精益生产之2箱补充拉系统2-bin_replenishment_pull(中英文对照)

2-Bin Replenishment Pull,Introduction to 2-Bin Replenishment PullLine-side versus Point-of-Use Stocking2-Bin Data Needs and CalculationsInventory Disposition OptionsCard Triggered 2-Bin Process1-Bin SystemsAppendix,RD011202,2-Bin 补充拉系统,2-箱补充拉系统的介绍线旁VS使用点库存2-箱数据的要求和计算库存部署选择卡触发2-箱流程1-箱系统附录,RD011202,2-Bin Replenishment Pull,3,Lean Six Sigma Improvement Process Road Map,Analyze,Control,Improve,DefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDF,MeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability Analysis,AnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical Xs,ImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot Solution,ControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation Opportunities,Measure,Define,Project ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad Charts,Process MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&R,Cp & CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEA,BrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt Charts,Check SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-Yoke,Revised 1-12-02,2-Bin Replenishment Pull,4,Learning Objectives,Understand the various types of bin replenishment systemsKnow the benefits of a bin systemUnderstand when to use a bin SystemBe able to size (calculate) all the parameters for a bin system,2-Bin Replenishment Pull,5,课程目的,理解箱补充系统的不同类型知道一个箱系统的好处理解何时使用一个箱系统能够去计算一个箱系统的所有参数,2-Bin Replenishment Pull,6,Whats in It for Me?,Be able to apply this tool to a Black Belt projectAble to implement a Bin system,2-Bin Replenishment Pull,7,我学到了什么?,能够在黑带项目中应用这个工具能够实施一个箱系统,2-Bin Replenishment Pull,8,2-Bin Replenishment Pull Introduction,A 2-Bin Replenishment Pull System is a simplified version of a standard replenishment pull system and maintains the benefits:Establishes strategically located buffers of parts within a processRaw materialManufactured partsPurchased partsFinished goodsDe-couples the supplying process from the consuming process via the buffer inventoryPart replenishment is “triggered” based on consumption,2-Bin Replenishment Pull,9,2-箱补充拉系统的介绍,2-箱补充拉系统是一个标准的补充拉系统的简化版本，其好处是：在一个流程中建立战略性的零件缓冲区原材料制造的零件采购的零件成品通过缓冲库存将供应过程和消耗过程联系起来零件的补充是基于消耗而触发的,2-Bin Replenishment Pull,10,What Is a 2-Bin Replenishment?,For many parts in a process, a 2-Bin system can be used to replenish the parts versus a synchronous supply:A bin has enough parts/supplies to cover a calculated period of usage at the point-of-use.When the bin runs out, a 2nd bin is there to take its place while the “1st” is being refilled/replenished.There are two primary replenishment locations: Line-Side and Point of Use,2-Bin Replenishment Pull,11,2-箱补充拉系统是什么?,对于在流程中的众多零件而言，一个2-箱系统可以被用来补充零件相对于同步供应:一箱有足够零件/供应品以满足在使用点上已计算出的用量周期。当第一箱用完了后，在补充/重新装料时，第二箱取代第一箱的位置继续满足使用。有两个主要的补充地点：线旁和使用点,2-Bin Replenishment Pull,12,Benefits of 2-Bin Replenishment,Organized and overall cleaner appearance of stored materialsReduced frequency of orders submitted to the stockroom/vendorReduced number of trips for re-supplyBetter management of inventory on the shop floorMore predictable inventory costsImprove employee productivity by:Eliminating part/supply shortages at the point-of-useReduce time wasted by personnel/supervision retrieving supplies/inventory from the stockroom and/or vendorsEliminate lost or misplaced material2-Bin Replenishment can be used for office/safety supplies, production inventory, production supplies even at home!,2-Bin Replenishment Pull,13,2-箱补充拉系统的好处,存储的材料外观非常清洁和有条理提交给库房/供应商的频率减少重复供应的差错数量减少了现场库存的管理更好库存成本更具有预测性提高员工生产率:排除在使用点的零件/供应短缺减少由于人员/管理等，从库房和/或供应商重新找回供应/库存的时间浪费排除材料的丢失或放错地方2-箱补充可以被使用在办公室，安全供应，生产库存，生产供应甚至在家里!,2-Bin Replenishment Pull,14,When to Use 2-Bin Replenishment Pull,Repetitive product offering/processRelatively consistent demand/volume (low variability)Part/supply shortages are a consistent/costly problemPart/supply inventory costs are “out of control” due to:Lost or misplaced parts/suppliesLack of issue/dispersal discipline or control,2-Bin Replenishment Pull,15,何时使用2-箱补充拉系统,重复的产品供应/流程重复稳定的需求 (底变异)零件/供应短缺是常事，且是一个代价很大的问题零件/供应库存成本是失控的，由于：零件/供应品丢失或放错地方缺乏投料/分发的一致性或控制,2-Bin Replenishment Pull,16,What Is a Bin?,Doesnt necessarily look like a “bin”Can be a standard plastic bin (Acro-bin)Can also be the box/container the part/supply is shipped in (also called a “standard pack” purchasing definition)When the box/container method is used, a “bin” can be one standard pack or several standard packs. Examples:1 box of screws2 boxes of screws1 drum of oil30 bags of connectors1 roll of labels4 tubes of sealant,2-Bin Replenishment Pull,17,一箱是什么?,这并不是说一定要看上去像个“箱子”它可以是一个标准的塑料箱它也可以是用于零件运输的一个盒子或容器 (也可以用采购的定义被称为一个“标准包” )当盒子/容器方式使用了后, 一个“箱”可以是一个标准的包或几个标准包。例如：1 盒螺钉2 盒螺钉1 打油30 包连接器1 卷标贴4 管子密封剂,2-Bin Replenishment Pull,18,2-Bin Replenishment Data Parameters/Needs,Demand / Usage (DMD)Typically expressed in terms of Average Daily Usage (ADU) in unitsLead Time (LT)The time it takes from when a trigger is sent to when replenishment arrivesIn this case, can also be thought of as “Restocking Time”Order Frequency (OF)If orders/triggers are sent at scheduled times (i.e., not every day, such as once per week)Typical 2-Bin systems do not use an Order Frequency, as replenishment can occur every day/shift (or more)Box/Container QuantityIf stock/supply room or vendor does not break down shipping quantity, then the bin quantity may be set equal to some multiple of the box/container quantity (standard pack) that the part/supply is shipped inSafety StockTypically 1/2 the max (LT, OF) * DMD, may be set otherwise dependent on individual conditions,2-Bin Replenishment Pull,19,2-箱补充系统数据参数/要求,需求/使用 (DMD)一般来说用平均每天用量（ADU）来表达交货期 (LT)从补充需求触发到补充品到达的时间。在这里，也可以被认为是“再进货时间”。订单频率 (OF)如果订单/触发信号的发放是按预定时间（如：并不是每天，而是每周一次）2-箱系统是不需要用订单频率的。补充可以发生在每天、每班（或更多）盒子/容器数量如果库房或供应商没有列出运输数量的明细分类，那么箱数量可以设定为等于运送零件/供应品的若干盒子/容器数量安全库存一般来说的设定为1/2 max (LT, OF) * DMD, 否则根据独立的情况来看,2-Bin Replenishment Pull,20,Stock Room or Vendor,1,2,FullBin/Card,Move 1 to 2 when 2 is pulled,Send Trigger,UseComponents,EmptyBin/Card,Point-Of-Use (POU) Locations or Work-In-Process (WIP),2-Bin Replenishment (“Line-Side” Stocking),Reduces part/supply shortages increasing productivityFacilitates WIP reductionWill result in significant productivity improvements in stock/supply roomReduces/eliminates stockroom impact on lot sizesMay simplify inventory/cycle count processes,Line-SideStorage,LTOF,2,2-Bin Replenishment Pull,21,库房或供应商,1,2,添满的箱/卡,当 2 被拉动时，移动 1 到 2 ，发送触发信号,使用的部件,空的箱/卡,使用点位置 (POU) 或工作库存 (WIP),2-箱补充 (“线旁” 库存),减少零件/供应品库存，增加生产效率促进 WIP的降低将导致在库房里的显著的生产力提高降低/消除库房在批数量上的影响可以简单化存货/周转的计算流程,线旁库存,LTOF,2,SS/2,DMD,OF),LT,max(,箱数量,+,*,=,2-Bin Replenishment Pull,22,FullBin/Card,Pull from 1 until empty, send trigger and pull from 2 until empty, send trigger, etc.,UseComponents,EmptyBin/Card,2-Bin Replenishment (“Point-of Use” Stocking),LTOF,1,2-Bin POU stocking is used when re-stocking is not an issue.,Stock Room or Vendor,Point-Of-Use (POU) Locations or Work-In-Process (WIP),2,2-Bin Replenishment Pull,23,拉动从1开始直到用完为止, 发送触发信号，然后拉动从2开始直到用完为止，发送触发信号, 等等.,使用部件,2-箱补充(“使用点” 库存),LTOF,1,SS/2,DMD,OF),LT,max(,箱数量,+,*,=,当重新备库存不是一个问题时，使用2-箱 POU 库存,库房或供应商,2,添满的箱/卡,空的箱/卡,使用点位置 (POU) 或工作库存 (WIP),2-Bin Replenishment Pull,24,2-Bin Replenishment Calculations,Bin Quantity = Max(LT, OF) + SS/2If replenishing in standard packs, Bin Quantity is rounded up to the nearest standard pack multipleExample:Calculate the Bin Quantity for the following (standard pack replenishment):Part Number:40567Description:Rubber GlovesDemand/Usage:25 pairs/dayLead Time:2 days (trigger - stock/supply room - replenishment)Order Frequency:N/ABox Quantity:50 pairsBin Quantity= Max (2 days, N/A) * 25 pairs/day + .5 * Max (2 days, N/A) * 25 pairs/day /2= 63 pairsBut we have to round up to the nearest standard pack, so:Bin Quantity = 100 pairs = 2 boxes,2-Bin Replenishment Pull,25,2-箱补充的计算,箱数量 = Max(LT, OF) + SS/2如果是标准包的补充，箱数量应该是近似于标准包的倍数举例:计算下列数据的箱数量 (标准包补充):零件号码:40567描述:橡胶手套需求/用量:25 双/天交货时间:2 天 (触发 库房 补充)订单频率:不适用箱数量:50 双箱数量= Max (2 天, N/A) * 25 双/天 + .5 * Max (2 天, N/A) * 25 双/天 /2= 63 双但是我们要取一个近似标准箱的数量，所以:箱数量 = 100 对 = 2 箱,2-Bin Replenishment Pull,26,Exercise #1:2-Bin Replenishment,Calculate the Bin Quantity for the following supply item in a 2-Bin Line-Side Replenishment process directly linked to the supplier:Part Number:80886Description:Printer PaperDemand/Usage:22 reams/dayLead Time:4 days (trigger - purchasing - supplier - receiving - replenishment)Order Frequency:5 daysBox Quantity:10 reamsBin Quantity = Max ( , ) * + .5 * Max ( , ) * /2= . But we have to round up to the nearest standard pack, so:Bin Quantity = = .,2-Bin Replenishment Pull,27,练习 #1:2-箱补充,如下供应品的2-箱线旁补充流程直接连接着供应商，计算箱数量:零件号码:80886描述:打印纸需求/用量:22 令/天交货时间:4 天 (触发 采购 运输 收货 补充)订单频率:5 天箱数量:10 令箱数量 = Max ( , ) * + .5 * Max ( , ) * /2= . 但是我们要取一个近似标准包的数量，所以:箱数量 = = .,2-Bin Replenishment Pull,28,Exercise #2:2-Bin Replenishment,Calculate the Bin Quantity for the following assembly item in a 2-Bin Line-Side Replenishment process linked to the warehouse :Part Number:A44B2Description:4 Dia. Steel ExtrusionDemand/Usage:225 ft/dayLead Time:1 day (trigger - warehouse - replenishment)Order Frequency:N/AExtrusion Length:30 ftBin Quantity = Max ( , ) * + .5 * Max( , ) * /2= . But we have to round up to the nearest standard pack, so:Bin Quantity = = .,2-Bin Replenishment Pull,29,练习 #2:2-箱补充,如下组装线2-箱线旁补充流程直接连接着供应商，计算箱数量:零件号码:A44B2描述:直径4“ 的钢铁拉丝需求/用量:225 英尺/天交货时间:1 天 ( 触发 仓库 补充 )订单频率:不适用拉丝长度:30 英尺箱数量 = Max ( , ) * + .5 * Max( , ) * /2= . 但是我们要取一个近似标准包的数量，所以:箱数量 = = .,2-Bin Replenishment Pull,30,1,2-Bin ReplenishmentBin Labeling and Information,Each Bin/Storage Location should have a barcode label or tag.Make sure not to use a permanent label applied to a rack/bin, because you will eventually want to resize and may have to make new labels!Labels for Line Side Bins/Tags for Resupply BinsPart Number, Description, and Location are Printed.Bin Quantity should not be printed (requires too many label changes when resizing trigger mechanism or system will have Bin Quantity)Each Bin Location should be unique to avoid confusion when restocking.Examples are in the Appendix.,LocationPart NumberDescription,2,LocationPart NumberDescription,2-Bin Replenishment Pull,31,1,2-箱补充箱标贴和信息,每个箱/库存 地点都应该有一个条码标贴或标签确保不要用永久的标签贴在一个货架/箱。因为你将会调整大小，且贴上一个新的标贴！在线旁的需要重新补充的箱上的标贴被打印的零件号码, 描述, 地点等箱数量不应该被打印出来 ( 当调整大小时需要太多的标签变化 触发机制或系统将有箱数量)每个箱地点必须是独一无二的以避免在重新补充库存时混淆举例在附件里.,地点零件号码描述,2,地点零件号码描述,2-Bin Replenishment Pull,32,Notes on a 1-Bin System,A one bin system is an exception to the 2-bin for very slow moving parts/supplies.1-bin parts are not stored in 2-bins because of:High inventory costSpace requirementsRacking/storage cost1-bins are replenished upon stock out at the Line-Side location.Stock out impact should be low because:Parts/supplies are very low users.Parts/supplies are also at point of use when Line-Side stock out occurs.Parts/supplies are stocked in nearby stock/supply room easy to replace.,2-Bin Replenishment Pull,33,1-箱系统的注意,对于流动非常缓慢的零件/供应品来说，一个1-箱系统是2-箱系统的例外.1-箱零件不象2-箱那样被存储，因为:高库存成本空间需要货架/仓储成本在线旁的地点库存短少时，1-箱被补充。库存短少的影响应该是微弱的，因为:零件/供应品是非常少的使用者。当线旁的存货短缺发生时，零件/供应品也同样在使用点.零件/供应品被存放在库房附近容易补充.,2-Bin Replenishment Pull,34,Stock Room or Vendor,1,1,FullBin/Card,Move 1 to 2 when 2 is pulled,Send Trigger,UseComponents,EmptyBin/Card,Point-Of-Use (POU) Locations or Work-In-Process (WIP),1-Bin Replenishment (Typically from “Line-Side”),Reduces part/supply shortages increasing productivityFacilitates WIP reductionWill result in significant productivity improvements in stock/supply roomReduces/eliminates stockroom impact on lot sizesMay simplify inventory/cycle count processes,Line-SideStorage,LTOF,1,2-Bin Replenishment Pull,35,库房或供应商,1,1,1-箱补充(特别是从“线旁”),LTOF,1,添满的箱/卡,空的箱/卡,当 2 被拉动时，移动 1 到 2 ，发送触发信号,使用点位置 (POU) 或工作库存 (WIP),减少零件/供应品库存，增加生产效率促进 WIP的降低将导致在库房里的显著的生产力提高降低/消除库房在批数量上的影响可以简单化存货/周转的计算流程,线旁库存,SS/2,OF),LT,max(,箱数量,+,*,=,使用的部件,DMD,2-Bin Replenishment Pull,36,Stockroomor Vendor,1,Line POU,1-Bin Replenishment Transactions,1-Bin System inventory transactions mirror those of the 2-Bin systemFrontflush for reducing transactions but reduce overall inventory accuracyBackflush for increasing inventory accuracy (slightly) but increase number of system transactions,1,1-bin Card Part XYZ,Trigger,Replenishment,1-bin Card Part XYZ,2-Bin Replenishment Pull,37,库房或供应商,1,线 POU,1-箱补充事务处理,1-箱系统库存交接与2-箱系统相似前端堆积 减少交接过程但降低总体库存量的准确性后端堆积 增加了库存准确性（幅度轻微）但增加了系统处理的事务量,1,1-箱卡零件 XYZ,触发,补充,1-箱卡零件 XYZ,2-Bin Replenishment Pull,38,Takeaways,Know the the various types of Bin Replenishment systemsBe able to describe the benefits of a Bin systemHow to size (calculate) all the parameters for a Bin system,2-Bin Replenishment Pull,39,总结,知道箱补充系统的不同类型能够描述一个箱系统的利益能够去计算一个箱系统的所有参数,APPENDIX2-Bin Replenishment Pull,附录2-箱补充拉系统,2-Bin Replenishment Pull,42,Instructions for Typical Card Triggered 2-Bin Replenishment,This process uses green and red cards to trigger replenishment; “bins” are actually the box/container the part/supply is shipped in.1. Employee removes a bin and drops its green 2-bin card into the mailbox:Pull parts from “bin” with green card before using any with the red card.2.At same time(s) each day, the cards are picked up from the mailbox and returned to the stock/supply room.3. The stock/supply room pulls proper amount of parts/material (noted on card, set equal to the calculated “bin” quantity).4. Inventory transactions are performed (depending on issue method), and the materials and cards are delivered to the storage location.5.Employee stocks material in storage location and returns card to its proper place.When stock/supply room replaces the material, ensure that the red card is placed on the full bin.Always leaves you a full red bin remaining when green bin runs out.If not, you could run down both bins and stock out before either is replaced; if a red card is in the replenishment process, a part shortage is imminent act fast!,2-Bin Replenishment Pull,43,典型的卡触发2-箱补充的介绍,这个流程用绿色和红色卡来触发补充；“箱”是实际用来发货零件/供应品的盒子/容器.1. 员工清掉一个箱后，将绿色的2-箱卡放入邮箱:在使用有红色卡的零件前，先从有绿卡的箱中拉零件2.每天的同一时候, 邮箱卡片被收集并返回到库房中.3. 库房拉动零件/材料的适合数量 (在卡上注明，将之设定为计算出的“箱”数量).4. 库存处理被执行了(根据发放的方式), 然后材料和卡被传送到仓储地点.5.员工将物料放在仓储地点然后将卡返回到适合的地方.当库房补充材料时，确保红色卡被放在添满的箱上.当绿箱被放出去使用时，始终保持红卡箱中的零件已经被填满.如果不是这样，在任一箱补充前你将用尽每个箱存货；如果红卡在补充过程中，零件短缺现象即将出现尽快采取行动。,2-Bin Replenishment Pull,44,Maintaining a Card Triggered 2-Bin Process,Check periodically for lost cards and replace.Best time is right after replenishment; any cards not replaced or in the mailbox are lost.Police the proper use of cards:Supervisor/Lead drop green cards when green bin is empty.Supervisor/Lead drop red cards on stock out investigate!Supervisor/Lead ensure cards are replaced when parts are restocked.Green bins are completely used before red bins.Resize bins when demand changes.Add cards for new parts, delete cards for obsolete parts.,2-Bin Replenishment Pull,45,保持卡触发2-箱系统的过程,定期检查卡片是否丢失并更换.最佳时间是在补充之后，如果卡片未被更换或未在邮箱都视为丢失维持卡片的合理使用:当绿卡箱用完变空时，主管/组长投放绿卡.当存货用完时，主管/组长投放红卡 调查!当零件重新补充时，主管/组长确保卡片被更换.在用红卡箱前，确保绿卡箱已经被用完.当需求改变时需要重新调整箱的数量.新增的零件要增加不同的卡，过期的死库存零件要将卡片毁尸灭迹.,2-Bin Replenishment Pull,46,Example Card Triggered Line-Side 2-Bin Rack,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 1,Bin 2,Bin 1,Bin 2,Bin 2,Bin 1,Bin 2,Bin 1,Bin 1,2-Bin Mailbox,Order Cards,1.Always pull material from bin with GREEN card if it is there.2.Store/supply room replaces material and switches RED card to material just replaced.3.The cards are attached to magnetic strip labels (for ease of movement for resizing).,Bin 1,Bin 1,Bin 2,2-Bin Replenishment Pull,47,举例：由卡触发的线旁2-箱货架,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 1,Bin 2,Bin 1,Bin 2,Bin 2,Bin 1,Bin 2,Bin 1,Bin 1,2-箱邮箱,订单卡片,1.如果这里有绿卡箱，那么必须要从绿卡箱里拉材料.2.库房补充材料并将红卡换到刚补充的材料里.3.卡片最好是有磁性的 ( 这样在调整数量时可以方便移动).,Bin 1,Bin 1,Bin 2,2-Bin Replenishment Pull,48,Example Card Triggered Line-Side 2-Bin System,2-Bin Replenishment Pull,49,举例：由卡触发的线旁2-箱系统,2-Bin Replenishment Pull,50,Example Card Triggered Line-Side 2-Bin System,2-Bin Cards are Green and Red, per the process. Cards are placed into plastic sheaths to protect them from getting knocked off the racking.Clear plastic sheaths are attached to metal racking via sticky magnetic strip make resizing easier.Bin labels are white sticky backed and placed inside of plastic sheath for protection.A clear plastic sheath over a white lab