GE LEAN现场管理资料-瓶颈管理(PDF 36页)英文版

Ccapacity.ppt-1,APACIT1994GeneralMotorsCorporation.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,withstakeholdersWORKSTATIONAREADRAWNTOSCALE03/23/941994GeneralMotorsCorporation.Allrightsreserved.PDF文件使用pdfFactory试用版本创建,capacity.ppt-4,CAPACITYWORKSHOPAGENDA,IntroductionTheoryofConstraintOverview5StepImprovementProcessDataCollection/DataAnalysisConstraintIdentificationStrategyImplementationMeasureImprovementWrap-Up1994GeneralMotorsCorporation.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,OPERATIONCAPACITYDEMAND,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#shiftsavailable,thenaconstraintexistsNote: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,RunconstraintatitsbasiccapacityinisolationScheduleOperationEffectivelyDontWasteOutputEliminatedefectivepartsbeforetheyarriveMakesurepartsarenotscrappedlaterintheprocessEliminatereworkthatmustgobackthroughconstraintImprovethetoolsorgaugesusedImproveyieldbyassuringthequalityoftheprocess“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,OperatorRulesofEngagementRunmachineswhenyouhavematerialDosomethingproductivewhenyoudonthavematerial(setup,PM)Cross-trainworkerstopreventidletimeduetoabsenteeismEliminateBlockandStarvethrougheffectivebufferingi.e.partsbeforeandspaceafterwards,capacity.ppt-232/07/01PDF文件使用pdfFactory试用版本创建,1994GeneralMotorsCorporation.Allrightsreserved.,Starving/Blocking,NeverStarveaConstraintUtilizeBufferManagementPlacebufferinventoryaheadtoassureitalwayshaspartstorunLoadpartsaheadtoensureconstraintrunsNeverBlocktheConstraintDe-coupletheOperationsAssurepartsarepulledawaysooperationdoesntstop(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,Station1994GeneralMotorsCorporation.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,BLOCK1994GeneralMotorsCorporation.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)ResourcesinfavorofrunningtheconstrainingoperationMovepeoplefromnon-constraintstoconstrainingoperationeveniftheyarentfinishedatthenon-constraintPerformmaintenanceontheconstraintoperationbeforeothersRunallothermachinestoeliminatestarve/block“Improvingthroughputonanyoperationotherthantheconstraintdoesnotimprovethesystemsoverallthroughput”,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,KeepItRunningRunthroughlunch,breaks(tagrelief),etc.Afterchangeover,runproductionsimultaneouslywithfirstpieceapprovalReducenumberofsetupsbyprocessingfamiliesofjobsthatrequiresimilarsetupsReducesetuptimeImprovepreventativemaintenancetoreducebottleneckdowntime,capacity.ppt-312/07/01PDF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-322/07/01PDF文件使用pdfFactory试用版本创建,1994GeneralMotorsCorporation.Allrightsreserved.,Step4b:Elevate-AddCapacity,AddcapacitytotheconstraintoperationImproveCycleTime(canitgofaster?)AddaMachine/PersonProduceMorePartsperCycleReduceWorkloadatBottleneckMoveworktoalternateworkcentersormanufactur