【文章內容簡介】 7)** = = % Finished Goods Raw Material * 在檢驗工作站中的時間沒有算到關鍵路徑的計算中，因為檢驗不是增值的 . ** 烘烤 / 機器時間沒有包含在 MCE的計算中 Improve Generic Pull System 36 Target MCE ? Table of Manufacturing Cycle Efficiency Benchmarks based on process application Application Low E nd M CE High End M CE Mac hi ni ng 1% 25% Fabric ati on 10% 30% As s emb ly (wi th Batch Tran sfer ) 15% 40% As s emb ly (wi tho u t Ba tch Tran sfer ) 20% 50% Improve Generic Pull System 37 目標 MCE ? 制造周轉效率表是基于流程應用的基準 應用 低端 MCE 高端 MCE 加工 1% 25% 裝配 10% 30% 組裝 ( 用批傳輸 ) 15% 40% 組裝 20% 50% ( 不用批傳輸 ) Improve Generic Pull System 38 Theoretical Best MCT Theoretical Best MCT is: ? The “best” or lowest manufacturing cycle time achievable based on the process characteristics. ? It is measured as: ? VA(Critical Path) is the value add time along the critical path. It does not include the value add time of parallel processes. MCETarg et VAMCT pa th) (cri ticalTB ?Improve Generic Pull System 39 理論的最佳 MCT 理論的最佳 MCT 是 : ? 基于過程特性可以達到的“最佳 ” 或最低的制造周期時間 . ? 它可以由下列公式計算 : ? VA(Critical Path) 是沿關鍵路徑的增值時間，它并不包括并行工序的增值時間 MCETarg et VAMCT pa th) (cri ticalTB ?Improve Generic Pull System 40 MCTTB = hrs/.2 = hrs = 1 day Example: Theoretical Best MCT MCETarg et VAMCT pa th) (cri ticalTB ?Improve Generic Pull System 41 MCTTB = hrs/.2 = hrs = 1 day 舉例 : 理論的最佳 MCT MCETarg et VAMCT pa th) (cri ticalTB ?Improve Generic Pull System 42 WIP Cap ? The WIP cap determines the maximum WIP allowed within the process at any time. ? It is measured as: R ateExit MC TC ap W IP TB ??Improve Generic Pull System 43 WIP Cap ? WIP cap 決定在任意時間內過程允許的最大 WIP. ? 它可以由下列公式計算 : R ateExit MC TC ap W IP TB ??Improve Generic Pull System 44 WIP Cap = 1 day x 20 units/day = 20 units Example: WIP Cap R ateExit MC TC ap W IP TB ??Improve Generic Pull System 45 WIP Cap = 1 day x 20 units/day = 20 units 舉例 : WIP Cap R ateExit MC TC ap W IP TB ??Improve Generic Pull System 46 Example: Summary Current State: Desired State: MCT =5 days WIP =100 units Exits =20 units/day Value Add time = hrs MCE =% MCT =1 day WIP =20 units Exits =20 units/day Value Add time = hrs MCE =20% Improve Generic Pull System 47 舉例 : 摘要 目前的狀況 : 期望的狀況 : MCT =5 days WIP =100 units Exits =20 units/day 增值時間 = hrs MCE =% MCT =1 day WIP =20 units Exits =20 units/day 增值時間 = hrs MCE =20% Improve Generic Pull System 48 T i m eVa l u e A d dEx i ts WIP PC T PC EC u rre n t M o n t h 0 1 . 5 h rs 2 0 / d a y 100 5 4 . 5 %St e p 1 M o n t h 1 1 . 5 h rs 2 0 / d a y 80 4 6 . 0 %St e p 2 M o n t h 2 1 . 5 h rs 2 0 / d a y 60 3 8 . 8 %St e p 3 M o n t h 3 1 . 5 h rs 2 0 / d a y 40 2 1 6 . 7 %St e p 4 M o n t h 4 1 . 5 h rs 2 0 / d a y 20 1 2 0 . 0 %W I P R e d u c ti o n Pl a n Ex a m p l eAchieving WIP Cap ? Typically the current WIP level will be significantly greater than the WIP Cap level. Therefore, a plan must be developed to reduce the WIP. Improve Generic Pull System 49 時間 增值 Exits WIP PCT PCE Current Month 0 hrs 20/day 100 5 % 步驟 1 Month 1 hrs 20/day 80 4 % 步驟 2 Month 2 hrs 20/day 60 3 % 步驟 3 Month 3 hrs 20/day 40 2 % 步驟 4 Month 4 hrs 20/day 20 1 % WIP 降低計劃 達到 WIP Cap ? 目前的 WIP水平明顯高于 WIP Cap 的水平 . 因此，必須制定計劃減少 WIP. Improve Generic Pull System 50 How to Release WIP into a Generic Pull System ? Release logic for Generic Pull Systems Actual WIP = WIP Cap Do not release any more work into this process flow. Actual WIP WIP Cap More work should be released into the process (given that demand 0). The amount of work released should make Actual WIP approximately equal to WIP cap. Action Required WIP Status Improve Generic Pull System 51 如何將 WIP發(fā)放到普通拉系統中 ? 普通拉系統的發(fā)放邏輯 實際 WIP = WIP Cap 不發(fā)放任何的工單到流程中 . 實際 WIP WIP Cap 應該發(fā)放更多的工單到流程中去 ( 給定的需求 0). 發(fā)放的工單將讓實際的 WIP和 WIP cap大致相等。 需要采取的行動 WIP 狀況 Improve Generic Pull System 52 Generic Pull Exercise: Part A ? Given the following Information: ? Average Demand is 10 units/day ? Current MCT is 20 days ? Value Add Time = 8 hours ? Fabrication Shop ? 1 shift operation that works 5 days per week ? Answer the following questions: ? What should my WIP cap (in units) be? ? How much inventory should I drain from the operation? Improve Generic Pull System 53 普通拉系統的練習 : 零件 A ? 已知下列信息 : ? 平均的需求是 10 單位 /天 ? 目前的 MCT 是 20 天 ? 增值時間 = 8 小時 ? 裝配車間 ? 每周工作 5天，一班運作 ? 回答下列問題 : ? 我的 WIP cap (單位 ) 將會是什么 ? ? 應該從工序中減少多少庫存？ Improve Generic Pull System 54 Generic Pull Exercise: Part B ? Using the calculated WIP cap from Part A answer the following questions: ? Current WIP level is 105 units and my MRP system wants me to release a quantity of 5 units into the line what should I do? Why? ? Current WIP level is 95 units and my MRP system wants me to release a quantity of 5 units into the line what should I do? Why? ? Current WIP level is 98 units and my MRP system wants me to release a quantity of 5 units into the line what shoul