精益生产工具（英文PPT22 22页

TenantsofSinglePieceFlowDoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectsZeroDefects=0DefectsNot3.4ppmQuality,Quality,Quality…DefectsaretheWorstKindofWaste7TypesofWasteDefectivePartsOverProductionInventoryMotionTransportationWaitingManualTouches BatchSinglePieceFlowFrom:TheToyotaProductionSystemBuildingQualityintotheProcessSinglePieceFlowThenextprocessisthecustomer…neversenddefects!SampleInspectcatchesDefecttooLateWhenyouFinallyFindaDefectHowmanymoredoyouhave?Wherearetheyintheprocess?WhatistherootCause?SinglePieceFlowcatchesDefectsimmediatelyWhenyoufindaDefectYouonlyhaveoneYouknowwhereitoccurredYouCanfind/ResolvetheRootCauseimmediately Check,Do,VerifyCheck-Thepreviousoperatorswork.Do-Yourwork.Verify-Thatyoudidyourworkcorrectly. ProcessInspectTransportTransportationisintegratedintotheproductionprocessviaautomatione.g.,movinglineProcessInspectProcessInspectTransportProcessInspectTransportationisintegratedintotheproductionprocessviahumanconveyancee.g.,Chaku-ChakuBuildingQualityintotheProcess2waystoperformSPFThenextprocessisthecustomer…neversenddefects! Check,Do,VerifyGetsyouintoPartsPerMillionquality-Whenyouverifyyourwork,youcatch1flawin100parts.Thenextpersonchecksyourworkandcancatch1/100sothat’s1/10,000.ThenthatpersonVerifiestheirworkandcancatch1/100.That’s1/1,000,000errorsthatcangetthrough. Check,Do,VerifyEveryCustomerinaProcesshas:-arighttoexpectperfectmaterial-anobligationtoinspectthematerialbeforeuse.-anobligationtoinformthepreviousstepintheprocessofanyproblem.-anobligationtostoptheprocessuntilanyproblemhasbeenresolved. SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess.ThisisachievedbyestablishingataktTime,developingstdwork,andswip.ThepremiseisthatanOperatorcanonlyworkononepieceatatime,andperformsaQuickqualitycheckontheCTQsoftheprocessbeforemovingTheparttothefollowingprocess.Ifadefectisdetected,JidokaIsenacted…thelineisstopped,andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurenceTakttimeStdworkFlow:work(process)thatisdoneinconjunctionwithorsimultaneoustotransportation OnePieceFlowTheproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis/hersupplierandcustomerinthechain.Asonepersonfinishestheirelement,sodoall.Workisthenmoveddownthelinesynchronously.Everypersonisempoweredtostoptheproductionprocessifarejectisspotted. OrganizationAreaSupervisorNew/RevPageofDateProductionLinePartNumberPartNameOperatorStandardWorkSheetTo:TurnsDPU"sScopeofOperationsFrom:QualityCheckSafetyPrecautionStandardWork-in-Process#LotsofStandardWork-in-ProcessTakt/RateTimeTotalManual&TravelTimeMan/TravelTimeOperatorEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeTubingCFMCellFernBissonnetteCell6AllPartsAllTubes11Mech.CleanRawmaterialWeld100/DayFPIX-RayEDM2ndQtr.‘01EndFinishOutsideCell27-avglot=6FlexFinishedGoodsACTIONWORKOUTgGEMSGlobalProductionSystemThenextprocessisthecustomer…neversenddefects!Check,Do,Verify OnePieceFlowYourcustomeristhenextstepintheprocess.Givetoyourcustomer,exactlywhattheyneed(1item),exactlywhentheyneedit,doneperfecteverytime. Tenantsof1pcsFlowDoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectQuality,Quality,Quality…DefectsaretheWorstKindofWaste Systemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals,intheexactstandardizedamountneeded.PullProductionMethodology&SequenceDefinitionRefMaterialPresentationtrainingforexplanationonSupermarketdefinitionanduse Parts13456789102AssemblyLineCellorChaku-ChakulineSupplierMaterialInformationSupermarketEmptycontainerFullcontainerLegend1Sequence/TimingPullProductionMethodology&Sequence JITJidokaeGPSforGPCHeijunkaLevelLoadingSequencingFindingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacityAdjustingaproductionscheduletomeetunexpectedchangesincustomerdemandOrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitemstakenfrommemoryJogger Leveledproductionmeansloweringthepeaksamongthedailyproductionvolumesasmuchaspossibleandmakingtheproductionflowsmoothandunflucuating.Ingeneral,themorefluctuationsyouintheproductionflow,themoremudayouenduphaving.Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand.Iftheproductionlineproducesonlyasingleproduct,youmaybeabletoreducemudasimplybyadjustingtheproductionscheduleandstaffinglevel.Butifyouwanttoproduceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline,youhavetodotheaveragingnotjustinvolumebutinkindsaswell.ThiswayofaveragingbothvolumeandinkindsiscalledproductionlevelingorheijunkainJapanese.LeveledProductionAmountofproductsthatcanbesoldHEIJUNKAAveragebytotalvolumeAveragebymodel LeveledLoadProductionBuildtoforecastBuildtoFGinvBuildafterorderisreceivedALLcomponentsneedtobestockedinRMAnorderfromtheseproductstakesprecedenceover1-2-3products…buildthisfirst!UseStocksBuildStocksTAKT%F1F1F1F1F1F1F2F2F2F2F2F2TAKTTimeDeterminedbyPSI2Q3Q4QOktoBuildtoFGRepeatableProductsNon-RepeatableProducts NeedtoDetermine...HowMuch20bulbsperdayWhatKind15/60Watts5/100WattsWhen5-60W,2–100W,5–60W,2–200W,5–60W,1–100WTAKTLevelLoadMixLevelLoadSequenceIfweweremakinglightbulbs...QuarterlyWeeklyWeeklyFrequency606060606010010060606060601001006060606060100TaktTime=OperatingtimeperdayProductionrequirementperdayAssumptions:MachineBreakdown=0hourSetupChange=0hourDefectRate=0%TaktTimeEquationFormoreinformationonTAKT–RefertoJITSectionQuickExample SettingtheproductionsequenceofmultipleTRAM–RACTypes(MedSystemsProduct)ProductMonthlyRequirementDailyRequirementTAKTTimeModel1720units24units5minModel2360units12units10minModel3360units12units10minTotal1440units48units7.5minThisisdatafor3products,Model1,Model2,andModel3,areproducedatGEMS.Thechartdisplaysthemonthlyproductionlevel,thedailyproductionlevel(monthlydividedby30),andtheTakttimeforeachproducttype.THEYAREALLPRODUCEDONTHESAMELINE.Howcantheseunitsbebuiltinalevelproductionmodeusingthisexample?Model1Model2Model3DetailedExample Sincethesethreeproductsareonthesameline,youwillneedtofollowthesequencepatternof1-2-1-3inyourproductionmix.Bydoingitthiswayyouareabletolevel-loadyourproductionbothintermsofquantityandtypes.#1–Prod1#4–Prod3#2–Prod2#3–Prod1REPEATMixedAssemblyLineProductionSequencebyTypeIfproducedinbatches,onlytheModel1’swillmeetTakttimesIfproducedtoasequence,2unitswillbeproducedin2TakttimesLet’sshowhowwevalidatethis… ModelLineTaktTakt/CycleGraphPart-QuantityPartRouter1327.57.57.5SeeStdWorkComboSheetforexample.OnesheetiscreatedforeachoperatorSCT=25SCT=40SCT=30766676138127.597.5 TaktBuildTime=#ofOperations*TaktActualBuildTime=SCT130230330125240330ModelTBTModelABT1-52+1030ModelObjectives:ProducetoTaktTime(understandingno2productswillhavetheexactsameABT)ThesumoftheDTotiszeroEveryproductisproduceatleastonceNoproductisproducedtwiceinarowCreateaproductsequencewhere:Dtot=S(#ofUnitsinsequence*D)Dtot=-5(#of1’s)+10(#of2’s)+0(#of3’s)0=-5(2)+10(1)+0(1)IneachsequencewillcontainoneModel1,twoModel2s,and1Model3)Accordingtotherulesthesequencemustrun:Model1–Model2–Model1–Model3 GuidingPrinciples:GPSLevel-loadingPurpose:Toprovideguidelinesfordevelopingthemethodandtoolstolevel-scheduletheshopfloor.KeyElementsofLevel-schedulingProductionunitsarestratifiedaccordingtoplannedsalesvolumeTheproductionsequencecombinesbothordersandforecastSequenceisdesignedtoachievethecombinedTAKTtimeforallitemsEliminatingproductionratevarianceisrequiredtoachieveTAKTtimeOnlybuildhighvolumeproducts(top80%)toFGinventory,ifordersarenotavailableFGinventorylevelsareNOTtargeted,butaresultofTAKTtime&ordersflowLower-levelgroupitemsareNOTsequencedwithoutfirmordersHoldRMcomponentsinventoryonlyforlowvolumeitems.Theseareitemsthatyoucan’tbuilduntilyouhaveanorderFillordersfirstfromFG,secondWIP,&thirdsequencethem(attachtheordertotheproductionplan)