【正文】 0 R OCT = 62 sec D/R = 62 sec C/O = 0 REJ = 6% U/T =100% 2 Shifts 27, 600 sec. Avail. OCT = 40 sec D/R = 40 sec C/O = 0 REJ = 7% U/T = 100% 2 Shifts 27,600 sec. Avail. Shipping Staging I I I 1600 L 850 R 1200 L 640 R 2700 L 1440 R Ferrous Metals Co. 500 ft coils Tues Thurs Machine 1 OCT= 39 sec D/R = 39 sec C/O = 10 min REJ = 4% U/T= 100% 2 Shifts 27, 600 sec Avail. MCT = 1 second C/O = 1 hour REJ = 3% U/T = 85% 27,600 sec. avail. EPE = 2 weeks Stamp 200 t Weld 1 OCT = 46 sec D/R = 46 sec C/O = 10 min REJ = 5% U/T = 80% 2 Shifts 27,600 sec. Avail. 1x daily SubAssembly 1 Assembly 1 MRP 18,400 pcs/mo 12,000 “L” 6,400 “R” Tray = 20 pcs 2 Shifts Highland Manufacturing Sheet Metal Housings Current State (Date) Daily Ship Schedule Weekly Schedule TT = 60 sec. Manchester Avenue 6week Forecast Weekly fax Production Control 90/60/30 day Forecasts Daily Order 5 days days days days 2 days days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec. Lead Time= days Process Time= 188 sec Where else can onepiece flow be implemented now that we have looked at OCT? 看過操作員周期時間后，還有別的地方可執(zhí)行一件流嗎？ By establishing onepiece flow here, what goes away? 這里用一件流，什么會消失？ VRK STD WK 38% Prod. Imp SMED 10 min. Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. Tues Thurs 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day I Coils 5 days VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order Here is what our FutureState map now looks like so far… 這是到目前為止，未來圖看起來的樣子 Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. Tues Thurs 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day I Coils 5 days VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order 60 5. What pull systems will be used between disconnected processes? Examine Stamping Pull 中斷的制程之間使用何種拉引系統(tǒng)？試試 沖壓制程的 拉引 Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. Tues Thurs 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day I Coils 5 days VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order 60 Now that the withdrawal kanban is place,how will the production kanban in Stamp work? 若運輸看板已 被提取 ， 沖壓 工作的生產(chǎn)看板 將 會如何？ 60 Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. Tues Thurs 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day I Coils 5 days VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order 60 Why won’t the pull system we’ve designed work here? 為何不在此處使用拉引系統(tǒng)？ Because of the 1 hour changeover! 因為換模時間 要一小時 60 Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. Tues Thurs 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day I Coils 5 days VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order 60 We will need to use a signal kanban for batch processes that have changeover times 對于換模時間較長的批量制程，必須使用訊號看板 batch Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. Tues Thurs 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. R