【正文】 blers/processors and average takt time it will take to satisfy the demand. ? Approach 2 – DaytoDay Scheduler: ? Given the inputs of average productivity, assembly/processing time, number of assemblers/processors, and desired output (demand), calculate the hours per shift and takt rate it will take to satisfy the demand. ?What’s the difference? ? Long Term Planner allows management to understand staffing increments based upon some forecasted demand on a line by line basis. ? DaytoDay scheduler allows line supervision to calculate process parameters (takt rate, hours to work) based on the number of units to process and the number of people who show up to work that day. Control Line Balance Model 18 線平衡步驟 ?兩種不同的方法 : ?方法 1 – 長(zhǎng)期計(jì)劃員 : ? 作出平均投入生產(chǎn)率、裝配 /加工時(shí)間、及預(yù)計(jì)的產(chǎn)量（需求），每班的時(shí)間，計(jì)算裝配工 /操作工的數(shù)量，及滿足需求所花的平均時(shí)間。 ?區(qū)別是什么 ? ?長(zhǎng)期計(jì)劃員允許管理來(lái)了解在以生產(chǎn)線為基礎(chǔ)上的需求預(yù)測(cè)而增加員工。 Measure Analyze Control Improve Lean Six Sigma Approach 1 Long Term Planner Measure Analyze Control Improve Lean Six Sigma 途徑 1 長(zhǎng)期計(jì)劃員 Control Line Balance Model 21 Input 1. Demand requirements 2. Labor efficiency times 4. Hours per shift or number of assembler/stations Output 1. Takt rate 2. Number of Assemblers/Processors OR Number of hours per shift 3. Staffing levels at varying demand Process Balance Model (spreadsheet) Process Balance Model: Design process Or I N PU T S H o u rs / U n i t 0 . 4 5 0 0 . 4 5 0T o t a l As s e m b l y T i m e (h rs ) C VA + BV A+ N VA 0 . 2 2 4 0 . 2 2 4T o t a l As s e m b l e rs 2 7 . 0 2 7 . 0Ma x D e m a n d R e q u i re m e n t (u n i t s / s h i f t ) 500 450O U T PU T SMa x h rs p e r s h i f t 8 . 3 7 . 5T a kt R a t e (u n i t s / h o u r) 60 60T ak t Rat e C al cu la t o r5 0 % S t a f f i n g I n c r e m e n t s C o v e r a g e G r a p h6 78 910 116 78 910 116 78 910 116 78 910 11051015202575 113 150 225 300 450 600 900u n i t s / d a y of assemblers and of hours o f A s s e m b l e r s h o u r sControl Line Balance Model 22 投入 1. 需求需要 2. 勞動(dòng)效率 /加工任務(wù)和時(shí)間 4. 每班時(shí)間或裝配工 /工作站數(shù)量 產(chǎn)出 1. Takt 比率 2. 裝配工 /操作工數(shù)量或每班時(shí)間 3. 在變化基礎(chǔ)上的員工水平 過(guò)程平衡模型 (spreadsheet) Process Balance Model: 設(shè)計(jì)流程 Or I N PU T S H o u rs / U n i t 0 . 4 5 0 0 . 4 5 0T o t a l As s e m b l y T i m e (h rs ) C VA + BV A+ N VA 0 . 2 2 4 0 . 2 2 4T o t a l As s e m b l e rs 2 7 . 0 2 7 . 0Ma x D e m a n d R e q u i re m e n t (u n i t s / s h i f t ) 500 450O U T PU T SMa x h rs p e r s h i f t 8 . 3 7 . 5T a kt R a t e (u n i t s / h o u r) 60 60T ak t Rat e C al cu la t o r5 0 % S t a f f i n g I n c r e m e n t s C o v e r a g e G r a p h6 78 910 116 78 910 116 78 910 116 78 910 11051015202575 113 150 225 300 450 600 900u n i t s / d a y of assemblers and of hours o f A s s e m b l e r s h o u r sControl Line Balance Model 23 Process Balance Model: Steps Step 1: Understand present state process operation (gather and document data) Step 2: Determine total time required to process unit (value add and business value add) Step 3: Determine maximum operating parameters and plug parameters into yellow cells Step 4: Determine target unit/day output requirement and plot on table to determine number of shift hours to work to achieve requirement Step 5: Plot current operating range to determine labor reduction required to meet operating goals Step 6: Group tasks in logical and efficient manner that does not violate design principles Control Line Balance Model 24 過(guò)程平衡模型 步驟 Step 1: 了解目前的生產(chǎn)流程狀況 (收集數(shù)據(jù)并文件化 ) Step 2: 確定處理單元所需的全部時(shí)間（增值和業(yè)務(wù)增值） Step 3: 確定最大的運(yùn)行參數(shù)并將參數(shù)插入黃格中 Step 4: 將目標(biāo)單元 /天所需的產(chǎn)量在桌面上標(biāo)出以確定達(dá)到需要的每班工作時(shí)間 Step 5: 標(biāo)出目前的運(yùn)行變化以確定滿足生產(chǎn)目標(biāo)所需減少的勞動(dòng)力 Step 6: 在不影響設(shè)計(jì)原則的情況下，按邏輯和效率態(tài)度將任務(wù)分解 Control Line Balance Model 25 BRY AN CURRE NT (A lum S ing le Hun g)Task s/P eop le Actu al Activity1 15 Fr am e J am b P r es s2 15 Fr am e J am b P r es s3 18 J am b P r ep O ut4 18 J am b P r ep O ut5 20 S as h P r es s6 10 S as h Hea d P r es s7 18 S as h H S P r es s8 20 Fr am e A s s y9 18 Fr am e S i l l P r ep10 20 MR Fr am e S i l l P r es s11 18 MR P r ep O ut12 20 Fr am e A s s y13 20 V en t B ui l di ns14 20 V en t B ui l di ns15 20 V en t Drop c au l k16 20 V en t Drop c au l k17 15 Fr am e B ed er18 18 G l as s Dr op19 18 G l az er20 18 G l az er21 18 G l az er22 18 G l az er23 18 G l az er24 18 G l az er25 20 Cl ea n an d B oo t26 20 Cl ea n an d B oo t27 20 Cl ea n an d P ad 39。s471 S ec s7. 85 Mi ns0. 13 08 33 33 3 Hou r s1步驟 1 了解現(xiàn)在過(guò)程狀況 (收集、記錄活動(dòng)時(shí)間 ) 注意 : 時(shí)間應(yīng)該包括 CVA、 BVA、 與每一步驟、作業(yè)、與任務(wù)的時(shí)間 步驟 2 決定全部（目前）需要完成任務(wù)的時(shí)間。 過(guò)程平衡模型 步驟 1 和 2 Control Line Balance Model 27 I N P U TS M a x 5 0 % I n c r e m e n t 5 0 % I n c r e m e n t 5 0 % I n c r e m e n tM a x L a b o r E f f i c i e n c y 60% 55% 50% 45%T o t a l A s s e m b l y / P r o c e s s i n g T i m e ( h r s ) 0 . 1 3 0 . 1 3 0 . 1 3 0 . 1 3M a x D e m a n d R e q u i r e m e n t ( u n i t s / s h i f t ) 1100 550 275 138M a x h r s p e r s h i f t 11 11 11 11O U TP U TSM a x D e m a n d ( u n i t s / h o u r ) 1 0 0 . 0 0 5 0 . 0 0 2 5 . 0 0 1 2 . 5 0M a x D e m a n d ( u n i t s / m i n u t e ) 1 . 6 7 0 . 8 3 0 . 4 2 0 . 2 1T a k t T i m e ( s e c o n d s / u n i t ) 36 72 144 288T o t a l P r o c e s s o r s 2 2 . 0 1 2 . 0 7 . 0 4 . 0W o r k s t a t i o n T i m e ( s e c s / w o r k s t a t i o n ) 21 39 67 118L a b o r P r o d u c t i v i t y ( U n i t s / L a b o r H o u r ) 4 . 5 5 4 . 1 7 3 . 5 7 3