【正文】 A = 75SSA = ____ 件 (安全庫存計算式 )____ 件 / 15件 / 天 = ___ 天 SSADUB = 10 標準差 B = 75SSB = ____ 件 (安全庫存計算式 )____件 / 10件 / 天 = ___ 天 SSADUC = 5 標準差 C = 75SSC = ____ 件 (安全庫存計算式 )____件 / 5件 / 天 = ___ 天 SS一般的方法是對所有的產(chǎn)品項目盡量保持同樣的庫存 . 這種方法可能對某些產(chǎn)品來說庫存太多，而對另外的產(chǎn)品又不夠。 需求變化圖67Replenishment Pull SystemsImproveBasic Pull Formulas forPurchased PartsBOHPurchased Orders(SumPO)SLTMax Loop* = (LT * Dmd) + (OF * Dmd) + SSMin Kanban/Trigger Point = (LT * Dmd) + SSOrder If: (BOH* + SumPO) = Trigger PointOrder Qty = Max Kanban – (BOH* + SumPO)OFSSLTPurchasedParts AvgBOH* Balance OnHand (BOH) Max Loop = Max KanbanMaxMin68Replenishment Pull SystemsImprove采購零件拉系統(tǒng)的基本公式現(xiàn)存余額現(xiàn)存余額BOH采購定單SLTMax Loop* （ 拉系統(tǒng)環(huán)里的最大庫存） = (LT * Dmd) + (OF * Dmd) + SSMin Kanban/Trigger Point 拉系統(tǒng)環(huán)里的最小庫存 /觸發(fā)點 = (LT * Dmd) + SS如果 : (BOH* + SumPO) = Trigger Point 觸發(fā)點時就訂貨訂單數(shù)量 = Max Kanban – (BOH* + SumPO)OFSSLT采購的零件AvgBOH* Balance OnHand (BOH) 策略緩沖中的庫存數(shù)量 Max Loop = Max Kanban MaxMin69Replenishment Pull SystemsImproveExample 1:Purchase Pull System Purchase Part Number “11111” has the following data:OF = 10 daysLT = 20 daysSafety Stock = 50 partsDemand = parts / dayDetermine the Max Loop (Kmax)Max Loop = (OF x Demand)+(LT x Demand)+SS = (____ x ______)+(___ x ______)+(__) = ________Determine the Min Kanban / Trigger Point (Kmin)Min Kanban = (LT x Demand)+SS = (___ x ______)+(__) = ________BONUS QUESTION: If the BOH = 50 parts and the SumPO’s = 50 parts, should we replenish and if so how much? 70Replenishment Pull SystemsImprove舉例 1:采購拉系統(tǒng) 采購件 “11111” 已知以下數(shù)據(jù) :OF = 10 天LT = 20 天安全庫存 = 50 天需求 = 件 / 天決定最大看板數(shù)量 (Kmax)Max Loop = (OF x 需求 )+(LT x 需求 )+SS = (____ x ______)+(___ x ______)+(__) = ________決定最小看板數(shù)量 / 觸發(fā)點 (Kmin)Min Kanban = (LT x 需求 )+SS = (___ x ______)+(__) = ________有獎問答 : 如果 BOH = 50 件， SumPO’s = 50 件 , 我們要補充嗎？如果要，補充多少？ 71Replenishment Pull SystemsImprove舉例 1:采購拉系統(tǒng) （答案）采購件 “11111” 已知以下數(shù)據(jù) :OF = 10 天LT = 20 天安全庫存 = 50 天需求 = 件 / 天決定最大看板數(shù)量 (Kmax)Max Loop = (OF x 需求 )+(LT x 需求 )+SS = (_10_ x __2__)+(_20__ x __2___)+(50*2) = ___160_____決定最小看板數(shù)量 / 觸發(fā)點 (Kmin)Min Kanban = (LT x 需求 )+SS = (_20_ x ___2__)+(50*2) = ___140____有獎問答 : 如果 BOH = 50 件， SumPO’s = 50 件 , 我們要補充嗎？ 50+50140,需要補充 1605050=60，72Replenishment Pull SystemsImproveUsing the data on the previous slide, calculate the following:What is the Highest Buffer Inventory? ______What is the Lowest Buffer Inventory? ______SS QuantityLT Quantity__________________Trigger PointBuffer Max LoopOF QuantityExample 1:Purchase Pull System (Cont.)73Replenishment Pull SystemsImprove用前面的數(shù)據(jù)，計算下列：最高的緩沖庫存是多少 ? ______最低的緩沖庫存是多少 ? ______SS 數(shù)量LT 數(shù)量__________________觸發(fā)點緩沖 Max LoopOF 數(shù)量舉例 1:采購拉系統(tǒng)74Replenishment Pull SystemsImproveuDemand = 7 parts / dayuSafety Stock (SS) = 10 partsuVendor Lead Time (LT) = 10 daysuOrder Frequency (OF) = 5 daysExample 2:Purchase Pull System SS QuantityLT Quantity__________________Trigger PointBuffer Max LoopOF QuantityUsing the data to the left, calculate the following: uWhat is the vendor lead time quantity = ________ ?uWhat is the trigger point = _________?uWhat is the typical order quantity = ________ ?uWhat is the typical (avg) BOH (buffer inventory) = _________?75Replenishment Pull SystemsImproveu需求 = 7 件 / 天u安全庫存 (SS) = 10 件u供應商交貨期 (LT) = 10 天u訂單頻率 (OF) = 5 天舉例 2:采購拉系統(tǒng) SS 數(shù)量LT 數(shù)量__________________觸發(fā)點緩沖 Max LoopOF 數(shù)量用左邊的數(shù)值計算下列： u供應商的交貨期數(shù)量是多少 = ________ ?u觸發(fā)點是多少 = _________?u典型的訂貨數(shù)量是多少 = ________ ?u典型的 (平均 ) BOH (緩沖庫存 )是多少 = _________?76Replenishment Pull SystemsImproveu需求 = 7 件 / 天u安全庫存 (SS) = 10 件u供應商交貨期 (LT) = 10 天u訂單頻率 (OF) = 5 天舉例 2:采購拉系統(tǒng) SS 數(shù)量LT 數(shù)量__________________觸發(fā)點緩沖 Max LoopOF 數(shù)量用左邊的數(shù)值計算下列： u供應商的交貨期數(shù)量是多少 = __7*10______ ?u觸發(fā)點是多少 = ___7*10+10______?u典型的訂貨數(shù)量是多少 = __5*7______ ?u典型的 (平均 ) BOH (緩沖庫存 )是多少 = 7*10+10?77Replenishment Pull SystemsMeasureAnalyzeControlImproveLean Six SigmaPull Systemsu Pull System Platformsu Manual vs. Electronicu Pull Systems: Handling Seasonalityu Performance MeasuresMeasureAnalyzeControlImproveLean Six Sigma拉系統(tǒng)u 拉系統(tǒng)平臺u 人工 VS 電子u 拉系統(tǒng) : 處理季節(jié)性u 績效量測ImprovePull System Platformsu Visual Card Systemsu Electronic Systemsu 2Bin/Asynchronousu Synchronous80Replenishment Pull SystemsImprove拉系統(tǒng)平臺u 目視卡系統(tǒng)u 電子系統(tǒng)u 2Bin/不同步的u 同步的81Replenishment Pull SystemsImprove目視卡系統(tǒng)該方法使用卡片流經(jīng)整個制造過程，并返回到拉系統(tǒng)板上通過目光就可以看到零件的情況82Replenishment Pull SystemsImproveReplenishment PullDemandCalculationParts ClassificationABC ClassificationSafety StockCalculationsOrder FrequencySystem Platform PC Based ModulesElectronicThis approach uses electronic system (typically integrated with MRP) to resize part quantities and to generate replenishment signals without the use of cards.83Replenishment Pull SystemsImprove補充拉系統(tǒng)需求計算零件分類ABC 分類安全庫存計算 訂單的頻率問題解答績效監(jiān)督系統(tǒng)平臺 基于模塊化的 PC電子的該方法使用電子系統(tǒng) (一般都與 MRP集成 ) 來調(diào)整零件庫存的大小規(guī)模，產(chǎn)生補充信號，而不需要用卡片84Replenishment Pull SystemsImprovePrimary Storage12Line Side12Bin/Asynchronousu Empty bin returns to primary storageu Bin is filledu Full bin returns to line85Replenishment Pull SystemsImprove初始的庫存12生產(chǎn)線側(cè)12Bin/異步的u 空箱回到初始庫存處u 箱子被填滿u 填滿的箱子回到生產(chǎn)線上86Replenishment Pull SystemsImproveAssemblyA2 daysAssemblyB2 daysAssemblyC2 daysAssemblyD2 daysSub Ass