【正文】 生產(chǎn)時間 TAKT TIME節(jié)拍時間 =TAKT TIME is just Math, but is Fundamental to Lean節(jié)拍時間不僅是數(shù)學(xué)公式 ,而且是精益生產(chǎn)的基礎(chǔ)AVAILABLE TIME: Total amount of TIME allocated for production可用生產(chǎn)時間 : 可用于安排生產(chǎn)的全部時間DEMAND: qty of scheduled parts for a given time frame需求 : 客戶在一定時間內(nèi)預(yù)定的數(shù)量each shift has ~ hrs available this is a constant! hrs is used to account for lunches, breaks, etc… 每個班別有 – 這是一個恒量 ! 這個值已經(jīng)考慮了午飯 ,休息等 …EXAMPLE 舉例Available Time = 60 min/hr x hrs/shift x 2 shifts/day x 5 days/wk = 3900 min/wk可用生產(chǎn)時間 = 60 分鐘 /小時 x 小時 /班 x 2 班 /天 x 5 天 /周 = 3900 分鐘 /周Your customer demand is 90 pcs per week 客戶的需求是每周 90個產(chǎn)品3900 min/wk 分鐘 /周90 pcs/wk 件 /周 = 43 min/pc 分鐘 /件TAKT Time節(jié)拍時間 = Customer Forecast客戶需求預(yù)測36LEAN TO EXCELLENCEWork Sequence 作業(yè)順序作業(yè)順序 The order of operations in which a worker places parts on a machine or in an assembly. 操作員在機(jī)器或者裝配中的操作順序42Standard WIP標(biāo)準(zhǔn) WIP Work Sequence作業(yè)順序TAKT Time節(jié)拍時間machine processing機(jī)器運行中? ? ? ? ? ?Remove part 移動Inspect檢查 Deburr清理毛刺Place in box 固定Mount part 裝配Start啟動機(jī)器標(biāo)準(zhǔn) 作業(yè)的第二要素The Same Thing, The Same Way, Every Time每次都是一樣的對象，一樣的方法37LEAN TO EXCELLENCEStandard WorkinProcess (SWIP)標(biāo)準(zhǔn)在線庫存標(biāo)準(zhǔn)在線庫存Refers to the minimum workinprocess needed to perform repetitive operations, 使用所需要的最小量的 WIP來進(jìn)行重復(fù)性的操作 ? parts mounted on machines 部件裝配到機(jī)器 ? parts on conveyors 部件在傳送帶上移動 ? parts needing time to cool, etc. 部件需要時間來冷卻One Piece Is The Standard Goal 單件流是標(biāo)準(zhǔn)作業(yè)的目標(biāo)TAKT Time節(jié)拍時間Standard WIP標(biāo)準(zhǔn) WIP Work Sequence作業(yè)順序43End FinishWeldEnd FinishWeldOrbital WeldHydro TorchBrazeMech.CleanFlex標(biāo)準(zhǔn) 作業(yè)的第三要素38LEAN TO EXCELLENCEPull Production 拉動式生產(chǎn)39LEAN TO EXCELLENCE? Withdraws needed parts from preceding process 從前工序拉動需求的產(chǎn)品? Preceding process “owns” Supermarket 前工序負(fù)責(zé)管理超市? “Purchasing” intervals derived from TAKT time 對的需求間隔時間由節(jié)拍時間決定? “Purchased” quantities in standardized amounts 拉動需求的量是標(biāo)準(zhǔn)化的拉動 客戶 Consume Before Bringing More Material In要把物料消耗完才可以領(lǐng)取新物料 40LEAN TO EXCELLENCE1234Cell or ChakuChaku lineParts78910SupplierMaterial 物料Information 信息Supermarket超市Empty container 空的容器Full container滿的容器Legend圖例1 Sequence / Timing順序 /時機(jī)拉動 的方法 順序Assembly Line5641LEAN TO EXCELLENCE看 板系統(tǒng)42LEAN TO EXCELLENCE? Circulation of Information信息流動? Cards are Like $ Used to “Buy” Parts from the Supermarket 卡片好比錢 $用來從超市買零件? Tool Used in Pull Production拉動式生產(chǎn)工具的使用看 板系統(tǒng)的基礎(chǔ)Kanban is Not Material…It is Information 看板不是物料 . . .是信息43LEAN TO EXCELLENCEThere are 4 conditions that need to be met before you can introduce the Kanban effectively… 在有效的引進(jìn)看板之前四個條件需要滿足 of Preceding Process in Quality and Productivity 前制程有穩(wěn)定的質(zhì)量和生產(chǎn)率 Production 均衡生產(chǎn) Production / Pull System節(jié)拍生產(chǎn) /拉動系統(tǒng) Member Education隊員的教育 看 板系統(tǒng)的先決條件Kanban Can Paralyze Without Satisfying These Conditions看板系統(tǒng)不能滿足這些條件就會癱瘓44LEAN TO EXCELLENCE? Physical Goods Control: Movement of Kanban corresponds to physical goods 控制實物：看板的移動反映了實物的移動? Instruction of Operation: What do you produce and how many? 操作說明：你的產(chǎn)出是什么？有多少數(shù)量？? Tool for Kaizen: Easier to see material deficiencies 看板的工具 。Materials原材料Machines設(shè)備Cell Layout單元布局單 件流30LEAN TO EXCELLENCE18’14’BracketTubeWiresAssembly IConnectorAssembly IIIAssembly IIAssembly IVPreparationICJumperAssembly II angled to keep cell inside Width about 5’ 擺成斜的，使 Cell的寬度在 5’左右。 q Avoid batching避免或者消除計數(shù)。 q Locate the beginning end processes near one another 單元出入口一致。If produced to a sequence, 2 units will be produced in 2 Takt times, or 15 minutes 如果按順序生產(chǎn)，每次將生產(chǎn)2種產(chǎn)品按 15分的節(jié)拍時間。Current situation is we group all account as “Forecast” or keep changing the socalled “Frozen schedule”現(xiàn)狀是，我們集合所有項目類似 “預(yù)測 ”或者總是改變所謂的 “固定 ”計劃。 Kanban System 看板系統(tǒng) 2LEAN TO EXCELLENCE概述 范圍q Lean manufacturing is a generic process management philosophy derived mostly from the Toyota Production system (TPS) but also from other sources. It is renowned for its focus on reduction of 39。 The Flextronics Lean Enterprise偉創(chuàng)力精益 生產(chǎn)屋 167。 Heijunka均衡生產(chǎn) 167。seven wastes39。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(yù)測SemiFrozen半凍結(jié)Frozen凍結(jié)Week 12Week 11Week 10Week 9Week 8W