精益生产之线平衡模式__Line_Balance_Models_(中英文版).ppt

LineLeanSixSigmaImprovementProcessRoadMap,DefinitionLineBalanceModelDesignPrinciplesValueDefinitionsApproachestoLineBalanceExercise,RD011202,LineLeanSixSigma改善过程路径,定义线平衡模型设计原则价值定义线平衡方法练习,RD011202,LineBalanceModel,3,LeanSixSigmaImprovementProcessRoadMap,Analyze,Control,Improve,DefineIdentifyProblemDevelopListofCustomersDevelopListofCTQsfromVoiceoftheCustomerFinalizeProjectFocusandKeyMetricsCompletePDF,MeasureMapBusinessProcessMapValueStreamDevelopDataCollectionPlanConductMeasurementSystemAnalysisCollectDataConductProcessCapabilityAnalysis,AnalyzeProposeCriticalXsPrioritizeCriticalXsVerifyCriticalXsEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCauseAnalysisonCriticalXs,ImproveCriticalXsConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolution,ControlImplementProcessChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunities,Measure,Define,ProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadCharts,ProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&R,Cp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEA,BrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttCharts,CheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-Yoke,Revised1-12-02,LineBalanceModel,4,精益6过程改善流程,分析,控制,改进,定义选定题目列出客户从顾客之声中列出关建需求定出项目焦点和重要指标完成PDF,测量绘制业务流程图绘制价值流程图制定数据收集计划测量系统分析收集数据过程能力分析,分析提出关键因子区分关键因子验证关键因子评枯每个关键因子对结果的影响量化机会根本原因排序寻找根本原因针对关键因子,改进关键因子确认发掘潜在的解决方法选择方案优化方案实行方案,控制过程变革和控制制定控制计划计算最终财务过程指标项目过渡给未来项目管理者项目鉴别转化机会,测量,定义,项目编号工具项目定义表净现值分析内部回报率分析折算现金流分析？（按现值计算的现金流量分析）PIP管理过程RACIQuad表,过程图价值分析脑力风暴投票归类法柏拉图因果图/鱼骨图FMEA查检表运行图控制图量具R&R,Cp&Cpk供应链加速器分析多变动图i盒状图交互作用图回归分析ANOVAC&E矩阵图FMEA,脑力风暴拉系统减少设置TPM流程图标杆管理亲和图DOE假设检验力场分析图树状图甘特图,查检表运行图柱状图散布图控制图柏拉图互动回顾愚巧法,Revised1-12-02,LineBalanceModel,5,LearningObjectives,Howtodesignandimplementaprocesssupportedbyalinebalancingmodelthatensuresoptimaluseof:PeopleFloorspaceCapitalAssetsMaterialKnowhowtomaximizeproductivity,LineBalanceModel,6,学习目标,如何设计和实施由“线平衡模型”支持的一个流程以确保优化配置：人地方固定资产材料知道如何使生产率最大化,LineBalanceModel,7,WhatsinItforMe?,AbletodesignandimplementabalancedprocesslineUnderstandtheissuesinatypicalprocessenvironmentandhowtoimpactthoseissues,LineBalanceModel,8,益处,能够设计和实施一个线平衡的生产线了解典型流程环境中的问题及如何影响那些问题,LineBalanceModel,9,LineBalanceModel,ALineBalancingModelallowstheusertoviewtasktimesacrossaprocesstoidentifybottlenecksandthuscalculateoutputrates(throughput)andTaktTimes.Inaddition,theuserwillbeabletovisuallyseeunbalancedareasandwheretaskscanbeshiftedtobalancetheprocess.TheLineBalancetechniquesareapplicableintransactionalaswellasmanufacturing,e.g.,orderentryoperations.,LineBalanceModel,10,线平衡模型,线平衡模型允许用户在一个流程中确定瓶颈问题，并计算产出比率（产能）和TaktTimes。除此，用户将能直观地看到不平衡的区域和使流程平衡所做的任务。线平衡方法与生产互动一样是可行的，如订单进入生产。,LineBalanceModel,11,PrimaryIssuesinTypicalProcessEnvironments,LargeorerraticbatchesExcessiveWIPPoorfloorspaceutilizationLowemployeeefficiencyLong/erraticcycletimesPoorbalanceofoperationsandlaboracrossprocessstepsConveyance,standbyandmotionwasteDisorganizedworkspaceandcomponent/supplystorageHighvariabilityofdemandonmultipleprocessingcenters,e.g.,callcenters/flowlines,LineBalanceModel,12,典型的流程环境中的主要问题,大批量或反复无常的批量过多的WIP地方利用的差较低的员工效率长的/反复无常的周期时间流程步骤中差的生产平衡和劳动力传送、备用和启动浪费无规则的工作地点和元件/供应存储对于多重的流程中心，需求变化差异大2，如电话中心/流出线,LineBalanceModel,13,LineBalanceDesignPrinciples,MinimizeBatchSize/TransferQuantity/WorkInProcessMinimize/StabilizeCycleTimeMaximizeLaborEfficiencyOptimizenumberofworkstations/processstepsBalancetasks/laboracrossworkstationsMaximizespaceutilizationMinimizetaktvarianceMinimizeNVA(conveyance,standby,andmotionwastes)Minimizetheneedtore-balanceasdemandrequirementschangeMinimizevolumevariability(combineproductcategorydemand)Maximizeflexibilitytoallowforproductintroductionsanddiscontinuations,LineBalanceModel,14,线平衡设计原则,使批量规模/转移质量/在制品最小化将周期时间最小化/稳定化使劳动效率最大化优化配置工作站/流程步骤平衡任务/工作站里的劳动最大限度利用空间使takt的变化最小化最小化NVA(运送、备用和启动浪费)根据需求的变化使再平衡的需求最小化使批量差异最小化(综合产品种类需求)使柔性最大化以允许产品引入和非持续性,LineBalanceModel,15,ValueDefinitions,ValueAdd:Addingform,fit,orfunctiontotheproduct.Ataskoractivityforwhichthecustomerwouldbewillingtopay.ExampleAssemblerscrewingaboltintoapieceofaluminumrequiredtoholdthewindowtogetherExampleFinancialServicesemployeeaddingcredithistorytoacreditapplicationBusinessValueAdd:AtaskthatisrequiredtobuildawindowbutforwhichthecustomerisnotwillingtopayExampleThetimeittakesforanassemblertograbapartthatisatpoint-of-useandreadyitforassemblyExampleThetimeittakesforaFinancialServicesemployeetosecureacreditapplicationandreadyitforprocessingNon-ValueAdd:AtaskthatisnotrequiredandshouldbeeliminatedbecauseitiswastefulExampleAssemblerhavingtosearcharoundtheirareatoretrieveapartforassemblyExampleFinancialServicesemployeehavingtolookformissinginformationneededtoaddcredithistoryinformation,LineBalanceModel,16,价值定义,增值:增加产品的形式、或功能。客户愿意付费的任务或活动。如在铝合金中装配螺钉以把窗子固定在一起如给员工在应用信用方面提供信用历史的财务服务业务增值:所需的一项任务是一扇窗子，但是客户不愿付费如装配商花时间抓住一个零件在使用点上进行装配如为员工提供财务服务是花时间确保信用的应用,LineBalanceModel,17,LineBalanceApproaches,TwoDifferentApproaches:Approach#1LongTermPlanner:Giventheinputsofaverageproductivity,assembly/processingtime,andforecastedoutput(demand),andhourspershift,calculatethenumberofassemblers/processorsandaveragetakttimeitwilltaketosatisfythedemand.Approach#2Day-to-DayScheduler:Giventheinputsofaverageproductivity,assembly/processingtime,numberofassemblers/processors,anddesiredoutput(demand),calculatethehourspershiftandtaktrateitwilltaketosatisfythedemand.Whatsthedifference?LongTermPlannerallowsmanagementtounderstandstaffingincrementsbaseduponsomeforecasteddemandonalinebylinebasis.Day-to-Dayschedulerallowslinesupervisiontocalculateprocessparameters(taktrate,hourstowork)basedonthenumberofunitstoprocessandthenumberofpeoplewhoshowuptoworkthatday.,LineBalanceModel,18,线平衡步骤,两种不同的方法:方法#1长期计划员:作出平均投入生产率、装配/加工时间、及预计的产量（需求），每班的时间，计算装配工/操作工的数量，及满足需求所花的平均时间。方法#2日常安排员:作出平均投入生产率,装配/加工时间，装配工/操作工的数量，理想的产量（需求），计算每班所用的时间和满足需求的takt比率。区别是什么?长期计划员允许管理来了解在以生产线为基础上的需求预测而增加员工。日常安排员允许生产的监督来计算流程参数（takt比率，工时），这个参数是基于加工单元数量和人员数量。,Approach#1LongTermPlanner,途径#1长期计划员,LineBalanceModel,21,Input1.Demandrequirements2.Laborefficiency3.Assemble/processtasksandtimes4.Hourspershiftornumberofassembler/stations,Output1.Taktrate2.NumberofAssemblers/ProcessorsORNumberofhourspershift3.Staffinglevelsatvaryingdemand,ProcessBalanceModel(spreadsheet),ProcessBalanceModel:Designprocess,Or,LineBalanceModel,22,投入1.需求需要2.劳动效率3.装配/加工任务和时间4.每班时间或装配工/工作站数量,产出1.Takt比率2.装配工/操作工数量或每班时间3.在变化基础上的员工水平,过程平衡模型(spreadsheet),ProcessBalanceModel:设计流程,Or,LineBalanceModel,23,ProcessBalanceModel:Steps,Step1:Understandpresentstateprocessoperation(gatheranddocumentdata)Step2:Determinetotaltimerequiredtoprocessunit(valueaddandbusinessvalueadd)Step3:DeterminemaximumoperatingparametersandplugparametersintoyellowcellsStep4:Determinetargetunit/dayoutputrequirementandplotontabletodeterminenumberofshifthourstoworktoachieverequirementStep5:PlotcurrentoperatingrangetodeterminelaborreductionrequiredtomeetoperatinggoalsStep6:Grouptasksinlogicalandefficientmannerthatdoesnotviolatedesignprinciples,LineBalanceModel,24,过程平衡模型步骤,Step1:了解目前的生产流程状况(收集数据并文件化)Step2:确定处理单元所需的全部时间（增值和业务增值）Step3:确定最大的运行参数并将参数插入黄格中Step4:将目标单元/天所需的产量在桌面上标出以确定达到需要的每班工作时间Step5:标出目前的运行变化以确定满足生产目标所需减少的劳动力Step6:在不影响设计原则的情况下，按逻辑和效率态度将任务分解,LineBalanceModel,25,Step1Understandpresentstateprocessoperation(gatheranddocumentactivitytimeactuals)Note:Timeshouldincludecustomervalueadd,businessvalueadd,andnon-valueaddtimesforeachstep/operation/task,Step2Determinetotal(current)timerequiredtoprocessunit.Note:Modelshouldautomaticallycalculatetotaltimeenteredinseconds,minutes,andhours,ProcessBalanceModel:Steps1and2,LineBalanceModel,26,步骤1了解现在过程状况(收集、记录活动时间)注意:时间应该包括CVA、BVA、与每一步骤、作业、与任务的时间,步骤2决定全部（目前）需要完成任务的时间。注意：模型应该可以自动计算时间。,过程平衡模型步骤1和2,LineBalanceModel,27,Step3Determinemaximumoperatingparametersandplugparametersintohighlightedcells-Allothercellsarecalculatedautomatically(Examplecalculationsarelocatedattheendofthissection.),ProcessBalanceModel:Step3,LineBalanceModel,28,步骤3决定最大的作业参数与加乘参数到设定的格位中。其他的格位可自动计算。(计算案例在本节最后。),过程平衡模型步骤3,LineBalanceModel,29,Step4Determinetargetunit/dayoutputrequirementandplotontabletodetermine#ofshifthourstoworktoachieverequirement,ProcessBalanceModel:Step4,ThislinesaysthatIneedtoworkan8hourshiftwith12processorstoachievea400unit/dayoutputrequirement,LineBalanceModel,30,步骤4决定需要的目标单位/日表，并图示需要完成任务需要的工作时间。,过程平衡模型:步骤4,这行说明我需要使用12人，8小时班来完成每天400单位的需要,LineBalanceModel,31,Modelwillbuildthefollowinggraphwhichshowshowweshouldplanto:Staffinequalincrements(tolimithavingtore-balanceline)Varyhoursworkedtogetcompletecoverageofdemandrequirements,ProcessBalanceModel:Step4(Cont.),LineBalanceModel,32,模型可建立如下图说明:每一阶段需要的人力完成任务需要的工作时间,过程平衡模型:步骤4(续.),LineBalanceModel,33,Step5Plotcurrentoperatingrangetodeterminelaborreductionrequiredtomeetoperatinggoals,ProcessBalanceModel:Step5,Themodelhascalculatedthatatarateof150units/day,theareashouldbeworkinga6hourshiftwith7processors.Thisis2fewerprocessorsthantheircurrentenvironment.,LineBalanceModel,34,步骤5绘制目前的作业范围来决定完成目标可节约的人力,过程平衡模型:步骤5,在150单位/天的需求下,需要每班6小时，7位作业员.比目前人力少两人,LineBalanceModel,35,Step6Groupprocesstasksinlogicalandefficientmannerthatdoesnotviolatedesignprinciples(eg-(tasktimetaktratetime),ProcessBalanceModel:Step6,LineBalanceModel,36,步骤6合乎逻辑与共效率的团队工作不违反设计原则(例-(tasktimetaktratetime),过程平衡模型:步骤6,LineBalanceModel,37,Thisworksheetprovidesasummaryofinputsusedandoutputsgeneratedforeachwindowcategorythatisrunthroughthemodel.Thisworksheetisautomaticallycreatedandupdatedbythemodel.,ModelSummary,LineBalanceModel,38,这个工作表提供了在本模式运行下的按窗口分类的投入和产出的总结。这份表格是自动生成的并能通过该模式更新。,模型总结,LineBalanceModel,39,Approach#1:CalculationNotes(Step3),MaxLaborEfficiencyBestinclassis65%AssumptionisthatlaborefficiencydeclinesthemoretaskseachprocessorisaskedtoperformMaxhrspershiftShouldbesetto11hourstoobtainoptimalcoverageofrequirementsMaxDemand(units/hour)=MaxDemandRequirement/MaxhrspershiftMaxDemand(units/minute)=MaxDemand(units/hour)/60TaktTime(seconds/unit)=60/MaxDemand(units/minute)Thisistheamountoftimebetweenproductsexiting-ThisisalsothemaximumamountofprocesstimethatanyoneworkstationshouldperformwithoutcompromisingthelineflowTotalAssemblers/Processors=(TotalProcessTime(hrs)*MaxDmdReq(units/shift)/Maxhrspershift)/MaxLaborEfficiencyTheresultisroundeduptothenextwholeassemblerThisisthenumberofassemblers/processorsIshouldhavetoprocessthemaximumdemandrequirementatthemaximumlaborefficiencyWorkstationTime(secs/workstation)=TotalProcessTime(hrs)*60*60/TotalProcessors1processor=1workstationThisistheoptimalamountoftimethattasksshouldbegroupedbytobalancethelineLaborProductivity(Units/LaborHour)=MaxDemand(units/hour)/TotalProcessors,LineBalanceModel,40,途径#1:计算说明(步骤3),最高劳动效率最好是65%假设劳动效率下降，需要每个操作工做更多的工作每班最多工时应该设为11个小时以最好地满足需要最大需求(units/hour)=最大需求需要/每班最多工时最大需求(units/minute)=最大需求(units/hour)/60Takt时间(seconds/unit)=60/最大需求(units/minute)这是现有产品之间的时间量-这也是每个工作站的最多的流程时间全部装配工/操作工=(TotalProcessTime(hrs)*最大需求需要(units/shift)/Maxhrspershift)/最高劳动效率这个结果接近下次的全部操作工这是在最高劳动效率下的满足了最高需求下的操作工人数工作站时间(secs/workstation)=TotalProcessTimehrs)*60*60/TotalProcessors1操作工=1工作站这是将任务分组的最佳时间劳动生产率(Units/LaborHour)=最大需求(units/hour)/全部操作工,LineBalanceModel,41,Approach#1:TeamExercise,1.GototheVirtualCoachExerciseTabandopenthefiletitled:WindowsRUsLineBalancingExercise.doc2.Readthescenarioandcompletesteps1through4usingthespreadsheettitled:WindowsRUsLineBalancingData.xls3.Preparea5minutepresentationwithyourteamanswers.Youhave45minutestobuildthispartofalinebalancemodel.Detailedinstructionsareonthenextslide.,LineBalanceModel,42,Approach#1:小组练习,1.看虚拟辅导练习并打开以下抬头的文件:WindowsRUsLineBalancingExercise.doc2.读情节并完成第1到第4步，使用有以下抬头的工作表格:WindowsRUsLineBalancingData.xls准备5分钟的展示你有45分钟的时间来建这个线平衡模型部分具体的指导显示在下一个幻灯片上.,LineBalanceModel,43,ExerciseObjectives,TeachthestudenthowtobalancealinemathematicallyTeachthestudentthemethodtore-layoutthelinetorealizethemathematicalbalanceTheexercisewilldevelop:TaktTimechartSkillMatrixProposedtimecalculation,LineBalanceModel,44,练习的目标,教学生怎样用数学方法来平衡一条线教学生对线进行再布局的方法以实现数学上的平衡这个练习将制作出:Takt时间图表技能距阵拟定时间的计算,LineBalanceModel,45,ExerciseInstructions,1.UsingtheExcelspreadsheet,lookatthe“Currenttimes”tabtocompletethe“CurrentTaktTimeChart.”2.Lookatthe“CurrentStaffing”tabtocompletethe“SkillMatrix”tab.3.Usethethreetabsandre-dividethetaskstohaveabalancednumberoftaskswiththesamenumberofpeopleandsamesequenceastheoriginalline.Note:Aproposedlayoutisnottobemade.Currentextrusiondataisnottobedeveloped.Improvementstabisnottobecompleted.,LineBalanceModel,46,练习指南,1.使用Excel工作表格,看“目前的时间”以完成“CurrentTaktTimeChart.”2.看“CurrentStaffing”完成“SkillMatrix”3.使用这三个表重新分配任务，用同样的认输和程序在原来的生产线上平衡任务数量。Note:不必做出一个拟定的布局不用做出目前的数据不必完成改进表,LineBalanceModel,47,AssemblyBalanceModel:Day-to-DayScheduler,Step1:Understandcurrentstateoperation(gatheranddocumentdataaroundlayout,processflow,etc.).Step2:Determinetotaltimerequiredtoprocessunit(customervalueadd,businessvalueadd,currentnon-valueadd).Step3:Determinemaximumoperatingparametersandplugparametersintotaktratecalculator.Step4:Reviewoutputs:taktrateandnumberofhourstoworktoachieverequirement.Usethisoutputtofilloutlinetaktboard.,LineBalanceModel,48,组装平衡模型日常安排员,Step1:了解目前的生产状况(在布局和流程周围收集数据并使之文件化).Step2:确定单元流程所需的全部时间(客户增值、业务增值、目前非增值）Step3:确定最大的生产参数并将参数插入taktratecalculatorStep4:回顾产能:takt比率和满足需要所需的工时。用这个产能来填linetaktboard.,Approach#2Day-to-DayScheduler,途径#2每天作业的计划,LineBalanceModel,51,Step1Understandcurrentstateoperation(gatheranddocumentactivitytime).Note:Timeshouldincludecustomervalueadd,businessvalueadd,andnon-valueaddtimesforeachstep/operation/task.,Step2Determinetotal(current)timerequiredtoprocessunit.Note:Modelshouldautomaticallycalculatetotaltimeenteredinseconds,minutes,andhours.,Day-To-DayScheduler:Steps1and2,LineBalanceModel,52,步骤1了解目前作业状况(收集、记录作业与作业时间)。注意:时间应包括每一步骤、作业、任务的CVA、BVA与NV时间。,步骤2决定目前总时间。注意：模型要能够自动运算时间,日计划:步骤1与2,LineBalanceModel,53,Step3DetermineoperatingparametersandplugparametersintoTaktRateCalculator-Allothercellsarecalculatedautomatically,Step4Reviewo