精益生产工具.ppt

TenantsofSinglePieceFlow DoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectsZeroDefects 0DefectsNot3 4ppm Quality Quality Quality DefectsaretheWorstKindofWaste 7TypesofWasteDefectivePartsOverProductionInventoryMotionTransportationWaitingManualTouches 天马行空官方博客 Batch SinglePieceFlow From TheToyotaProductionSystem BuildingQualityintotheProcessSinglePieceFlow Thenextprocessisthecustomer neversenddefects SampleInspectcatchesDefecttooLateWhenyouFinallyFindaDefectHowmanymoredoyouhave Wherearetheyintheprocess WhatistherootCause SinglePieceFlowcatchesDefectsimmediatelyWhenyoufindaDefectYouonlyhaveoneYouknowwhereitoccurredYouCanfind ResolvetheRootCauseimmediately Check Do Verify Check Thepreviousoperatorswork Do Yourwork Verify Thatyoudidyourworkcorrectly 天马行空官方博客 Process Inspect Transport Transportationisintegratedintotheproductionprocessviaautomatione g movingline Process Inspect Process Inspect Transport Process Inspect Transportationisintegratedintotheproductionprocessviahumanconveyancee g Chaku Chaku BuildingQualityintotheProcess2waystoperformSPF Thenextprocessisthecustomer neversenddefects Check Do Verify GetsyouintoPartsPerMillionquality Whenyouverifyyourwork youcatch1flawin100parts Thenextpersonchecksyourworkandcancatch1 100sothat s1 10 000 ThenthatpersonVerifiestheirworkandcancatch1 100 That s1 1 000 000errorsthatcangetthrough Check Do Verify EveryCustomerinaProcesshas arighttoexpectperfectmaterial anobligationtoinspectthematerialbeforeuse anobligationtoinformthepreviousstepintheprocessofanyproblem anobligationtostoptheprocessuntilanyproblemhasbeenresolved SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess ThisisachievedbyestablishingataktTime developingstdwork andswip ThepremiseisthatanOperatorcanonlyworkononepieceatatime andperformsaQuickqualitycheckontheCTQsoftheprocessbeforemovingTheparttothefollowingprocess Ifadefectisdetected JidokaIsenacted thelineisstopped andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurence TakttimeStdwork Flow work process thatisdoneinconjunctionwithorsimultaneoustotransportation OnePieceFlow Theproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis hersupplierandcustomerinthechain Asonepersonfinishestheirelement sodoall Workisthenmoveddownthelinesynchronously Everypersonisempoweredtostoptheproductionprocessifarejectisspotted Organization Area Supervisor New Rev Page of Date ProductionLine PartNumber PartName Operator StandardWorkSheet To Turns DPU s EndFinish Weld EndFinish Weld OrbitalWeld HydroTest Mark Mech Clean TorchBraze Tubing CFMCell FernBissonnette Cell6AllPartsAllTubes 11 Mech Clean Rawmaterial Weld 100 Day FPIX RayEDM 2ndQtr 01 EndFinish OutsideCell 27 avglot 6 Flex FinishedGoods ACTIONWORKOUT g GEMSGlobalProductionSystem Thenextprocessisthecustomer neversenddefects Check Do Verify OnePieceFlow Yourcustomeristhenextstepintheprocess Givetoyourcustomer exactlywhattheyneed 1item exactlywhentheyneedit doneperfecteverytime Tenantsof1pcsFlow DoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefect Quality Quality Quality DefectsaretheWorstKindofWaste Systemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals intheexactstandardizedamountneeded PullProductionMethodology Sequence Definition RefMaterialPresentationtrainingforexplanationonSupermarketdefinitionanduse 1 3 4 5 6 7 8 9 10 2 AssemblyLine CellorChaku Chakuline Supplier PullProductionMethodology Sequence JIT Jidoka eGPSforGPC Heijunka LevelLoading Sequencing FindingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacityAdjustingaproductionscheduletomeetunexpectedchangesincustomerdemand OrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitems takenfrommemoryJogger Leveledproductionmeansloweringthepeaksamongthedailyproductionvolumesasmuchaspossibleandmakingtheproductionflowsmoothandunflucuating Ingeneral themorefluctuationsyouintheproductionflow themoremudayouenduphaving Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand Iftheproductionlineproducesonlyasingleproduct youmaybeabletoreducemudasimplybyadjustingtheproductionscheduleandstaffinglevel Butifyouwanttoproduceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline youhavetodotheaveragingnotjustinvolumebutinkindsaswell ThiswayofaveragingbothvolumeandinkindsiscalledproductionlevelingorheijunkainJapanese LeveledProduction LeveledLoadProduction BuildtoforecastBuildtoFGinv BuildafterorderisreceivedALLcomponentsneedtobestockedinRMAnorderfromtheseproductstakesprecedenceover1 2 3products buildthisfirst F1 F1 F1 F1 F1 F1 F2 F2 F2 F2 F2 F2 TAKTTimeDeterminedbyPSI 2Q 3Q 4Q OktoBuildtoFG RepeatableProducts Non RepeatableProducts NeedtoDetermine HowMuch20bulbsperdayWhatKind15 60Watts5 100WattsWhen5 60W 2 100W 5 60W 2 200W 5 60W 1 100W TAKTLevelLoadMixLevelLoadSequence Ifweweremakinglightbulbs QuarterlyWeeklyWeekly Frequency 60 60 60 60 60 100 100 60 60 60 60 60 100 100 60 60 60 60 60 100 TaktTime Operatingtimeperday Productionrequirementperday Assumptions MachineBreakdown 0hourSetupChange 0hourDefectRate 0 TaktTimeEquation FormoreinformationonTAKT RefertoJITSection QuickExample SettingtheproductionsequenceofmultipleTRAM RACTypes MedSystemsProduct Thisisdatafor3products Model1 Model2 andModel3 areproducedatGEMS Thechartdisplaysthemonthlyproductionlevel thedailyproductionlevel monthlydividedby30 andtheTakttimeforeachproducttype THEYAREALLPRODUCEDONTHESAMELINE Howcantheseunitsbebuiltinalevelproductionmodeusingthisexample Model1 Model2 Model3 DetailedExample Sincethesethreeproductsareonthesameline youwillneedtofollowthesequencepatternof1 2 1 3inyourproductionmix Bydoingitthiswayyouareabletolevel loadyourproductionbothintermsofquantityandtypes 1 Prod1 4 Prod3 2 Prod2 3 Prod1 REPEAT MixedAssemblyLine ProductionSequencebyType Ifproducedinbatches onlytheModel1 swillmeetTakttimes Ifproducedtoasequence 2unitswillbeproducedin2Takttimes Let sshowhowwevalidatethis Model LineTakt Takt CycleGraph Part Quantity PartRouter 1 3 2 7 5 7 5 7 5 SeeStdWorkComboSheetforexample Onesheetiscreatedforeachoperator SCT 25 SCT 40 SCT 30 7 6 6 6 7 6 13 8 12 7 5 9 7 5 TaktBuildTime ofOperations Takt ActualBuildTime SCT Model TBT Model ABT Model Objectives ProducetoTaktTime understandingno2productswillhavetheexactsameABT ThesumoftheDTotiszeroEveryproductisproduceatleastonceNoproductisproducedtwiceinarow Createaproductsequencewhere 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 M