【文章內(nèi)容簡介】 L 850 R 1200 L 640 R 2700 L 1440 R Ferrous Metals Co. 500 ft coils Tues Thurs Machine 1 OCT= 39 sec D/R = 39 sec C/O = 10 min REJ = 4% U/T= 100% 2 Shifts 27, 600 sec Avail. MCT = 1 second C/O = 1 hour REJ = 3% U/T = 85% 27,600 sec. avail. EPE = 2 weeks Stamp 200 t Weld 1 OCT = 46 sec D/R = 46 sec C/O = 10 min REJ = 5% U/T = 80% 2 Shifts 27,600 sec. Avail. 1x daily SubAssembly 1 Assembly 1 MRP 18,400 pcs/mo 12,000 “L” 6,400 “R” Tray = 20 pcs 2 Shifts Highland Manufacturing Sheet Metal Housings Current State (Date) Daily Ship Schedule Weekly Schedule TT = 60 sec. Manchester Avenue 6week Forecast Weekly fax Production Control 90/60/30 day Forecasts Daily Order 5 days days days days 2 days days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec. Lead Time= days Process Time= 188 sec Where else can onepiece flow be implemented? 還有別的地方可執(zhí)行一件嗎？ By establishing onepiece flow here, what goes away? 這里用一件流，什么會消失？ VRK 0s 39s 46s 62s 40s Takt time 60 seconds Stamp Machine Weld Subassy Assy (autofeed) Where else can onepiece flow be implemented? The assembly processes? 還有別的地方可執(zhí)行一件 流 嗎？是組 裝制程 嗎？ Yes! 正是 I Coils 5 days I 4600 L 2400 R I 1100 L 600 R OCT = 62 sec D/R = 62 sec C/O = 0 REJ = 6% U/T =100% 2 Shifts 27, 600 sec. Avail. OCT = 40 sec D/R = 40 sec C/O = 0 REJ = 7% U/T = 100% 2 Shifts 27,600 sec. Avail. Shipping Staging I I I 1600 L 850 R 1200 L 640 R 2700 L 1440 R Ferrous Metals Co. 500 ft coils Tues Thurs Machine 1 OCT= 39 sec D/R = 39 sec C/O = 10 min REJ = 4% U/T= 100% 2 Shifts 27, 600 sec Avail. MCT = 1 second C/O = 1 hour REJ = 3% U/T = 85% 27,600 sec. avail. EPE = 2 weeks Stamp 200 t Weld 1 OCT = 46 sec D/R = 46 sec C/O = 10 min REJ = 5% U/T = 80% 2 Shifts 27,600 sec. Avail. 1x daily SubAssembly 1 Assembly 1 MRP 18,400 pcs/mo 12,000 “L” 6,400 “R” Tray = 20 pcs 2 Shifts Highland Manufacturing Sheet Metal Housings Current State (Date) Daily Ship Schedule Weekly Schedule TT = 60 sec. Manchester Avenue 6week Forecast Weekly fax Production Control 90/60/30 day Forecasts Daily Order 5 days days days days 2 days days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec. Lead Time= days Process Time= 188 sec Where else can onepiece flow be implemented? The assembly processes? 還有別的地方可執(zhí)行一件 流 嗎？是組 裝制程 嗎？ By establishing onepiece flow here, what goes away? 這里用一件流，什么會消失？ VRK 187 seconds work = operators 60 seconds TAKT = 4 operators = 3 operators (target) Where else can onepiece flow be implemented? Let’s look at OCT to evaluate: 還有別的地方可執(zhí)行一件流嗎？看看操作員周期時間？ 5 days days days days 2 days days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec. MCT OCT OCT OCT OCT What is the total human work content to machine, weld and assemble one housing? 完成一件的總?cè)斯r間是多久？ 39 + 46 + 62 + 40 = 187 seconds But customer needs a housing every 60 seconds 但是顧客每 60秒需要一件 More important to assign 4th operator to other meaningful work 第四位操作員做其它有意義的工作比較重要 Takt time 60 seconds Machine Weld Weld 60 secs. 60 secs. 54 secs. 58 x 3 = 174 seconds Highland Operator Loading Chart FutureState未來狀態(tài)的操作員負(fù)荷表 I Coils 5 days I 4600 L 2400 R I 1100 L 600 R OCT = 62 sec D/R = 62 sec C/O = 0 REJ = 6% U/T =100% 2 Shifts 27, 600 sec. Avail. OCT = 40 sec D/R = 40 sec C/O = 0 REJ = 7% U/T = 100% 2 Shifts 27,600 sec. Avail. Shipping Staging I I I 1600 L 850 R 1200 L 640 R 2700 L 1440 R Ferrous Metals Co. 500 ft coils Tues Thurs Machine 1 OCT= 39 sec D/R = 39 sec C/O = 10 min REJ = 4% U/T= 100% 2 Shifts 27, 600 sec Avail. MCT = 1 second C/O = 1 hour REJ = 3% U/T = 85% 27,600 sec. avail. EPE = 2 weeks Stamp 200 t Weld 1 OCT = 46 sec D/R = 46 sec C/O = 10 min REJ = 5% U/T = 80% 2 Shifts 27,600 sec. Avail. 1x daily SubAssembly 1 Assembly 1 MRP 18,400 pcs/mo 12,000 “L” 6,400 “R” Tray = 20 pcs 2 Shifts Highland Manufacturing Sheet Metal Housings Current State (Date) Daily Ship Schedule Weekly Schedule TT = 60 sec. Manchester Avenue 6week Forecast Weekly fax Production Control 90/60/30 day Forecasts Daily Order 5 days days days days 2 days days 1 sec. 39 sec. 46 sec. 62 sec. 40 sec. Lead Time= days Process Time= 188 sec Where else can onepiece flow be implemented now that we have looked at OCT? 看過操作員周期時間后，還有別的地方可執(zhí)行一件流嗎？ By establishing onepiece flow here, what goes away? 這