【文章內(nèi)容簡介】 再定貨POSITION 工位 :REORDER POINT 定貨點 :53420Part 11023Qty.= 50(Card)3.12 345 67 89 1011 12(Dolly)小車1 2 3(貨盤 t)裝配順序部分物流供給呼叫按鈕Part Number SMART No Market Address Line Side AddressF7C65422401AG 000122 DTLA02 E26N010F8C65426075AA 005126 DTLA03 E27S020F7C65467934AB 003412 DTLA01 E26N030需求看板燈需求超市需求零件需求零件Market Address SMART Number Line Side AddressPart NumberPart DescriptionRoute NumberDock NumberSerial NumberQuantityDTLA01 001423F7C65467934ABBlack Clip500A1C27N10LCL00007智能卡線旁的 “郵箱 ”AAA A A AA A AA A ABB C CBBB B BB B BD D DD D DC C CC C CD D標(biāo)牌市場標(biāo)牌零件每個零件都應(yīng)仔細(xì)規(guī)劃— 每個零件都應(yīng)有正確的包裝和運貨方式 什么是均衡生產(chǎn) ?傳統(tǒng)生產(chǎn)過程 (未經(jīng)均衡 )換模周一產(chǎn)量周二產(chǎn)量周三產(chǎn)量周四產(chǎn)量周五產(chǎn)量換?；旌仙a(chǎn) (均衡 )周一產(chǎn)量周二產(chǎn)量周三產(chǎn)量周四產(chǎn)量周五產(chǎn)量Heijunka 均衡生產(chǎn) : 價值流程的領(lǐng)跑者在領(lǐng)跑過程中釋放的工作增量是什么？1 周1 天1 班次1 小時1 動均衡生產(chǎn) =每次小批量的投入，同時取走相當(dāng)量的成品為什么要均衡生產(chǎn)？? 使上道工序的需求變得平滑? 拉動系統(tǒng)的基礎(chǔ)? 庫存最小? 最優(yōu)化資源利用? 創(chuàng)建最大的彈性來應(yīng)對變化的需求vOnePiece Flow 一件流vEfficient Space Utilization 充分利用場地vExcellent Visual Management 優(yōu)良的視覺管理Lean Manufacturing Cell 精益生產(chǎn)單元Benefits of UShaped Cell U形單元之優(yōu)點vEqual Productivity at any Volume 所有產(chǎn)量的效率均等vEfficient Material Handling 高效的材料搬運vExcellent Communication 優(yōu)良的溝通Raw MaterialFinished PartsA. Quality 質(zhì)量 :Work is passed directly to next Process with no defects 合格工件直接轉(zhuǎn)入下道工序 B. Productivity 效率 :Minimize wasted movement, warehouses, and double handling 將倉庫，重復(fù)搬運和無用動作減至最低C. Space 場地：Free up floor space for new products 為新產(chǎn)品騰出生產(chǎn)場地F. Cost 成本 :Reduced Inventory Levels縮減的庫存量Benefits of Creating Flow 一條流的好處D. Lead Time 交付周期 :Shortest supply chain, highest fliexibility to satisfy customer demand 以最短的供應(yīng)渠道，最高的靈活性來滿足客戶的要求 E. Team Member Morale 團(tuán)隊成員的士氣 : Value of work is more visible recognized 。 teamwork 工作的價值更加顯而易見并獲廣泛認(rèn)可；團(tuán)隊精神 Source 來源 : Toyota 豐田Batch Processing Example批量生產(chǎn)例子Product requires three processes that take one minute each生產(chǎn)一臺計算機(jī)需用三道工序，每道工序用時 1分鐘Batch Processing Example批量生產(chǎn)例子Product requires three processes that take one minute each生產(chǎn)一臺計算機(jī)需用三道工序，每道工序用時 1分鐘? Complete processing of first batch of 10 takes 30 minutes 完成 10件一批需時 30分鐘? First good part out takes 21 minutes (plus transport time) 首件合格品需時 21分鐘（不算周轉(zhuǎn)時間）? There are at least 21 parts inprocess 系統(tǒng)內(nèi)至少有 21件在制品Batch Processing Example批量生產(chǎn)例子Product requires three processes that take one minute each生產(chǎn)一臺計算機(jī)需用三道工序，每道工序用時 1分鐘Continuous Flow Processing Example一件流生產(chǎn)工藝? First part out in 3 minutes 三分鐘首件做出? 10 pleted in 12 minutes 做 10件僅需 12分? Only 2 subassemblies in process at a time.任何時間段整個系統(tǒng)內(nèi)只有兩件在制品。Product requires three processes that take one minute each生產(chǎn)一臺計算機(jī)需用三道工序，每道工序用時 1分鐘Takt Time 客戶同步時間The Beat of Production 生產(chǎn)的節(jié)拍Takt time is the time in which a unit must be produced in order to match the rate of customer demand. 客戶同步時間是按客戶要求的速度來生產(chǎn)一件產(chǎn)品所需的時間Takt Time客戶同步時間 =Available Time 可利用時間Unit Demand 要貨量0102030405060A B C DCycle Time 循環(huán)時間T/T 客戶同步時間OPERATORS 操作工TIME時間Value System: Exploitation vs. Better Way to Work 價值流程：苦干與巧干1. Exploitation苦干2. Better Wayto Work巧干We ChooseOption 2我們選擇巧干Value AddedWork 增值工作Staffing Requirements 員工需求Total Op Cycle Time 總循環(huán)時間Takt Time 客戶同步時間= of Operators 員工數(shù)量This assumes 100% efficiency以上公式假設(shè) 100% 效率Need to account for需考慮 :Work Sequence inefficiency 工序間協(xié)調(diào)Sick Time 病假Vacation Time 休假Down Time 停機(jī)Use 85% for planning purposes 用 85%做計劃Construct A Bar Chart 做柱狀圖*Draw in a Red line for the Takt Time 用客戶同步時間畫一條 紅線Set Part in ContainerWalkUnload/Load DrillUnload/Load PressPickup Raw MaterialWalk to Raw MaterialOperator 1 Operator 220401008060120Unload/Load MillDeburr PartUnload/Load LatheWalkWalk*Construct a Bar Chart using the elements of each operator 用每一操作工的操作內(nèi)容畫出柱狀圖*Wasted time bees obvious 浪費的時間便顯而易見Waste浪費 Waste浪費Balance Workload to Takt Time 以客戶同步時間平衡工作負(fù)荷vBalance the operator’s workload to the Takt Time 以客戶同步時間平衡員工的工作負(fù)荷Set Part in ContainerWalkUnload/Load DrillUnload/Load PressPickup Raw MaterialWalk to Raw MaterialOperator 員工 1 Operator 員工 220401008060120Unload/Load MillDeburr PartUnload/Load LatheWalkWalkvEliminate the remaining time through improvements 通過改進(jìn)來去掉多余時間v17 seconds of improvement will yield a 50% cost reduction in labor and 50% productivity improvement 改進(jìn) 17秒將節(jié)省一半勞力并提高工效一倍。Set Part in ContainerWalkUnload/Load DrillUnload/Load PressPickup Raw MaterialWalk to Raw MaterialkanbanTreat ValueAdded Worker as a Surgeon 象對待外科大夫那樣對待做增值工作的工人12334123:.|:.:::|Present Material and ToolsOptimally (and In Sequence) to the Va