【正文】 這樣為制定計(jì)劃 /工藝變更提供了最大的彈性。此外，底 WIP意味著更快的周轉(zhuǎn)時(shí)間，這樣可以增加基于客戶的訂單而不是根據(jù)預(yù)測(cè) “固定的 WIP” 改善彈性 15 Generic Pull System Improve The Power of a WIP Cap WIP Cap – Cycle time is reduced and stable No WIP Cap – Cycle time fluctuates with amount of WIP 16 Generic Pull System Improve WIP Cap的能力 WIP Cap – 周轉(zhuǎn)時(shí)間被降低了且穩(wěn)定 沒(méi)有 WIP Cap – 周轉(zhuǎn)時(shí)間隨 WIP的金額而波動(dòng) 17 Generic Pull System Improve United Technologies: Hose and Fittings Division (PTG) Before Metal ware flare running large batches with large amounts of WIP 18 Generic Pull System Improve 聯(lián)合技術(shù) : Hose and Fittings 分部 (PTG) 之前 金屬器械運(yùn)行大批次并伴隨大的 WIP 19 Generic Pull System Improve United Technologies: Hose and Fittings Division (PTG) After Metal ware flare area with controls placed on material releases to the department 20 Generic Pull System Improve 聯(lián)合技術(shù) : Hose and Fittings 分部 (PTG) 之后 金屬器械區(qū)域?qū)Πl(fā)料到部門的材料放置進(jìn)行控制 21 Generic Pull System Improve Teledyne Continental Motors Before No internal limits existed for the number of cylinders a supplier could push to its customer, resulting in large amounts of WIP in the line. 22 Generic Pull System Improve Teledyne Continental Motors 之前 對(duì)于缸體數(shù)量沒(méi)有內(nèi)部限制，供應(yīng)商向客戶推動(dòng)供應(yīng)，導(dǎo)致生產(chǎn)線有大量 WIP. 23 Generic Pull System Improve Teledyne Continental Motors After Limits were established workstations and the line was drained of excess WIP 24 Generic Pull System Improve Teledyne Continental Motors 之后 建立限制數(shù)量，過(guò)多的 WIP從工位和生產(chǎn)線清除 25 Generic Pull System Improve How to Size a Generic Pull System 1. Determine current Manufacturing Cycle Time (MCT) 2. Determine current Manufacturing Cycle Efficiency (MCE) 3. Identify appropriate target MCE 4. Calculate theoretical best MCT 5. Calculate WIP cap 26 Generic Pull System Improve 如何確定普通拉系統(tǒng)的規(guī)模 1. 確定目前的制造周期時(shí)間 (MCT) 2. 確定目前的制造周轉(zhuǎn)效率 (MCE) 3. 識(shí)別適合的 MCE目標(biāo) 4. 計(jì)算理論上的最佳 MCT 5. 計(jì)算 WIP cap 27 Generic Pull System Improve Manufacturing Cycle Time ? MCT – The time from work order release into manufacturing until pletion/movement into shipping/ finished goods. ? It is measured as: ? WIP is the inventory level at a given point in time ? EXITS is the amount of work pleted over a given period of time (Weekly, Daily) EXIT SWIPMC T ?28 Generic Pull System Improve 制造周期時(shí)間 ? MCT – 從工作單的下發(fā)到制造，直到完成 /移動(dòng)到成品的時(shí)間 . ? 他被量測(cè)如 : ? WIP 是在給定時(shí)間點(diǎn)的存貨水平 ? EXITS 是在一個(gè)給定的時(shí)間內(nèi) (每周，每天 )工作完成的金額 EXIT SWIPMC T ?29 Generic Pull System Improve MCT Exits = 20 units/day WIP = Sum of all Inventory within Physical work area = 100 units MCT = 100 units/20 units per day MCT = 5 days Example: Calculating MCT EXIT SWIPMC T ?30 Generic Pull System Improve MCT Exits = 20 單位 /天 WIP = 在物理工作區(qū)域里所有存貨的總和 = 100 單位 MCT = 100 單位 /20 單位每天 MCT = 5 天 舉例 : 計(jì)算 MCT EXIT SWIPMC T ?31 Generic Pull System Improve Manufacturing Cycle Efficiency ? MCE is a measure of the relative efficiency in a production system. It represents the percentage of value add time (changing form, fit, function) of a product down the critical path. ? It is measured as: ? MCE is the performance indicator for Generic Pull Systems. ? ?x10 0PC TTi me AddVa lueMC E Pa th Criti cal?32 Generic Pull System Improve 制造周轉(zhuǎn)效率 ? MCE 是在生產(chǎn)系統(tǒng)中相關(guān)聯(lián)的效率量測(cè) . 它代表關(guān)鍵路徑中的增值時(shí)間（改變形狀，尺寸，功能）的比率 . ? MCE 是對(duì)于普通拉系統(tǒng)的績(jī)效指示器 . ? ?x10 0PC TTi me AddVa lueMC E Pa th Criti cal?33 Generic Pull System Improve Example: Calculating MCE .2 hrs .3 hrs .2 hrs .2 hrs .6 hrs 1hrs Bake hrs .5 hrs Rework Inspect* Critical Path = Value AddTotal = hours Value AddCritical Path = hours* MCT = days MCE = ( 7) / ((5 x 8) 7)** = = % Finished Goods Raw Material * Time at the Inspect workstation does not contribute to the Critical Path calculations because inspection is not value add. ** Bake/Machine times are not included in MCE calculations 34 Generic Pull System Improve 舉例 : 計(jì)算 MCE .2 hrs .3 hrs .2 hrs .2 hrs .6 hrs 1hrs Bake hrs .5 hrs Rework Inspect* Critical Path = Value AddTotal = hours Value AddCritical Path = hours* MCT = days MCE = ( 7) / ((5 x 8) 7)** = = % Finished Goods Raw Material * 在檢驗(yàn)工作站中的時(shí)間沒(méi)有算到關(guān)鍵路徑的計(jì)算中，因?yàn)闄z驗(yàn)不是增值的 . ** 烘烤 / 機(jī)器時(shí)間沒(méi)有包含在 MCE的計(jì)算中 35 Generic Pull System Improve Target MCE ? Table of Manufacturing Cycle Efficiency Benchmarks based on process application Application Low E nd M CE High End M CE Ma c hi ni ng 1% 25% Fabric ati on 10% 30% As s em bl y (w ith Batch Tran sfer ) 15% 40% As s em bl y (w ith o u t Ba tch Tran sfer ) 20% 50% 36 Generic Pull System Improve 目標(biāo) MCE ?