【正文】 WIP=4 ? Build four antennas ? Record results Exercise 3 ? Start with WIP = 8 ? Build eight antennas ? Record results Exercise 4 ? Start with WIP = 0 ? Operation 2 Bottleneck ? Run simulation for two minutes ? Record results 78 Generic Pull System Improve 團隊練習 : 天線工廠 練習 1 ? 從零開始 (WIP = 0) ? 建一個天線 ? 記錄結(jié)果 練習 2 ? 從 WIP=4 開始 ? 建 4個天線 ? 記錄結(jié)果 練習 3 ? 從 WIP = 8開始 ? 建 8個天線 ? 記錄結(jié)果 練習 4 ? 從 WIP = 0 開始 ? 操作員 2 – 瓶頸 ? 運行模擬 2分鐘 ? 記錄結(jié)果 79 Generic Pull System Improve Exercise Cycle Time 1 2 3 4 Team 1 Team 2 Team 3 Team 4 Team 5 Team 6 WIP Exits Exercise Results 80 Generic Pull System Improve 練習的周轉(zhuǎn)時間 1 2 3 4 隊 1 隊 2 隊 3 隊 4 隊 5 隊 6 WIP Exits 練習結(jié)果 81 Generic Pull System Improve Operators 1 through 4 Production Supervisor records the cycle time and throughput of each run Exercise Roles Insert Screw Attach Antenna Base Operator performs the task of the operation assigned Attach Side Leg 1 Attach Side Leg 2 82 Generic Pull System Improve 操作員從 1 到 4 生產(chǎn)主管 記錄每次的周轉(zhuǎn)時間和生產(chǎn)能力 練習的角色 嵌入 螺絲 裝上基礎(chǔ) 天線 操作員按照給定的任務去完成 裝上腳 1 裝上腳 2 83 Generic Pull System Improve Exercise Observations ? As long as there is no queue time (WIP = 1 4), the cycle time is roughly equal to the sum of the process times or value add time (VA). ? The rate at which Antennas are pleted (throughput) is maximized when there is no idle time (WIP = 4 8), and it is governed by the slowest operation. ? When WIP = 4 antennas, there is no queue time (minimum cycle time) and no idle time (maximum throughput), this is the critical WIP level. ? For any WIP Critical WIP, cycle time will increase with no increase in throughput (assuming no variability). ? There exists a fundamental relationship between WIP, Cycle Time and Throughput. What is it? WIP CT Exits 1 60 sec 1/min 4 60 sec 4/min 8 120 sec 4/min 84 Generic Pull System Improve 練習的觀測報告 ?在這里是沒有排隊等待時間 (WIP = 1 4), 周轉(zhuǎn)時間大約等于工序時間的總和或者增值時間 (VA). ?當沒有空閑時間時 (WIP = 4 8) ，天線的完成比率（生產(chǎn)能力）是最大的 , 并且比率被最慢的那個工位所控制 . ?當 WIP = 4 個天線時 , 流程中沒有等待時間 (最小的周轉(zhuǎn)時間 ) 并且沒有空閑時間 ( 最大的產(chǎn)能 ), 這就是關(guān)鍵 WIP 水平 . ?對于任何 WIP 關(guān)鍵 WIP, 周轉(zhuǎn)時間將被延長而生產(chǎn)能力并沒有被提升 ( 假設(shè)沒有可變性 ). ?在 WIP、 周轉(zhuǎn)時間和生產(chǎn)能力 間存在這一個基本的關(guān)系。此外，底 WIP意味著更快的周轉(zhuǎn)時間，這樣可以增加基于客戶的訂單而不是根據(jù)預測 “固定的 WIP” 改善彈性 15 Generic Pull System Improve The Power of a WIP Cap WIP Cap – Cycle time is reduced and stable No WIP Cap – Cycle time fluctuates with amount of WIP 16 Generic Pull System Improve WIP Cap的能力 WIP Cap – 周轉(zhuǎn)時間被降低了且穩(wěn)定 沒有 WIP Cap – 周轉(zhuǎn)時間隨 WIP的金額而波動 17 Generic Pull System Improve United Technologies: Hose and Fittings Division (PTG) Before Metal ware flare running large batches with large amounts of WIP 18 Generic Pull System Improve 聯(lián)合技術(shù) : Hose and Fittings 分部 (PTG) 之前 金屬器械運行大批次并伴隨大的 WIP 19 Generic Pull System Improve United Technologies: Hose and Fittings Division (PTG) After Metal ware flare area with controls placed on material releases to the department 20 Generic Pull System Improve 聯(lián)合技術(shù) : Hose and Fittings 分部 (PTG) 之后 金屬器械區(qū)域?qū)Πl(fā)料到部門的材料放置進行控制 21 Generic Pull System Improve Teledyne Continental Motors Before No internal limits existed for the number of cylinders a supplier could push to its customer, resulting in large amounts of WIP in the line. 22 Generic Pull System Improve Teledyne Continental Motors 之前 對于缸體數(shù)量沒有內(nèi)部限制，供應商向客戶推動供應，導致生產(chǎn)線有大量 WIP. 23 Generic Pull System Improve Teledyne Continental Motors After Limits were established workstations and the line was drained of excess WIP 24 Generic Pull System Improve Teledyne Continental Motors 之后 建立限制數(shù)量，過多的 WIP從工位和生產(chǎn)線清除 25 Generic Pull System Improve How to Size a Generic Pull System 1. Determine current Manufacturing Cycle Time (MCT) 2. Determine current Manufacturing Cycle Efficiency (MCE) 3. Identify appropriate target MCE 4. Calculate theoretical best MCT 5. Calculate WIP cap 26 Generic Pull System Improve 如何確定普通拉系統(tǒng)的規(guī)模 1. 確定目前的制造周期時間 (MCT) 2. 確定目前的制造周轉(zhuǎn)效率 (MCE) 3. 識別適合的 MCE目標 4. 計算理論上的最佳 MCT 5. 計算 WIP cap 27 Generic Pull System Improve Manufacturing Cycle Time ? MCT – The time from work order release into manufacturing until pletion/movement into shipping/ finished goods. ? It is measured as: ? WIP is the inventory level at a given point in time ? EXITS is the amount of work pleted over a given period of time (Weekly, Daily) EXIT SWIPMC T ?28 Generic Pull System Improve 制造周期時間 ? MCT – 從工作單的下發(fā)到制造，直到完成 /移動到成品的時間 . ? 他被量測如 : ? WIP 是在給定時間點的存貨水平 ? EXITS 是在一個給定的時間內(nèi) (每周，每天 )工作完成的金額 EXIT SWIPMC T ?29 Generic Pull System Improve MCT Exits = 20 units/day WIP = Sum of all Inventory within Physical work area