【正文】 pull? What risks are there with pull? What impact will this have on inventory? What impact will this have on transactions? What measures should we use? ? Develop a 10 minute presentation to the staff on the process and impact of implementing a raw material pull system. The presentation must contain the following: ? The best part candidates to place on the new replenishment pull system ? The number of transactions for the new system versus the old system ? Calculate impact to of transactions (% increase or decrease) ? The size ($‘s) of the glass inventory using replenishment pull ? Calculate the maximum, minimum and average quantity of glass onhand ? Calculate inventory $ impact (% increase or decrease) ? Determine square footage of floor space needed for the glass on pull ? Remend platform for generating the replenishment signal ? Identify key measures for the process ? Be prepared to respond to the following questions: ? Did you make any assumptions? ? What logic did you use to exclude parts? 22 Purchased Parts Pull System – Case Study Improve 向員工介紹 ? 約翰繼續(xù)進(jìn)行關(guān)于新拉系統(tǒng)的設(shè)想，是不是全部零件都要拉動？拉動的風(fēng)險(xiǎn)有哪些？對庫存的影響有哪些？對定單的處理有哪些影響？應(yīng)該用哪些指標(biāo)衡量？ ? 用 10分鐘時(shí)間向你的員工介紹實(shí)施拉系統(tǒng)的過程和影響，發(fā)表應(yīng)包括以下內(nèi)容： ?在新系統(tǒng)中所包含的最合適應(yīng)用拉動系統(tǒng)的零件 ?新系統(tǒng)對比舊系統(tǒng)的定單處理量 ? 計(jì)算對定單處理量的影響 (% 增加或減少 ) ?用于拉系統(tǒng)中玻璃庫存的規(guī)模 ($‘s) ? 計(jì)算現(xiàn)有玻璃數(shù)量的最大、最小值、平均值 ? 計(jì)算庫存價(jià)值的變化（ % 增加或減少） ?決定拉系統(tǒng)中庫存玻璃的占用面積 ?建議的補(bǔ)充信號的可用平臺（條件） ?確定過程中的主要量測指標(biāo) ?準(zhǔn)備回答下列問題： ? 你是否使用了假設(shè)條件 ? ? 用了何種邏輯清除多余零件 ? 23 Purchased Parts Pull System – Case Study Improve Answer Sheet M i n i m u m S h i p Q u a n t i t yM u l t i p l e S h i p Q u a n t i t yL e a d T i m e i n w o r k d a y sS q u a r e Fe e t p e r c o n t a i n e rC o n t a i n e r s c a n b e s t a c k e d 3 h i g hC u r r e n t T o t a l G l a s s I n v e n t o r yP a r t O n H a n d $ S / X O c c u r r e n c e s OF ADUBad Pull Part Candidates 24 Purchased Parts Pull System – Case Study Improve 答案表 最小發(fā)貨數(shù)量多倍發(fā)貨數(shù)量交貨時(shí)間（工作日）每箱的面積可以碼放 3 層的料箱數(shù)量目前玻璃合計(jì)庫存零件 在手 $ S / X 發(fā)生 訂單頻率 ADU不利于拉動系統(tǒng)的零件 25 Purchased Parts Pull System – Case Study Improve Answer Sheet: Transactional Sizing Detail P a r t S t d C os tA D U ( U ni t s / D a y )S t a nd a r d D e v i a t i onABC C od eLe a d Ti m e ( D a y s ) C urr e nt O F ( D a y s ) P r op os e d O F ( D a y s )C urr e nt Trx n39。從 1993—1997年，增長速度達(dá) 15%（ CAGR） 高于行業(yè)平均增長速度，產(chǎn)品在位于達(dá)拉斯市的一個(gè)小工廠生產(chǎn)。我的目標(biāo)是降低庫存的同時(shí)減少材料管理的工作量。 Bill Glass于 1988年創(chuàng)建了 WindowsRUs公司。 ? 從原材料采購處： ? 只有 15種特定的原材料種類 ? 玻璃的交貨期為 1周（不考慮混型），供應(yīng)商可信度較高 ? 玻璃供應(yīng)商為 WINDOWS公司，每季度生產(chǎn)一次 ? 玻璃供應(yīng)商最小發(fā)貨量為一卡車（ 20箱 每箱 300塊） ? 料箱尺寸是 4? x ‘ ， 最多可以碼放 3層料箱 ? 玻璃原材料訂貨頻次多變（沒有固定的策略） 13 Purchased Parts Pull System – Case Study Improve Replenishment Pull Case Study (Cont.) ? From the Insulated Glass Production Manager: ? Production consists of 5 steps (cut, sort, wash, assemble, bake) ? Run 3 shifts per day ? Steps are connected via conveyors and therefore run synchronous ? Cycle time from glass cut to finished insulated unit is about 1 hour ? Changeover from 1 family to the next is about 2 hours ? Can cycle through the 15 families about once per week ? From the Warehouse Manager ? Is currently about 40% efficient with floor space (based on the haphazard ordering) ? Employs 4 full time material handlers and 2 temporary cycle counters John first gathered some information on the raw material parts (Exhibit 1). He then performed some high level analysis on the parts (Exhibit 2). This analysis should help him in identifying which parts make good candidates. 14 Purchased Parts Pull System – Case Study Improve 補(bǔ)充拉系統(tǒng)案例 ? 從絕緣玻璃生產(chǎn)經(jīng)理： ? 生產(chǎn)包含 5個(gè)步驟 (裁切，分選，清洗，組裝，烘烤 ) ? 每天分 3班 ? 工序是通過傳輸帶運(yùn)行，因此是同步運(yùn)行 ? 周轉(zhuǎn)時(shí)間從裁切到成品產(chǎn)出為 1小時(shí) ? 產(chǎn)品更換的換模時(shí)間為 2個(gè)小時(shí) ? 15個(gè)系列產(chǎn)品可以每周循環(huán)生產(chǎn)一次 ? 從倉庫經(jīng)理： ? 目前空置率為 40%（由于擺放順序隨意） ? 4個(gè)專職的搬運(yùn)工人和 2個(gè)臨時(shí)統(tǒng)計(jì)員 約翰首先收集到有關(guān)原材料的一些信息（表 1），然后他又對原材料做了進(jìn)一步的分析（表 2），這些分析能幫助他識別最佳選擇的零件。 s of C on t a i ne r