【文章內(nèi)容簡介】 ] + .5 * [Max ( , ) * ]/2 ? = . ?但是 我們要取一個近似標(biāo)準(zhǔn)包的數(shù)量，所以 : ? 箱數(shù)量 = = . 27 2Bin Replenishment Pull Improve Exercise 2: 2Bin Replenishment ? Calculate the Bin Quantity for the following assembly item in a 2Bin LineSide Replenishment process linked to the warehouse : ? Part Number: A44B2 ? Description: 4 Dia. Steel Extrusion ? Demand/Usage: 225 ft/day ? Lead Time: 1 day (trigger warehouse replenishment) ? Order Frequency: N/A ? Extrusion Length: 30 ft ? Bin Quantity ? = [Max ( , ) * ] + .5 * [Max( , ) * ]/2 ? = . ? But we have to round up to the nearest standard pack, so: ? Bin Quantity = = . 28 2Bin Replenishment Pull Improve 練習(xí) 2: 2箱補充 ?如下組裝線 2箱線旁補充流程直接連接著供應(yīng)商，計算箱數(shù)量 : ? 零件號碼 : A44B2 ? 描述 : 直徑 4“ 的鋼鐵拉絲 ? 需求 /用量 : 225 英尺 /天 ? 交貨時間 : 1 天 ( 觸發(fā) – 倉庫 – 補充 ) ? 訂單頻率 : 不適用 ? 拉絲長度 : 30 英尺 ?箱數(shù)量 ? = [Max ( , ) * ] + .5 * [Max( , ) * ]/2 ? = . ?但是 我們要取一個近似標(biāo)準(zhǔn)包的數(shù)量，所以 : ? 箱數(shù)量 = = . 29 2Bin Replenishment Pull Improve 1 2Bin Replenishment Bin Labeling and Information ? Each Bin/Storage Location should have a barcode label or tag. ? Make sure not to use a permanent label applied to a rack/bin, because you will eventually want to resize and may have to make new labels! ? Labels for Line Side Bins/Tags for Resupply Bins ? Part Number, Description, and Location are Printed. ? Bin Quantity should not be printed (requires too many label changes when resizing – trigger mechanism or system will have Bin Quantity) ? Each Bin Location should be unique to avoid confusion when restocking. ? Examples are in the Appendix. Location Part Number Description 2 Location Part Number Description 30 2Bin Replenishment Pull Improve 1 2箱補充 箱標(biāo)貼和信息 ? 每個箱 /庫存 地點都應(yīng)該有一個條碼標(biāo)貼或標(biāo)簽 ? 確保不要用永久的標(biāo)簽貼在一個貨架 /箱。因為你將會調(diào)整大小，且貼上一個新的標(biāo)貼！ ? 在線旁的需要重新補充的箱上的標(biāo)貼 ? 被打印的零件號碼 , 描述 , 地點等 ? 箱數(shù)量不應(yīng)該被打印出來 ( 當(dāng)調(diào)整大小時需要太多的標(biāo)簽變化 – 觸發(fā)機(jī)制或系統(tǒng)將有箱數(shù)量 ) ? 每個箱地點必須是獨一無二的以避免在重新補充庫存時混淆 ? 舉例在附件里 . 地點 零件號碼 描述 2 地點 零件號碼 描述 31 2Bin Replenishment Pull Improve Notes on a 1Bin System ? A one bin system is an exception to the 2bin for very slow moving parts/supplies. ? 1bin parts are not stored in 2bins because of: ? High inventory cost ? Space requirements ? Racking/storage cost ? 1bins are replenished upon stock out at the LineSide location. ? Stock out impact should be low because: ? Parts/supplies are very low users. ? Parts/supplies are also at point of use when LineSide stock out occurs. ? Parts/supplies are stocked in nearby stock/supply room – easy to replace. 32 2Bin Replenishment Pull Improve 1箱系統(tǒng)的注意 ? 對于流動非常緩慢的零件 /供應(yīng)品來說，一個 1箱系統(tǒng)是 2箱系統(tǒng)的例外 . ? 1箱零件不象 2箱那樣被存儲，因為 : ?高庫存成本 ?空間需要 ?貨架 /倉儲成本 ? 在線旁的地點庫存短少時， 1箱被補充。 ? 庫存短少的影響應(yīng)該是微弱的，因為 : ?零件 /供應(yīng)品是非常少的使用者。 ?當(dāng)線旁的存貨短缺發(fā)生時，零件 /供應(yīng)品也同樣在使用點 . ?零件 /供應(yīng)品被存放在庫房附近 —容易補充 . 33 2Bin Replenishment Pull Improve Stock Room or Vendor 1 1 Full Bin/Card Move 1 to 2 when 2 is pulled, Send Trigger Use Components Empty Bin/Card PointOfUse (POU) Locations or WorkInProcess (WIP) 1Bin Replenishment (Typically from “LineSide”) ? Reduces part/supply shortages increasing productivity ? Facilitates WIP reduction ? Will result in significant productivity improvements in stock/supply room ? Reduces/eliminates stockroom impact on lot sizes ? May simplify inventory/cycle count processes LineSide Storage LT OF 1 SS/2D MDOF),LTmax(Quant ity Bin ???34 2Bin Replenishment Pull Improve 庫房或 供應(yīng)商 1 1 1箱補充 (特別是從 “線旁 ”) LT OF 1 添滿的 箱 /卡 空的 箱 /卡 當(dāng) 2 被拉動時，移動 1 到 2 ， 發(fā)送觸發(fā)信號 使用點位置 (POU) 或工作庫存 (WIP) ? 減少零件 /供應(yīng)品庫存，增加生產(chǎn)效率 ? 促進(jìn) WIP的降低 ? 將導(dǎo)致在庫房里的顯著的生產(chǎn)力提高 ? 降低 /消除庫房在批數(shù)量上的影響 ? 可以簡單化存貨 /周轉(zhuǎn)的計算流程 線旁庫存 SS/2 OF) , LT max( 箱數(shù)量 ? ? ? 使用的 部件 DMD 35 2Bin Replenishment Pull Improve Stockroom or Vendor 1 Line POU 1Bin Replenishment Transactions ? 1Bin System inventory transactions mirror those of the 2Bin system ? Frontflush for reducing transactions but reduce overall inventory accuracy ? Backflush for increasing inventory accuracy (slightly) but increase number of system transactions 1 1bin Card Part XYZ Trigger Replenishment 1bin Card Part XYZ 36 2Bin Replenishment Pull Improve 庫房或 供應(yīng)商 1 線 POU 1箱補充事務(wù)處理 ? 1箱系統(tǒng)庫存交接與 2箱系統(tǒng)相似 ? 前端堆積 減少交接過程但降低總體庫存量的準(zhǔn)確性 ? 后端堆積 增加了庫存準(zhǔn)確性（幅度輕微）但增加了系統(tǒng)處理的事務(wù)量 1 1箱卡零件 XYZ 觸發(fā) 補充 1箱卡零件 XYZ 37 2Bin Replenishment Pull Improve Takeaways ? Know the the various types of Bin Replenishment systems ? Be able to describe the benefits of a Bin system ? How to size (calculate) all the parameters for a Bin system 38 2Bin Replenishment Pull Improve 總結(jié) ? 知道箱補充系統(tǒng)的不同類型 ? 能夠描述一個箱系統(tǒng)的利益 ? 能夠去計算一個箱系統(tǒng)的所有參數(shù) 39 2Bin Replenishment Pull Measure Analyze Control Improve Lean Six Sigma APPENDIX 2Bin Replenishment Pull Measure Analyze Control Improve Lean Six Sigma 附錄 2箱補充拉系統(tǒng) Improve Instructions for Typical Card Triggered 2Bin Replenishment This process uses green and red cards to trigger replenishment。 ―bins‖ are actually the box/container the part/supply is shipped in. 1. Employee removes a bin and drops its green 2bin card into the mailbox: ? Pull parts from ―bin‖ with green card before using any with the red card. 2. At same time(s) each day, the cards are picked up from the mailbox and returned to the stock/supply room. 3. The stock/supply room pulls proper amount of parts/material (noted on card, set equal to the calculated ―bin‖ q