精益生产之超市系统ppt课件

SupermarketSystem超市系统,ActivitySWNo.:4.5.7SupermarketSystemRevision#:004Lastimproved:06-Aug-2013Improvedby:A.Meester,ObjectivesofthisModule这个模块的目标,Participantswillbeableto:参与者能够Identifywheresupermarketsareneededwithinavaluestreamtosupportapullsystem识别出在价值流的哪里需要设置超市来支持拉动系统UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用PFEP数据库来正确的估算及维护超市Linksupermarketstotheoverallkanbansystemsandconveyanceroutes将超市与整个看板体系及运输路线链接起来,Topics主题,WhatisaSupermarket?什么是超市？ThreeStepsofSupermarketDesign超市设计的3大步骤SupermarketLocation超市地址SupermarketSizing超市大小PFEP(PlanforEveryPart)DatabasePFEP数据库DesignDeliveryRoutes设计交付路线RunningtheSupermarket运行超市GroupExercises团队练习,JargonBuster专业术语,Supermarket超市PFEP(PlanforEveryPart)单个零件计划Addresssystem地址系统Kanban看板Routes路线VMI供应商管理库存,JargonBusterPFEP?Supermarket?Addresssystem?,WhatisaSupermarket?什么是超市,PULL拉动,Supermarkets超市,Rawmaterials原材料,In-processstock在制品库存,Finishedgoods成品,WhatisaSupermarket?什么是超市？,Adeliberatelydesignedmaterialstoresareawithcontrolledquantitiesofmaterials故意设定的区域储存可控数量的材料Thedownstreamprocesstakeswhatisneededandthesupermarketowner(theupstreamprocess)replenishments下游工序拿取需要的材料，超市的所有人（上游工序）进行补料Unliketraditionalstoresarea,noorderforms,paperworktransactions,orstockrequisitionsareneededotherthankanban不同于传统的储存区域，没有除看板以外的订单格式，纸质的交割或者物料申请,HeijunkaBox,FinishedGoodsSupermarket成品超市,1,4,3,WhatisaSupermarket?什么是超市,RawMaterialsSupermarket原材料超市,2,5,PartsSupermarket零件超市,WhatisaSupermarket?什么是超市？,Amaterialstoresareawhich:物料储存区：Putsmaterialclosetopointofuse将物料放置在靠近使用点Eliminatesshortages消除物料短缺现象Setsminimumandmaximumlevelsforinventory设定最大库存及最小库存量Usesfloorspaceefficiently更有效的利用空间Simplifiesorderingandmaterialhandling订购及物料搬运简单化Removesnonvalueaddedactivities:(receiving,puttingaway,kitting,counting,cycling,requisitions)消除不增值的动作：（收货，摆料，配料，点数，循环，申请）Improvesmaterialflowintheproductcells改善生产线的物料流程Andmakesthestatusofmaterialsvisible让物料状态可视化,WhatisaSupermarket?什么是超市？,Simplevisualsystemsshowmaterialflow简单可视化的物料流Location,addressandquantitycontrol位置，地址及数量管理,WhatisaSupermarket?什么是超市？,Supermarketsandmaterialpresentation超市及物料准备Achieveexcellent6S实现卓越的6SPresentmaterialsandtheirinformationvisibly让物料及信息更加目视化Eliminatedefects消除不良Usegravityfeeds使用重力送料Reducemotionforloadingandunloading减少上料及退料的动作MaintainFIFO维护先进先出,ThreeStepsofSupermarketDesign超市设计的3大步骤,Setsupermarketlocation设置超市的地址Wherewillsupermarketshelpusmost?超市设置在哪里更有帮助Determinesupermarketsizing定义超市大小PFEPdatabasetodeterminequantitiesPFEP数据库来定义数量Spacerequired空间的要求Designdeliveryroutes定义送货路线Standardworkforwithdrawalanddeliveryofpartsandcontainers补料及送货及周转箱的标准作业,Step1:SupermarketsLocation第一步：超市选址,Typicalsupermarketlocations典型的超市地址Attheendoftheproducerprocesswheneverpossible,asarule在有可能的情况下设置在在生产工序的尾部Atpointofuse(VMI,Citems)在使用点（供应商管理库存，C类零件）Atreceiving(forexternalsuppliers)在收货区（外部供应商）,Closetothepointofuseaspossible越靠近使用点越好Directdeliverytothesupermarket直接交货到超市Minimizerepeatedhandling将重复搬运减少到最少,1,2,Step1:SupermarketsLocation第一步：超市选址,Step1:SupermarketsLocation第一步：超市选址,StandardApproach标准的方法Locatesupermarketsattheendofthesupplierprocessorproductionline将超市设置在供应流程的最尾端或生产线Makeproblemsimmediatelyvisibletotheproducerprocess将问题立刻可视化的传递到生产工序Donotsacrificevisibilityforthesakeofoptimizingtheworkofmaterialhandlers不为优化物料搬运工作的缘故而牺牲可视化,Step1:SupermarketsLocation第一步：超市选址,Line生产线F1,Line生产线F2,Line生产线F3,Supermarket超市1,Supermarket超市2,Supermarket超市3,Line生产线A1,Line生产线A2,Line生产线A3,Step1:SupermarketsLocation第一步：超市选址,CentralizedSupermarket集中化的超市Duetohighvolumeandormix,thefacilitylayout,thesupermarketmaynotalwaysfitattheendoftheline因为大批量或多品种，工厂格局的原因，超市也许不能总是设置在生产线的尾部。Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstreamanddownstreamprocesstominimizematerialhandling集中化的超市用于当他们设置在上游及下游工序来减少物料搬运Supermarketsforincomingpartsforassemblymaybelocatednearthereceivingdock来料零件超市可以设置在靠近收货区,Step1:SupermarketsLocation第一步：超市选址,Line生产线F1,Line生产线F2,Line生产线F3,ConsolidatedSupermarket统一的超市,Line生产线A1,Line生产线A2,Line生产线A3,GroupExercise#1团队练习#1,Goseeactivity去现场看WalkthroughthevaluestreamfromendtoendUsevaluestreammapstoassist通过现场查看整个价值流在价值流程图的帮助下Identifylocationswithinsitevaluestreamswheresupermarketsareneeded在价值流程图中识别出哪里需要超市Documentonfuturestatemapswhereapplicable将适用的地方在未来价值流程图上体现Wherecanwe哪里我们可以Supportkanbansystemefforts?支持看板系统？Minimizeinventorylevels?最小化库存水平？Improvevisibilityandeliminateshortages?提升可视化及消除物料短缺？,Step2:SupermarketSizing第二步：超市大小,Howmuchofeachpartwillwekeeplineside?每个零件我们需要多少在生产线旁Frequencyofconveyance运输的频率Quantityofconveyance运输的数量Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartofanoverallroute通过高频率小批量的交付来最小化生产线旁的物料,Step2:SupermarketSizing第二步：超市大小,Inordertodeterminesupermarketsize,weneedtoknow为了定义超市的大小，我们需要知道Usagevolume(quantity)用量的多少（数量）Whatistheschedulingmethod?什么是计划的方法？Hastheusagebeenleveled?用量被均衡化了吗？Hasthemixbeensmoothed?生产种类被稳定了吗？Isthereafrozentimewindow?有一个冻结的时间窗口吗？Deliveryfrequencyupstream上游工序的交货频率Deliveryquantity交货数量Containersize周转箱大小Locationofsignal信号的位置Weight重量Andmore等等,ThePlanforEveryPart(PFEP)answers:单个零件计划解答了：Howisthepartpurchased?零件如何进行采购？Whoproducesthispart?谁生产这个零件？Howisitpackaged?零件如何包装？Howisthepartreceived?零件如何收货？Whereisitstored?在哪里储存？Whereisitspointofuse?在哪里使用？Howisitdeliveredtopointofuse?如何交付到使用点?Andmuchmore.等等,Step2:SupermarketSizing第二步：超市大小,SamplePFEPData数据的案例,PFEP(PlanforEveryPart)DatabasePFEP数据库,SamplePFEPData数据的案例,PFEP(PlanforEveryPart)PFEP数据库,PFEPDatabasePFEP数据库,PFEP(PlanforEveryPart)DatabasePFEP数据库,Foreachpartnumberinthesupermarket:在超市中的每个零件编号：Whatistheaveragedailyusage?平均每天用量是多少？Whatistheincomingshipmentsize(daysusage)?来料出货的大小（多少天的用量）？Howmuchbufferisrequired(daysusage)?需要的缓冲库存（多少天的用量）？,PFEP(PlanforEveryPart)DatabasePFEP数据库,PlannedMaximumInventory计划的最大库存=Dailyusage每天用量xShipmentsizeindaysusage出货的大小（多少天的用量）xDaysusagepurchasedpartssafetystock（采购件安全库存使用的天数）,Safetystock:安全库存：Howmanydaysinventorydoweneedtoguardagainst我们需要多少天的库存来保障Supplierissues?供应商问题？Transportationissues?运输问题Internalissues?内部问题？,DeterminingBufferSize定义缓冲库存的大小,MaximumContainerQuantity最大周转箱数量=PlannedMaximumInventoryLevel计划的最大库存水平/ContainerQuantity包装箱数量,CalculatingContainerQuantity计算周转箱数量,UpdatingthePFEP更新PFEP,GroupExercise#2团队练习#2,Supermarketsizing超市大小CreatePFEPDatabase创建PFEP数据库Usethisinformationtosizethesupermarket使用这些信息来确定超市大小Designpilotsupermarketbasedonsizeandeaseofstorageandretrieval根据尺寸及储存的容易程度设计试产的超市的大小,Step3:DesignDeliveryRoutes第三步：设计送货路线,HeijunkaBox均衡化生产箱,FinishedGoodsSupermarket成品超市,1,4,3,RawMaterialsSupermarket原材料超市,2,5,PartsSupermarket零件超市,Step3:DesignDeliveryRoutes第三步：设计送货路线,Setroutedrivetimeatnomorethan33%ofthenon-loadtimeoftheroute设置路线运输时间不超过路线空载时间的33%Onlymovematerialwhenauthorizedbythepullsignal只有在收到被授权的拉动信号后才移动物料Ensurekanbansystemrulesarefollowedandworkersremovepullsignalswhenusingthefirstpieceinacontainer确保员工按照规则操作：在使用周转箱中第一个物料时员工发出信号Synchronizethelunchandbreaktimesofthematerialhandlerontheroutewiththoseoftheworkersintheareasbeingsupported将物料搬运员与生产线员工的午饭时间及休息时间进行同步Followspecificroutetimesandfrequenciesandinsurethatroutedeliveryisnotinterruptedforanyreason按照特定的路线时间及频率来保证运输交货不被任何原因被打断Standardizeworkonthedeliveryroutetoeliminateallwastedmotionandimprovecontinuously标准化在交货路线上的作业来消除所有的动作浪费及持续进行改进,Step3:DesignDeliveryRoutes第三步：设计送货路线,Designateone-wayandtwo-wayaislesalongnaturalflowpathsinthefacility指定的单向和双向沿自然流动路径的通道设施Designallroutestoflowthroughtheplantandbacktothesupermarket设计所有的通过工厂的路线及返回到超市Designstopsanddeliverypointsalongtheroutetominimizethenonvalue-addedworkforthematerialhandler在路线上设计停止点及交货点来最小化物料员非增值的工作Designstopsanddeliverypointsalongtheroutetominimizenonvalue-addedworkfortheoperatorwhoisbeingsupplied在路线上设计停止点及交货点来最小化生产线员工非增值的工作Startwithone-hourdeliveryroutes,aimingfora95%efficiency(57minutes)从一小时的送货路线开始，目标达到95%的效率Setloadingtimeatthesupermarketat33%orlessofthecoupleddeliverytime在超市设置取料时间是总交货时间的33%或更少,MaterialHandlerStandardWorkExample物料员标准作业的案例,Step3:DesignDeliveryRoutes第三步：设计送货路线,PUSH-basedMaterialHandlingRoute推动-基于物料搬运路线,C,C,B,A,C,C,B,B,A,A,Supermarket超市,C,B,A,Bulkdelivery(E.g.4hoursupply)交货大小Requiresextraspace需要额外的空间,A,A,A,B,B,B,B,A,C,C,C,C,C,1,2,3,PULL-basedMaterialHandlingRoute拉动-基于物料搬运路线,C,B,A,C,C,B,B,A,A,Supermarket超市,C,B,A,1,2,3,4,5,6,7,Time-fixeddelivery(30minutessupply)固定时间的交货Mixedloadconveyance多品种的运输,Finishedgoodssupermarket成品超市,ProductionLine生产线,LinkSupermarketwithPullSystem将超市与拉动体系进行链接,Tofinishedgoodssupermarket送至成品超市,Heijunkabox均衡化生产箱,GroupExercise#3团队连续#3,Designroutes路线设计Designmaterialhandlingroutesbetweensupermarketsandpointsofuse在设计物料在超市及使用点间的运输路线Practice,timeanddocumentthework练习，时间及将工作文件化Documentprovisionalstandardwork,practiceandimprove文件化暂定的标准作业，练习及提高,RunningtheSupermarket运行超市,SupermarketGoldenRules超市的金科玉律Theproducingprocesstakesownershipoftheinventoryinthesupermarket(regardlessofphysicallocation)生产工序负责超市中的库存（不管实质的地址）Thedownstreamprocessregularlywithdraws(pulls)whattheyneedintheamounttheyneed下游工序定期的取他们所需要的物料Clearsignalsareexchangedbetweenupstreamanddownstreamprocesseswhenmaterialiswithdrawnf