《标准化工作定义》PPT课件.ppt

,StandardWorkWorkshop标准化工作训练营,StandardizedWork标准化作业,Termstoknow:你需知道的术语Takttime客户需求节拍Targetcycletime目标加工周期Actualcycletime实际加工周期Manualtime手工时间Walktime行走时间Waittime等待时间Unassignedtime未分配时间Machinecycletime机器加工周期,StandardizedWork标准化作业,TaktTimeCalculation:客户需求节拍的计算AvailableDailyOperatingTime(Seconds)每天可用工作时间(秒)_TotalAverageDailyProductionRequirements(Pieces)总的平均日生产需求(件),StandardizedWork标准化作业,TaktTimeCalculationExample:客户需求节拍的计算举例Cell3000(Twoshiftoperation)单元3000(两班)Customerdemand=1504/perday客户需求-1504/天Availableworktime=16hours可用工作时间16h=960min/dayLess4breaksperday10min.each减4次休息=40minTotalAvailableTime总可用时间=920min920minutesX60seconds=55,200secondsTaktTime=55,200sec/1504units=36.7secondsWeneedtonet1unitevery36.7seconds我们每36.7秒需要加工一件零件,TargetCycleTime目标加工周期,TargetCycleTime=TaktTime-SpecialAllowances目标加工周期=客户需求节拍-允许的特殊耗时,TargetCycleTimemayincludeplanned,repetitiveoperations目标加工周期包括计划的、重复的操作,-ExamplesofSpecialAllowances允许的特殊耗时例子,TeamMeetings小组会议PM预防性保养Changeover换装,TargetCycleTime目标加工周期,Planned,repetitiveallowanceswillbedeterminedbyeachBusinessUnit计划的，重复的所允许的耗时由每个业务单元决定。,TargetCycleTimeExample目标加工周期举例,ProductionRequirement:1504partsperday生产需求每天1504件部件P.M.保养15minutesX2shifts=30min.EIMeetingEI会议12minutesX2shifts=24min.54min.54minutesX60seconds=3240seconds3240/1504=2.15secondslostforSpecialAllowancesTargetCycleTime=36.7(Takt)2.15(SPA)=34.55sec.目标加工周期,StandardizedWork标准化作业,ActualCycleTime实际加工周期=Manualtime+WalkTime+WaitTime手工时间+行走时间+等待时间,StandardizedWork标准化作业,ActualCycleTime=Manualtime+Walktime+Waittime实际加工周期=手工时间+行走时间+等待时间Longestoperatorsactualcycletimetellsushowmanypartsthecelliscapableofrunning最长的加工周期告诉我们单元有能力加工多少件零件,ActualCycleTimeisthetimeittakesanoperatortocompleteonecycleofhis/herstandardwork实际加工周期是指一位操作员完成其标准作业的周期,StandardizedWork标准化作业,ManualTime:手工时间Thetimerequiredforanoperatortoperformthephysicaltasksforonecycleofoperation(Inspecting,loading/unloading,andgauging)操作工在一个周期的操作中为完成手工任务所需的时间(如检验，装载，卸载，测量),StandardizedWork标准化作业,WalkTime:行走时间Thetimerequiredforthephysicalmovementfromonepointtoanother,withorwithoutapart从一点移动到另一点所需的时间，持有或无零件,StandardizedWork标准化作业,WaitTime:等待时间Thetimetheoperatorwaitswhilethemachinecompletesitsfunction操作工等待机器完成其操作的时间,StandardizedWork标准化作业,StandardizedWork标准化作业,MachineCycleTime:机器周期Thetimerequiredbyamachinetocompleteonecycleofoperation机器完成一个操作循环所需的时间*MachinecycletimemayalsobereferredtoasAutoTime机器周期也被称为自动时间,TargetCellManning目标单元人员配备,#OfMembers=,TotalManualTime+TotalWalkTimeTargetCycleTime目标周期,员工数总的手工时间总行走时间,GOAL:actualcycletimetargetcycletimetakttime,TargetCycleTime目标周期=Takttime-specialallowances特殊耗时,ActualCycleTime=Thetimeittakesanoperatortocompleteonecycleofstandardwork.Thelongestoperatorsactualcycletimetellsushowmanypartsthecelliscapableofrunning实际周期=一位操作员完成标准作业的整个周期的时间。操作员实际最长耗时告诉我们这个单元可以生产的部件数。,TaktTimeCalculation:计算,每日可得操作时间(秒),总平均每日生产要求(件数),目标：实际周期目标周期TAKT时间,LaborEfficiency劳动效率,LaborEfficiency=,StandardDirectLaborHours,ActualSpentHours,StandardLaborxStandardCycleTime(InHours)xOutput,ActualLaborxActualHours,=,ProductivityBenchmark生产力参照值,CellF1单元F1AverageManualTime(MT)-36.0seconds平均手工时间-36.0秒Manualtimeisthetimerequiredforanoperatortoperformthephysicaltasksforonecycleofoperation.(Inspecting,loading/unloading,andgauging)手工时间是一操作工完成一个操作周期所花在手工操作上的时间(检验，装卸，检测等)Takt-48.7seconds理论周期-48.7秒Manual(MT)%ofTakt-73.9%手工时间占理论周期的比例-73.9%,MT,TAKT,=,36,48.7,=,73.9%,PRODUCTMIX混流生产,ProductMixExample产品混合例子,TotalAvailableTime总共可用时:8hoursX60=480-20(2-10breaks)=460X60”=27,600”27600”/876dailyunitsrequired=31.5”TaktTime,TotalDailyAvailableTime总每日可用时Avg.DailyUnitsRequired(A,B,C)平均每天所需求的件数,TAKT=,TargetCycleTimeCalculation目标周期的计算,TargetCycleTime=TaktTime-SpecialAllowances目标周期=TAKE时间-特殊耗时TaktTime=31.5”SpecialAllowances特殊耗时=10ATPM+12TeamMeeting小组会议SpecialAllowances特殊耗时=22X60”=1320”SpecialAllowancepercycle=1320”/876units=1.5”每个循环的特殊耗时31.5”(TaktTime)-1.5”(SpecialAllowance)=30.0”TCT,ProductMixExample产品混合例子,PartA356”x.25=89”PartB300”x.35=105”PartC240”x.40=96”290”WeightedAverage加权平均的全部工作内容,CalculationofAvg.TargetManning平均目标人力的计算,TargetManningExample目标人力配备举例,290”30.0”,TargetCycleTime目标周期,TotalManualTime+TotalWalkTime总手动时间+总走动时间,TargetManning目标人力,=,=,=,9.6,Weroundtothenextfullpersonanduse10people我们取整数，用10人。,FixedManning/FlexTCT固定人力/可变的目标周期,Product产品ABC,Manual人力306”260”200”,Walk走动50”40”40”,Total总共356”300”240”,%Mix混合25%35%40%,PartA356”/9.6=37.08”TargetCycleTimePartB300”/9.6=31.26”TargetCycleTimePartC240”/9.6=25.00”TargetCycleTime,FixedTCT/FlexManning固定的目标周期/可变的人力,356”/30.0”=11.8TargetManning目标人力300”/30.0”=10.0TargetManning目标人力240”/30.0”=8.0TargetManning目标人力,ProductMixExample产品混合例子,FixedManning固定人力,FixedTCT固定目标周期,TargetManning目标人力,TargetCycle目标周期,TargetManning目标人力,TargetCycle目标周期,A30.0”11.837.0”9.6B30.0”10.031.2”9.6C30.0”8.025.0”9.6Gross30.0”9.630.0”9.6,9ContinuousImprovementProcessSteps持续改进的9个步骤,1.Observecurrentmethod观察目前的方法2.Documentcurrentmethod记录目前的方法3.Identifyimprovements(stepstoeliminate)识别改进(需消除的步骤)4.Implementimprovements实施改进5.Validatequalityandproductivityofnewmethod验证新方法的质量及生产力6.Standardizenewmethod将新方法标准化7.Document“Before”and“After”conditions记录改进前后的情况8.Recognizeachievements认可取得的成绩9.Lookfornextimprovement寻求下一次改进,ImplementingStandardWork实施标准作业,TrainthecellmembersinStandardWork&TaktTimeProduction.给每个单元的成员就标准作业和理论时间生产进行培训CalculateTaktandTargetCycleTime计算需求节拍和目标周期Developstandardworkchartswithflexmanning,plusandminusoneoperator做出的标准作业图表要体现灵活的人力配置，加1减1模式CreateStandardWorkCombinationTables建立标准作业组合表(SWCT)CreateaBalanceBoardasatool