【正文】 作區(qū)域（工作站）或流程中，在存貨金額上建立了一個 WIP cap. ?來維護 WIP cap, 從流程中的“出口” （ exits） 來觸發(fā)進入流程的“出發(fā)”（ Starts). 建立 WIP cap 是降低周轉時間的關鍵 11 Generic Pull System Improve When to Use Generic Pull ? Always ? Generic Pull systems can be used in any of the following manufacturing/transactional environments: ? Repetitive process/repetitive product ? Similar products/parts run within same process flow ? Example: Automotive assembly line, customer order processing ? Repetitive process/nonrepetitive product ? Dissimilar products/parts run within same process flow ? Example: Build to order printed circuit board manufacturer, customer plaint processing ? Nonrepetitive process/nonrepetitive product ? Dissimilar products/parts run within a dissimilar process flow ? Example: Machine model/prototype shop, NPI processes ? Generic Pull systems should always be used when a replenishment pull system is implemented 12 Generic Pull System Improve 何時使用普通拉系統(tǒng) ? 永遠 ? 普通拉系統(tǒng)可以被使用在下列任何制造 /事務處理的環(huán)境中 : ? 重復的流程 /重復的產(chǎn)品 ? 類似的產(chǎn)品 /零件在同一個流程中運行 ? 例如 : 汽車的組裝線 , 客戶定單流程 ? 重復的流程 /不重復的產(chǎn)品 ? 不同的產(chǎn)品 /零件在同一個流程中運行 ? 例如 : 根據(jù)定單定制的電路板制造商 , 客戶投訴流程 ? 不重復的流程 /不重復的產(chǎn)品 ? 不重復的產(chǎn)品 /零件在不同的流程里運行 ? 例如 : 機器模型 /原型制作車間 , NPI流程 ? 當補充拉系統(tǒng)被實施時，普通拉系統(tǒng)將永遠被使用 13 Generic Pull System Improve When flying from DFW to O’Hare, we often wind up waiting on the ground due to “flow control.” Since O’Hare is overloaded, air traffic control keeps us in Dallas until the congestion over O’Hare clears, versus getting there and circling Chicago. Either way, we end up late. However, using the “flow control” (fixed WIP) method, we use less fuel and reduce the risk of an accident. In addition, we keep our options open (such as rerouting if the weather bees too bad). In a pull system, maintaining a “fixed WIP” keeps work orders in paper form as long as possible. This provides the greatest flexibility to schedule/engineering changes. In addition, low WIP means a faster cycle time, which increases the probability releases are based on actual customer orders versus forecast. “ Fixed WIP” Improves Flexibility 14 Generic Pull System Improve 當航班從 DFW 到 O’Hare, 我們通常由于“流控制”而在地面上緊張的等待。因為 O’Hare機場超負荷了 , 空中交通控制要求我們在達拉斯等待，直到 O’Hare 的堵塞清除掉 ； 與在芝加哥上空盤旋相比，任何一條路都注定會讓我們晚點。這樣為制定計劃 /工藝變更提供了最大的彈性。 需要采取的行動 WIP 狀況 51 Generic Pull System Improve Generic Pull Exercise: Part A ? Given the following Information: ? Average Demand is 10 units/day ? Current MCT is 20 days ? Value Add Time = 8 hours ? Fabrication Shop ? 1 shift operation that works 5 days per week ? Answer the following questions: ? What should my WIP cap (in units) be? ? How much inventory should I drain from the operation? 52 Generic Pull System Improve 普通拉系統(tǒng)的練習 : 零件 A ? 已知下列信息 : ? 平均的需求是 10 單位 /天 ? 目前的 MCT 是 20 天 ? 增值時間 = 8 小時 ? 裝配車間 ? 每周工作 5天，一班運作 ? 回答下列問題 : ? 我的 WIP cap (單位 ) 將會是什么 ? ? 應該從工序中減少多少庫存？ 53 Generic Pull System Improve Generic Pull Exercise: Part B ? Using the calculated WIP cap from Part A answer the following questions: ? Current WIP level is 105 units and my MRP system wants me to release a quantity of 5 units into the line what should I do? Why? ? Current WIP level is 95 units and my MRP system wants me to release a quantity of 5 units into the line what should I do? Why? ? Current WIP level is 98 units and my MRP system wants me to release a quantity of 5 units into the line what should I do? Why? 54 Generic Pull System Improve 普通拉系統(tǒng)的練習 : 零件 B ?用零件 A部分的 WIP Cap計算結果回答下列問題 : ?目前的 WIP水平是 105 單位，我的 MRP系統(tǒng)要求我發(fā)放一個數(shù)量為 50單位的工單到生產(chǎn)線上，我應該做什么？為什么？ ?目前的 WIP水平是 95 單位，我的 MRP系統(tǒng)要求我發(fā)放一個數(shù)量為 5單位的工單到生產(chǎn)線上，我應該做什么？為什么？ ?目前的 WIP水平是 98 單位，我的 MRP系統(tǒng)要求我發(fā)放一個數(shù)量為 5單位的工單到生產(chǎn)線上，我應該做什么？為什么？ 55 Generic Pull System Improve How to Determine Unit of Measure for WIP Control ? Conceptually all Generic Pull Systems are identical, the primary difference being the WIP control parameter. The WIP control parameter is the unit of measure for WIP used to control the pipeline. ? Three types of parameters are used: ? Quantity ? Equivalent Units ? Time ? The most effective method for determining the proper parameter is using the “Coefficient of Variation (CV)” for the product value add times. 56 Generic Pull System Improve 如何決定 WIP控制的量測單位 ? 概念性的普通拉系統(tǒng)都是同樣的，主要的不同點在于 WIP的控制參數(shù) . WIP的控制參數(shù)是指用來控制整個路徑的 WIP的度量參數(shù) . ? 三種類型的指標被使用 : ? 數(shù)量 ? 等價單位 ? 時間 ? 確定適合參數(shù)的最有效的方法是將“變量系數(shù)”用于產(chǎn)品增值時間。 它是什么？ WIP CT Exits 1 60 sec 1/min 4 60 sec 4/min 8 120 sec 4/min 85 Generic Pull System Improve Takeaways ? Understand the relationship between Cycle Time, WIP, and Throughput ? Better understanding how to impact cycle time 86 Generic Pull System Improve 總結 ? 理解周轉時間、 WIP和生產(chǎn)能力間的相互關系 ? 更好的理解如何去影響周轉時間 87 Generic Pull System Improve 演講完畢，謝謝觀看！