GEEAN现场管理资料瓶颈管理F英文版.ppt

Ccapacity ppt 1 APACIT 1994GeneralMotorsCorporation Allrightsreserved Y 2 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved SUPPLIERDEVELOPMENTTOOLSCAPACITYWORKSHOPEXECUTIVESUMMARY PURPOSE SCOPE METHOD AssistSupplierintheIdentificationAndTheEliminationofPotentialProductionShortfallsBetweenCapacityandRequirements MayIncludeAllFunctionalAreasAndProductionOperations Datacollection workshop targettedactions LOGISTICS ConductedUtilizingJointGM SupplierTeam capacity ppt 22 07 01PDF文件使用 pdfFactory 试用版本创建 Q CHECK C OPERATION Identifypilotarea Makeallpeopleaffectedawareofwhatisgoingtohappen Selectteammembers Identify opportunitiestoimproveAnalyze select Developactionplan applyzero low costideasfirst Implementnewmethod A S A P Verify adjust LookfornewopportunitiesRecognizeeffortsofpeople Definecurrentsituation OPERATION NO DESCRIPTIONOFOPERATION W FROM TO ELEMENTTIMEHANDWORKMACHINEALK QUANTITYPERSHIFT SHIFT STANDARDIN QUALITYPROCESSSTOCK CUSTOMERCYCLETIME OPERATORCYCLETIME CRITICALSAFETY SupplierDevelopmentWorkshopProcess Discussplan withstakeholdersWORKSTATIONAREADRAWNTOSCALE03 23 94 1994GeneralMotorsCorporation Allrightsreserved PDF文件使用 pdfFactory 试用版本创建 capacity ppt 4 CAPACITYWORKSHOPAGENDA IntroductionTheoryofConstraintOverview5StepImprovementProcessDataCollection DataAnalysisConstraintIdentificationStrategyImplementationMeasureImprovementWrap Up 1994GeneralMotorsCorporation Allrightsreserved 2 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved TheoryofConstraintOverviewFLOW capacity ppt 52 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved BOTTLENECKAnOperationWhichLimitstheOverallOutputofaSeriesofOperations1 000900 800700600500 4003002001000 1 2 3 4 5 6 7 8 Bottleneck Demand CAPA CITY OPERATIONCAPACITY DEMAND capacity ppt 62 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved CONSTRAINTABottleneckbecomesaConstraintwhenitcannolongersatisfythedemandplaceduponitThus anyresourcewhosecapacityislessthanthedemandplaceduponitisaConstraint1 000900 800700 6005004003002001000 1 2 3 4 5 6 7 8 Constraint Demand CA PACITY OPERATIONCAPACITY DEMAND capacity ppt 72 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved DEFINITIONAconstraintisthatactivitywhichmostlimitstheorganization sabilitytoachievehigherperformancerelativetoitspurposeorgoal TypesofConstraintsCapacity CapacityDemandPolicy ManagementDecision capacity ppt 82 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved ConstraintTypesCapacity Customerswantmoreproductthancanbesupplied Symptoms equipmentoverworked noPreventativeMaintenance highpremiumcosts overtime Example StampingPresscanonlymake5 000partsperday butthecustomerrequires6 100 Market Customersdonotwantasmuchproductascanbeproduced Symptoms wastedequipment highercostsincurred lowefficiency Example CastingforsixhourswiththemachineidlefortheremainderofthedayPolicy Managementdecisionsdictatehowthebusinessshalloperate Symptoms unabletochange highcostsolutionsinsteadoflowcost Example tagreliefnotusedduringaconstraint maximumovertimeallowedperweek resultsinmoremachinerybeingused capacity ppt 92 07 01PDF文件使用 pdfFactory 试用版本创建 capacity ppt 10 CONSTRAINTSYMPTOMS BuildupofInventoryPriortoanOperationDownStreamOperationsStarvedforPartsExpeditingExcessiveMaterialHandlingatanOperationPremiumFreightOvertimeNoTimeforPreventativeMaintenanceConstantScheduleChanges 1994GeneralMotorsCorporation Allrightsreserved 2 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved 5StepImprovementProcessStep0 EstablishBaselineStep1 IdentifyConstraint BottleneckStep2 ExploitConstraintStep3 Subordinatenon constraintsStep4 Elevatea RunAlloftheTimeb AddCapacityStep5 Restudy capacity ppt 112 07 01PDF文件使用 pdfFactory 试用版本创建 RepairLoop s Station BuffersParallel Power FreeConveyor ISTHEREACONSTRAINT Back UpStation Buffers FinishedProductExitPoint RawMaterialEntryPointcapacity ppt 12 ParallelStationsHERE HERE StationsHERE AccumulatingConveyorBack Up HERE 1994GeneralMotorsCorporation Allrightsreserved HERE 2 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved ISONEPARAMETERSUFFICIENT 10 20 30 40 50 1000 89 190 280 300 10 20 30 40 50 65 10 20 30 40 50 4 7 10 20 30 40 50 10 20 30 40 50 1 0 10 20 30 40 50 65 2 MeanTimeBetweenFailures JobsPerHour OccurrencesofFailure MeanTimeToRepair6 5 Scrap Lookingattheseindividualreports whatwouldyousayisthemainbottleneck 67 80 75 71 4 5 5 3 12 8 0 44 4 4 2 0 1 5 4 2 2 0 1 0 0 1 0 4 37 6 4 6 TotalDowntime87 5 0 3 capacity ppt 132 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved THETYPICALPLANTENVIRONMENT PlantOperatesataProductivityPlateau WithHighThroughputVariability PlantThroughputIsOften10 to50 BelowDesignedRate LostProductionIsMadeupWithOvertime ProductionBlamesMaintenance MaintenanceBlamesProduction GeneralAssemblyBlamesPaint PaintBlamesBody Etc InManyofOurPlants We reCollectingVastQuantitiesofDataandWe reNotUsingIt InSomeofOurPlants NOProductionMonitoringIsPerformed High Tech andLow TechSystemsComplicateAnalysisoftheProductionProcess capacity ppt 142 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved 5StepImprovementProcessStep0 EstablishBaselineStep1 IdentifyConstraint BottleneckStep2 ExploitConstraintStep3 Subordinatenon constraintsStep4 Elevatea RunAlloftheTimeb AddCapacityStep5 Restudy capacity ppt 152 07 01PDF文件使用 pdfFactory 试用版本创建 Step0 EstablishBaseline capacity ppt 16 Goalofthisstepistodetermine Wherearewetoday DefinethescopeofthesystemDeterminethemeasurementsystemtouse ifyouknowitatthispointCompletetheCapacityAnalysisWorksheet LogicalProcesstoIdentifyanyConstraint EstimatestheCapacityatEachOperation NoteAdditionalConstraints Market Policy 1994GeneralMotorsCorporation Allrightsreserved 2 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved CapacityAnalysisTool Requiresafewsimpleinputs CapacityRequirements ScrapandRework Downtime ScheduledandUnscheduled OperationCycleTimesOutputincludes EstimationofTotalCapacityofOperation TotalNumberofShiftsRequiredperWeektoProduceRequirements OverallEquipmentEffectivenessMeasurement FlagforConstraintOperations capacity ppt 172 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved Step0 Re CompletionoftheCapacityAnalysisWorksheet NotetoSDEs ShowanexampleoftheCapacityAnalysisWorksheet Workthroughthesheetwiththesupplierwithasmuchactualdataaspossible Accuracyofinformationisimportant asthiswillformthebasisfortheremainderofthediscussion Brainstormingforimprovementscanbestructuredtofolloweachoneoftheinputstothecapacityanalysis capacity ppt 182 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved 5StepImprovementProcessStep0 EstablishBaselineStep1 IdentifyConstraint BottleneckStep2 ExploitConstraintStep3 Subordinatenon constraintsStep4 Elevatea RunAlloftheTimeb AddCapacityStep5 Restudy capacity ppt 192 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved Step1 IdentifytheConstraint Bottleneck If shifts weekrequired shiftsavailable thenaconstraintexists Note Thiswillbeshownbya ontheCapacitySpreadsheetIfnoconstraintexists examinetheoperationsforthegreatestnumberofshiftsrequired andthelowestnetcapabilityperday Theoperationwiththegreatestnumberofshiftsclosesttotherequirementisthebottleneck Notethatconstraintsmaynotbeimmediatelyvisibleonthecapacityspreadsheetduetointeractionsbetweenoperations buffers Shiftsavailable 15Requirement day 450 capacity ppt 202 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved 5StepImprovementProcessStep0 EstablishBaselineStep1 IdentifyConstraint BottleneckStep2 ExploitConstraintStep3 Subordinatenon constraintsStep4 Elevatea RunAlloftheTimeb AddCapacityStep5 Restudy capacity ppt 212 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved Step2 ExploitConstraint RunconstraintatitsbasiccapacityinisolationScheduleOperationEffectivelyDon tWasteOutput Eliminatedefectivepartsbeforetheyarrive Makesurepartsarenotscrappedlaterintheprocess Eliminatereworkthatmustgobackthroughconstraint Improvethetoolsorgaugesused Improveyieldbyassuringthequalityoftheprocess Rushto before Handlewithcare after capacity ppt 222 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved Step2 ExploitConstraint continued OperatorRulesofEngagement Runmachineswhenyouhavematerial Dosomethingproductivewhenyoudon thavematerial setup PM Cross trainworkerstopreventidletimeduetoabsenteeismEliminateBlockandStarvethrougheffectivebuffering i e partsbeforeandspaceafterwards capacity ppt 232 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved Starving Blocking NeverStarveaConstraint UtilizeBufferManagement Placebufferinventoryaheadtoassureitalwayshaspartstorun LoadpartsaheadtoensureconstraintrunsNeverBlocktheConstraint De coupletheOperations Assurepartsarepulledawaysooperationdoesn tstop enoughracks containers space Unloadaftertheconstraintifthesystemdownstreamisdown capacity ppt 242 07 01PDF文件使用 pdfFactory 试用版本创建 STARVEDSystem NoJobstoWorkOn BLOCKEDSystem Choked NoPlacetoputJob DESIREDSystem L uuZZZZZZ LBlockedStation FullBuffe r uuZZZZZZFailedStation FailedStation EmptyBuffer StarvedStation JWorking Station JConstraintWorking Station 1994GeneralMotorsCorporation Allrightsreserved STARVE BLOCKNote Thisisapplicablefortheconstraintoperationonly andnotalloperations MaxMinBuffer MaxMinEmptyBuffer capacity ppt 252 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved DE COUPLINGTakingonecontinuousprocessandbreakingitinto2ormoresmallerprocesseswithasmallinventorybetweeneachprocessinordertoreducethelevelofdependency CoupledDe coupled Buffer AutoTransfer Machine Machine Machine Constraint Machine Machine Machine AutoTransferAutoTransfer capacity ppt 262 07 01PDF文件使用 pdfFactory 试用版本创建 BLOCK 1994GeneralMotorsCorporation Allrightsreserved CONSTRAINTS BOTTLENECKSFLOW STARVEcapacity ppt 272 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved 5StepImprovementProcessStep0 EstablishBaselineStep1 IdentifyConstraint BottleneckStep2 ExploitConstraintStep3 Subordinatenon constraintsStep4 Elevatea RunAlloftheTimeb AddCapacityStep5 Restudy capacity ppt 282 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved Step3 SubordinateOtherOperationtoRuntheConstraint Subordinate Optimize Resourcesinfavorofrunningtheconstrainingoperation Movepeoplefromnon constraintstoconstrainingoperationeveniftheyaren tfinishedatthenon constraintPerformmaintenanceontheconstraintoperationbeforeothersRunallothermachinestoeliminatestarve block Improvingthroughputonanyoperationotherthantheconstraintdoesnotimprovethesystem soverallthroughput capacity ppt 292 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved 5StepImprovementProcessStep0 EstablishBaselineStep1 IdentifyConstraint BottleneckStep2 ExploitConstraintStep3 Subordinatenon constraintsStep4 Elevatea RunAlloftheTimeb AddCapacityStep5 Restudy capacity ppt 302 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allrightsreserved Step4a Elevate RunAlloftheTime KeepItRunning Runthroughlunch breaks tagrelief etc Afterchangeover runproductionsimultaneouslywithfirstpieceapproval Reducenumberofsetupsbyprocessingfamiliesofjobsthatrequiresimilarsetups Reducesetuptime Improvepreventativemaintenancetoreducebottleneckdowntime capacity ppt 312 07 01PDF文件使用 pdfFactory 试用版本创建 1994GeneralMotorsCorporation Allright