【正文】 570 60 309,600247。1213Let’s show how we validate this… 讓我們看如何確認(rèn)它。 How can these units be built in a level production mode using this example? 如何建立均衡生產(chǎn)模式？ System 1System 2System 3B AAssumption假設(shè) :1. Available working hours is 15LEAN TO EXCELLENCESince these three products are on the same line, you will need to follow the sequence pattern of 1213 in your production mix. By doing it this way you are able to levelload your production both in terms of quantity and types.因?yàn)槿N產(chǎn)品要在同一個(gè)生產(chǎn)線生產(chǎn)，你需要按 1213的順序安排混合生產(chǎn)計(jì)劃，只有這樣你才能平衡各類型和數(shù)量System 1 System 3System 2 System 1REPEAT重復(fù)Mixed Assembly Line混合生產(chǎn)If produced in batches, only the System 1’s will be built within minutes Takt time 如果按批量生產(chǎn)，只有 1產(chǎn)品能按 。 THEY ARE ALL PRODUCED ON THE SAME LINE. 它們都在同一條生產(chǎn)線生產(chǎn)。167。凍結(jié) 計(jì)劃11LEAN TO EXCELLENCERelationship between Schedule visibility and manufacturing lead time計(jì)劃的可見度和制造期限的關(guān)系Forecast預(yù)測SemiFrozen半凍結(jié)Frozen凍結(jié)Week 12Week 11Week 10Week 9Week 8Week 7Week 6Week 5Week 4Week 3Week 2Week 1Lead time 1/ ? Schedule Visibility and Accuracy交貨時(shí)間 1/ ? 計(jì)劃的可見度和準(zhǔn)確性Lead time increase ? Schedule visibility and accuracy reduced交貨時(shí)間增加 ?計(jì)劃的可見度和準(zhǔn)確性降低Visibility and accuracy reduced可見度和準(zhǔn)確性降低凍結(jié) 計(jì)劃12LEAN TO EXCELLENCE順序 生產(chǎn)指引13LEAN TO EXCELLENCENeed to Determine . . .需要決定How Much 2 systems per dayWhat Kind 15 pcs of System A 5 pcs of System BWhen 5 of G, 2 of R, 5 of G,2 of R, 5 of G, 1 of RTAKT節(jié)拍時(shí)間Level Load Mix均衡化混合Level LoadSequence順序均衡化If we are making Systems. . . 如果我們正在生產(chǎn)產(chǎn)品QuarterlyWeeklyWeekly Frequency頻率Takt Time節(jié)拍時(shí)間 = Available Time可用時(shí)間Demand/Customer Forecast 客戶需求Assumptions假設(shè) :1) Machine Breakdown = 0 hour機(jī)器故障 =0小時(shí)2) Setup Change = 0 hour設(shè)置轉(zhuǎn)換 =0小時(shí)3) Defect Rate = 0%不良率 =0%Quick Example5 – 2 – 5 – 2 – 5 – 1 A BABBA A A A A B BAA A AA BA A A AA ABB A B順序 ：決定生產(chǎn)數(shù)量和節(jié)拍時(shí)間14LEAN TO EXCELLENCE順序：決定生產(chǎn)數(shù)量和節(jié)拍時(shí)間CSetting the production sequence of multiple Types設(shè)置多種類型的生產(chǎn)順序48 units1440 unitsTotal units min12 units360 unitsSystem 3 min12 units360 unitsSystem 2 min24 units720 unitsSystem 1TAKT Time節(jié)拍時(shí)間ShiftRequirement日需求MonthlyRequirement月需求Product產(chǎn)品167。All accounts’ schedule shall be categorized into above group所有的項(xiàng)目計(jì)劃都分成上述 3類。s achievement made Lean a hot topic in management science in the first decade of the 21st century.q 豐田的成就使 “精益 ”成為 21世紀(jì)初期管理學(xué)界的熱門話題q Lean Manufacturing can be defined as: A systematic approach to identifying and eliminating waste (nonvalueadded activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. 精益制造可以定義為： “識別并消除浪費(fèi)（無價(jià)值活動(dòng)）的系統(tǒng)方法，致力于通過客戶拉動(dòng)的產(chǎn)品生產(chǎn)流程化 持續(xù)改進(jìn)，追求完美Source: 3LEAN TO EXCELLENCE3精 益生產(chǎn)屋增加價(jià)值，消除浪費(fèi)Stop Abnormality異常停線Takt time production節(jié)拍時(shí)間生產(chǎn)Pull production拉動(dòng)式生產(chǎn)Autonomation自動(dòng)化Level Loading負(fù)荷均衡化VSM價(jià)值流程圖 , 5S, Supermarket超市Single Piece Flow單件流準(zhǔn)時(shí)生產(chǎn) 自動(dòng)化均衡生產(chǎn)Sequencing順序生產(chǎn)精益 企 業(yè)4LEAN TO EXCELLENCELevel Loading均衡投入 Sequencing順序生產(chǎn)Heijunka均衡 化生產(chǎn)5LEAN TO EXCELLENCEHeijunka is a Forcing Function均衡化生產(chǎn)是強(qiáng)制作用Customer Demand客戶需求Leveled Production均衡生產(chǎn)? How Can a Shop Resource This ?生產(chǎn)車間怎樣規(guī)劃? How Can the Supply Chain Cope ?供應(yīng)鏈怎樣應(yīng)付? What if the Supply Chain is Global ?如果是全球供應(yīng)鏈又怎樣HeijunkaHeijunka均衡化生產(chǎn)6LEAN TO EXCELLENCEProductionControl產(chǎn)量控制Pacemaker Sets the Pace for Upstream Processes節(jié)拍器設(shè)置在上游制程? Single Scheduling Point單個(gè)計(jì)劃控制點(diǎn)? Down Stream Processes Occur as a Flow下游流程化More leveled production更多均衡化生產(chǎn)Pacemaker節(jié)拍控制點(diǎn)Finished Goods Supermarket 成品超市Customer Demand客戶需求Customer客戶Kanban Post看板位Withdrawal (Pull)拉動(dòng)Withdrawal (Pull)拉動(dòng)Heijunka均衡化生產(chǎn)7LEAN TO EXCELLENCE均衡 投入指引8LEAN TO EXCELLENCEPurpose:目的目的 To provide guidelines for developing the method and tools for levelloading (or levelscheduling) the shop floor. 提供均衡投入（均衡計(jì)劃）生產(chǎn)的方法和工具的指引Key Elements of Levelscheduling 均衡計(jì)劃的主要基礎(chǔ)均衡計(jì)劃的主要基礎(chǔ)n Production units are stratified according to planned sales volume n 產(chǎn)品分類按計(jì)劃銷售量n The production sequence bines Build To Order (BTO) and Customer Forecastn 生產(chǎn)順序結(jié)合按訂單生產(chǎn)和客戶預(yù)測n Sequence is designed to achieve the bined TAKT time for all itemsn 生產(chǎn)順序結(jié)合了各個(gè)項(xiàng)目的節(jié)拍時(shí)間n Eliminating production rate variance is required to achieve TAKT timen 消除生產(chǎn)率差異是達(dá)到節(jié)拍時(shí)間的要求n Build only high volume products