【文章內(nèi)容簡介】 有價(jià)值工時(shí) 無價(jià)值工時(shí)Ratio1,728,000sec Non Value Add117sec Value Add=14769TT=117secKT=20*24*3600=1728000世界標(biāo)準(zhǔn)： TT:KT=1： 50 —— ？數(shù)據(jù)計(jì)算 —— 前置時(shí)間Effective Cycle Time Vs Takt TimeStamping Drill Grind AssembleTakt Time: sec 23 sec 23 sec 23 secC/T: 3sec 36 sec 20 sec 21 secX 2 machines= 46 sec.當(dāng) CT小于 T T時(shí)表示工序能力滿足有效 CT = 總 CT時(shí)間可動(dòng)率 有效率 X數(shù)據(jù)計(jì)算 —— 產(chǎn)能分析Effective Cycle Time Vs Takt TimeStamping Drill Grind AssembleTakt Time: sec 23 sec 23 sec 23 secEffective C/T: 3sec 36 sec 20 sec 21 sec (.7)() (.85)() (.75)() (.9)() = sec = sec = sec = secX 2 machines= 46 sec.數(shù)據(jù)計(jì)算 —— 產(chǎn)能分析當(dāng) T T小于 有效 CT時(shí)表示工序能力不足價(jià)值流圖示步驟現(xiàn)狀價(jià)值流圖價(jià)值流圖循環(huán)未來價(jià)值流圖實(shí)施計(jì)劃消除浪費(fèi)在當(dāng)前價(jià)值流圖中確定改善關(guān)鍵點(diǎn)分析、改善現(xiàn)狀存在的浪費(fèi)以理想的產(chǎn)品流為原則設(shè)計(jì)未來價(jià)值流圖繪制未來價(jià)值流圖1:什么是客戶需求的 價(jià)值和要求的前置時(shí)間 需求DemandProcessesEliminate消除Combine合并Reposition重排Simplify簡化45,000 pcs/mo.30,000 “L”15,000 “R”Container= 50 pcs2 shiftsShipStagingDrill, Grind AssembleStamping300 T press3 shiftsEPE = 1 dayCustomerSupplierTakt = secC/T= 3 sec.. = 80%FTQ = % C/O = 20 min, 1X/shift Scrap = %Rework = none operators = 1/shift. = 3 secShared:part 123,ABC250 ft coilsTakt =23 secC/T= 20 sec.. = 90%FTQ = 99% C/O =10min Scrap = %Rework = % operators = 3/shift. = 114 secDedicated: L,RGeneral Information 20 days/month hours avail./shift 2 shifts/day36” 20” 19” 20” 19”7’ 10’ 0’ 4’ 4’Drill Grind 30OPC/TC/02023繪制未來價(jià)值流圖4:哪里是可以實(shí)現(xiàn)持續(xù)流動(dòng)的Material Flow4:哪里是可以實(shí)現(xiàn)持續(xù)流動(dòng)的孤島生產(chǎn)流動(dòng)生產(chǎn)超市拉動(dòng)系統(tǒng)供應(yīng)過程A顧客過程B超市產(chǎn)品 產(chǎn)品生產(chǎn)看板 取貨看板45,000 pcs/mo.30,000 “L”15,000 “R”Container= 50 pcs2 shiftsShipStagingDrill, Grind AssembleStamping300 T press3 shiftsEPE = 1 dayCustomerSupplierTakt = secC/T= 3 sec.. = 80%FTQ = % C/O = 20 min 1X/shift Scrap = %Rework = none operators = 1/shift. = 3 secShared:part 123,ABC250 ft coilsTakt =23 secC/T= 20 sec.. = 90%FTQ = 99% C/O =10min Scrap = %Rework = % operators = 3/shift. = 114 secDedicated: L,RGeneral Information 20 days/month hours avail./shift 2 shifts/day36” 20” 19” 20” 19”7’ 10’ 0’ 4’ 4’Drill Grind 30OPC/TC/0202350LR50coil Batch ProductionControlMRP SystemCoils(at the press) Daily Milk Run 2 xdaily繪制未來價(jià)值流圖 (定拍工序 )下達(dá)計(jì)劃 (混線 )生產(chǎn)Information Flow (定拍工序 )下達(dá)計(jì)劃工序 1 工序 2 工序 3 工序 4超市定拍工序工序 1 工序 2 工序 3 工序 4定拍工序超市選擇定拍工序定拍取貨的例子定拍工序看板放到工序中 (混線 )生產(chǎn) —A裝配 (混線 )生產(chǎn) —B裝配定調(diào)量 =節(jié)拍時(shí)間 *最小送貨批量4 days 8 days 3 days 2 days 3 days TPc/t = 20 d. = 117 s3 sec, 36 sec. 20 sec. 58 sec.第四步：確定改善關(guān)鍵點(diǎn)GrindAssembleDrillStamping300 T press3 shiftsEPE = 2 daysTakt = secC/T= 3 sec.. = 70%FTQ = 98% C/O = 4 hrs, 1X/wk Scrap = 2%Rework = none operators = 1/shift. = 3 secShared:part 123,ABCTakt = secC/T= 21 sec.. = 90%FTQ = 95% C/O =16min,1X/day Scrap = noneRework = 5% operators = 2/shift. = 58 secDedicated: L,RGeneral Information 20 days/month hours avail./shift 2 shifts/day2 machinesC/T=36sec 19” 20” 19”10’ 8’ 8’10 20 30OPC/TC/012023 L 4000 RI4500 L1500 RI3000 L1000 RIShipStaging4500 L1500 RI50/Cont.Takt = secC/T= 18 sec.. = 85%FTQ = %C/O = 40 min,1X/wk Tool C/O= 30’/day Scrap = %Rework = none operators = 1/shift. = 36 secDedicated: L,RTakt = secC/T= 20 sec.. = 75%FTQ = 98%C/O = 60 min, 1X/wk ToolC/O = 2hrs, 1X/wkScrap = 2%Rework = none operators = 1/shift. = 20 secDedicated: L,RChangeoverGrindUptimeDrillChangeoverGrindChangeover45,000 pcs/mo.30,000 “L”15,000 “R”Container= 50 pcs2 shiftsShipStagingDrill, Grind AssembleStamping300 T press3 shiftsEPE = 1 dayCustomerSupplierTakt = secC/T= 3 sec.. = 80%FTQ = % C/O = 20 min, 1X/day Scrap = %Rework = none operators = 1/shift. = 3 secShared:part 123,ABC250 ft coilsTakt =23 secC/T= 20 sec.. = 90%FTQ = 99% C/O =10min Scrap = %Rework = % operators = 3/shift. = 114 secDedicated: L,RGeneral Information 20 days/month hours avail./shift 2 shifts/day36” 20” 19” 20” 19”7’ 10’ 0’ 4’ 4’Drill Grind 30OPC/TC/0202350LRtotecoilBatch ProductionControl8 weekForecastDailyFax30/60/90 dayForecastDailyOrderMRP System5050 Daily Milk RunCoils(at the press) 2 xdailyChangeoverGrindUptimeDate:1 day 1 day 1 day TPc/t = 3 d. = 117 s3 sec. 114 sec.DrillChangeoverGrindChangeover第五步：繪制未來價(jià)值流圖價(jià)值流圖示步驟現(xiàn)狀價(jià)值流圖價(jià)值流圖循環(huán)未來價(jià)值流圖實(shí)施計(jì)劃消除浪費(fèi)將未來價(jià)值流圖劃分成幾個(gè)部分或環(huán)為每個(gè)環(huán)制定有效的目標(biāo)指定專人負(fù)責(zé)每個(gè)目標(biāo)的達(dá)成為目標(biāo)的達(dá)成制定具體的時(shí)間表45,000 pcs/mo.30,000 “L”