流程标准化ppt课件

1、流程规范化Routing Standardization议程 Agenda目的 / 结果 Purpose / results与流线消费有关的问题 Issues relating to flow流程规范化六步骤 6 steps to routing standardization学习内容 What Youll Learn根据类似流程，将废品 (零件) 分类How to group products (parts) into families according to common routings如何简化零件流程How to simplify part routings根据零件系列，将流线消费单

2、元文件化，并予以实施How to implement and document flow production cells around part family groups及时消费原理 JIT Principles跟上“节拍时间Pace to “takt time 达成流线消费Create flow production 结合“拉动系统Incorporate “pull system 流程规范化的目的Purpose of Routing Standardization减少独特流程的数量Reduce the number of unique routings简化个别零件的流程Simplify

3、individual part routings制定规范化任务Develop standard work贵司的流程象哪个？ Which Is Your Process?流线型非流线型零件零件零件零件零件零件零件零件不良流线的缘由 Causes of Poor Flow演化式增长 Evolutionary growth人员安排变化 Staffing changes规范本钱会计 Standard cost accounting产能顶峰 Capacity peaks共用设备 Shared equipment数量变化 Quantity variations流程技术 Process technology

4、流程变化 Routing variations外部交接点 External handoffs回环工序 Loopbacks换模时间太长 Setups too long不同零件的数量 Number of different parts超级机器 Super machine大批量 Large batches流程思想 Process thinking必要的操作 (修缮) As-required operations (repair)变化的种类 Types of Variation数量变化 Quantity variation产品变化 Product variation变化的程度 Degree Of Va

5、riation产量比例 零件数量比例特征种类很少制造业里最常见，种类非常多种类极多，变化极大 (很稀有)流程规范化六步骤6 Steps To Routing Standardization进展零件-数量 (P-Q) 分析Prepare part-quantity (P-Q) analysis2.进展流程分析Prepare process route analysis3.根据类似流程，对零件进展分类Group parts by routing similarity4.定义设备可用性Define equipment availability5.简化零件流程Simplify part routing

6、s6.实施新的流程系列，并将其文件化Implement and document new process family groups零件-数量 (P-Q) 分析Part-Quantity (P-Q) Analysis* 由于圆整问题，各个比例之和并不等于100% Individual percentages dont equal 100 % due to rounding零件代号Part Number数量Quantity数量比例% of Quantity累计数量比例Cumulative Quantity (%)ABCD5684152524%24%2316848022%46%2351536017

7、%63%9851228513%76%756511457%83%216981306%89%189961055%94%45646804%98%15695653%100%*零件-数量 (P-Q) 关系图 Part-Quantity (P-Q) Chart数量零件代号累计数量比例流程分析 Process Route Analysis任务中心 Work Center零件 Part #数量 Quantity车削Lathe镗Bore机加工Mach焊 Weld磨Grind机加工Mach铣Mill检验Insp5684152523168480235153609851228575651145216981301899

8、6105456468015695651111111112342222222333333334454444442零件系列 (1) Part Family Group (1)任务中心 Work Center零件 Part #数量 Quantity车削Lathe镗Bore机加工Mach焊Weld磨Grind机加工Mach铣Mill平衡Bal检验Insp56811506510100423390321080453350123457643215746899832156987123457689987653421零件系列 (2) Part Family Group (2)= 外部工序 Outside proc

9、ess任务中心 Work Center零件Part #数量Quantity车削Lathe磨Grind热处置HT Treat滚光Tumble喷涂Coating内圆磨ID Grind机加工Mach检验Insp1289175765110064447516585111122223333444455556666777788889999定义设备可用性 Define Equipment Availability识别现有设备Identify existing available equipment分配设备予各个流程组别Allocate equipment to process groups识别潜在瓶颈问题Id

10、entify potential bottlenecks简化零件流程 Simplify Part Routings简化操作顺序Simplify the sequence of operations同一系列的一切零件都制定规范化流程Develop a standard route for all parts in a family减少工序数量Reduce the number of operations消除单元外的交接点Eliminate out-of-cell handoffs防止回环工序Eliminate loop-backs防止共用装卸中心Eliminate shared load centers思索运用规范化流程模块Consider using standard routing templates消除交换流程Eliminate alternative routings将新的系列文件化，并