【正文】 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day I Coils 5 days VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order 60 batch days 6. How will production be scheduled and withdrawn at the pacemaker to create level volume and mix? 為了帄穩(wěn)化和混合生產(chǎn)，在引導(dǎo)點(diǎn)該如何做生產(chǎn)排程和提?。? 46 trays stage 3 4 20 0X0X 20 1 2 RLLRLL… pitch = 20 min. Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order 60 batch days Where can Highland use one more supermarket in this doortodoor value stream? 逐一檢討什么地方可以再建立一個(gè)超市？ 46 trays stage 0X0X 20 1 2 3 4 20 RLLRLL… pitch = 20 min. Daily days Coil Daily I Coils 5 days Stamp Shipping Housing Cell 1x daily Ferrous Metals Co. 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% 500 ft coils 2 days Takt = 460 min. 460 pcs. = 60 sec Pitch = 60 sec. X 20 pcs. = 20min Highland Manufacturing Housings Future State (Date) Manchester Avenue Daily Ship Schedule 920 pcs/day VRK UT 95% STD WK 38% Prod. Imp SMED 10 min 6week Forecast Weekly fax Production Control MRP 90/60/30 day Forecasts Daily Order 60 batch days 46 trays stage 0X0X 20 1 2 3 4 20 RLLRLL… pitch = 20 min. Daily days Coil Daily We no longer need MRP to control production 不再需要用物料需求 計(jì)劃來管制生產(chǎn) days 1 sec. 174 sec 2 days days Lead Time Process Time = 5 days = 175 sec. Stamp Housing Cell Manchester Avenue 1x daily Shipping Stage Ferrous Metals Co. Production Control 6 week Forecast Daily Order Daily (milk run) Coils days 20 batch 60 COIL 20 20 20 0X0X Daily Ship Schedule 90/60/30 day Forecasts Daily Order days 1 sec. days 174 sec 2 days Lead Time Process Time = 5 days = 175 sec. SMED VRK U/T 95% Highland Future State Map MRP 40 46 Trays days 2 days RLLRLL… pitch = 20 min. 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts 920 pcs/day Takt = 460 min = 60 sec 460 pcs. Pitch = 60 sec x 20 pcs = 20 min 1 2 3 4 OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% . MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% STD WK 38% Prod. Imp Highland Manufacturing Housings Future State (Date) DMP SMED DMP DMP 7. What are the Kaizen events, projects, and DBS Tools that are needed to implement the futurestate? 需要何種改善活動(dòng)、項(xiàng)目和 DBS工具來達(dá)成未來狀態(tài)？ Stamp Housing Cell Manchester Avenue 1x daily Shipping Staging Ferrous Metals Co. Production Control 6 week Forecast Daily Order Daily (milk run) Coils days 20 batch 60 COIL 20 20 20 0X0X Daily Ship Schedule 90/60/30 day Forecasts Daily Order days 1 sec. days 174 sec 2 days Lead Time Process Time = days = 175 sec. SMED VRK U/T 95% Highland Future State Map MRP 40 46 Trays days 2 days RLLRLL… pitch = 20 min. 18,400 pcs/mo 12,000 “L” 6,400 “R”. Tray = 20 pcs 2 shifts 920 pcs/day Takt = 460 min = 60 sec 460 pcs. Pitch = 60 sec x 20 pcs = 20 min 1 2 3 4 OCT = 174 sec. D/R = 58 sec. MCT = 75 sec. C/O = 57 secs. Rej = 1% U/T = 80% MCT = 1 sec. C/O = 1 hour Rej = 1% U/T = 85% STD WK 38% Prod. Imp Highland Manufacturing Housings Future State (Date) DMP SMED DMP DMP Supplier Cycle Stamp Cycle Pacemaker Cycle 8. What is the priority sequence of the Kaizen events and projects? 改善活動(dòng)和項(xiàng)目的優(yōu)先順序如何？ Action 行動(dòng) Team Leader 小組領(lǐng)導(dǎo)員 When 完成日期 DMP event to implement the finished good supermarket. DMP改善活動(dòng) ─ 完成成品超市 Doug 3/14 Housing Cell SMED to allow production to takt time and mix leveling at the housing cell. 外罩群組的快速換模改善活動(dòng) ─ 使外罩群組的生產(chǎn)符合客戶需求時(shí)間并帄穩(wěn)混合生產(chǎn) Sandy 3/21 Spot Welder VRK to determine why the downtime is occurring, and what can be done to eliminate the root causes. 點(diǎn)焊工作的縮減變異量改善活動(dòng) ─ 找出停機(jī)的原因和解決方法，以消除根本原因 Bill 4/10 Standard work event to implement the new housing cell. 標(biāo)準(zhǔn)化工作改善活動(dòng) ─ 完成新的外罩群組 Doug 4/10 DMP event to implement pull at stamping and for the supply of coils. 壓字的 DMP改善活動(dòng) ─ 完成拉引系統(tǒng)，同時(shí)解決鋼料的供應(yīng) Sue 5/1 SMED kaizen event at stamping to reduce the changeover time to less than ten minutes 壓字的快速換模改善活動(dòng) ─ 縮短換模時(shí)間至十分鐘以內(nèi) . Bill 5/1 DMP to implement heijunka at the housing cell. 外罩群組的 DMP改善活動(dòng) ─ 實(shí)現(xiàn)帄準(zhǔn)化生產(chǎn) Sandy 5/15 Mapping Icons 繪圖符號(hào) Value Stream Mapping ASSEMBLY XYZ Corporation Material Icons物料符號(hào) Represents意義 Notes說明 Manufacturing