystem 1TAKT Time節(jié)拍時間ShiftRequirement日需求MonthlyRequirement月需求Product產(chǎn)品167。 THEY ARE ALL PRODUCED ON THE SAME LINE. 它們都在同一條生產(chǎn)線生產(chǎn)。1213Let’s show how we validate this… 讓我們看如何確認它。Things to Remember … 四件事情要牢記 …單 件流7 Types of Waste七大浪費?Defective Parts不良?Over Production生產(chǎn)過多產(chǎn)品 ?Inventory庫存?Motion動作? Transportation搬運?Waiting等待?Over Processing多余的流程 26LEAN TO EXCELLENCE在 生產(chǎn)過程中建立品質(zhì)The Next Process is the Customer…Never Send Defects!下一個工序就是你的客戶 … 決不傳遞不良品 ! Catches Defects too Late 發(fā)現(xiàn)不良（缺陷）太晚?How many more do you have 你已經(jīng)生產(chǎn)了多少 ?? Where are they in the process他們在流程的什么地方 ??What is the root cause 問題發(fā)生的根源是什么 ? Catches Defects Immediately及時發(fā)現(xiàn)不良（缺陷）? You only have one你只有一個? You know where it occurred你知道它在什么地方? Resolve the root cause immediately能馬上解決問題27LEAN TO EXCELLENCE單 件流Guidelines for Cell Layout單元設(shè)計的指單元設(shè)計的指引引Good Cell Layout Makes Work Redistribution Easy好的單元設(shè)計能使工作重新分配容易。q Eliminate spaces and surface where WIP can accumulate 消除任何能讓在制品聚集的空間和表面。 q Use small equipment dedicated to a single task 使用具有單一功能的小型設(shè)備。q At Pacemaker,strive to devise machine changeover betwe