计划生产的精益方法论Heijunka

1、Heijunka Cookbook方案消费的精益方法论.1. 选择消费线Analyze Historical Sales DataDetermine Build StrategyCalculate Takt TimeLevel LoadSequenceUnderstand what is made明白要做什么 型号3000400016种硬件配置 79 个零件编号23 个供应商每年14,000台 DASH2493 种定单组合.2. 识别特殊型号或配置 产品有多少种不同的型号?每种型号不同在哪里?举例:Dash 3000/4000 病人监护仪16种不同的硬件配置:3000 or 4000有没有复写

2、器有没有RF Nellcor or MasimoAnalyze Historical Sales Data首先搞清楚产品Determine Build StrategyCalculate Takt TimeLevel LoadSequenceUnderstand what is made.3. 做一个产品系谱Analyze Historical Sales DataDetermine Build StrategyCalculate Takt TimeLevel LoadSequence哪些零件是每个型号都要用上的? 哪些零件是用在部分型号上的?Understand what is made首先

3、搞清楚产品产品系谱不是简单的BOM. 它在了解一种零件的组装频率上起了很大的作用.4. 要明白哪些零件装到产品里每个组件都包括哪些零件(规格和数量)Understand what is madeAnalyze Historical Sales DataDetermine Build StrategyCalculate Takt TimeLevel LoadSequence首先搞清楚产品.5. 搜集以往的销售数据不能预测未来历史是最好的销售预言家Understand what is made 分析以往的销售数据Determine Build StrategyLevel LoadCalculate

4、 Takt TimeSequenceAnalyze historical sales data.6. 按照不同的部件分解销售 数据Analyze historical sales dataUnderstand what is made分析以往的销售数据Determine Build StrategyLevel LoadCalculate Takt TimeSequence.7. 总量数据Analyze historical sales data 计算出每个季度的总量Understand what is made分析以往的销售数据Determine Build StrategyLevel Loa

5、dCalculate Takt TimeSequence.8. 计算出组件的百分比用总量数据来计算出每个季度已销售组件的百分比Analyze historical sales data举例: 在2002年第四季度卖出的一切仪表板里66%的产品有Nellcor DAS组件.Understand what is made分析以往的销售数据Determine Build StrategyLevel LoadCalculate Takt TimeSequence.9. 选择数据预测未来的销售情况如何选择:市场的变化?产品的稳定性?Stage in product life?Analyze histor

6、ical sales data给市场变化下定义2002年第一季度的数据不再具有代表性. Understand what is made分析以往的销售数据Determine Build StrategyLevel LoadCalculate Takt TimeSequence.10. Weight PSI 25%, History 75%Analyze historical sales dataOPSI Percentages (Weighting = 25%)方案百分率Historical Percentages (Weighting = 75%)Dealing with mix . . .P

7、SI for volume, Heijunka for mixUnderstand what is made分析以往的销售数据Determine Build StrategyLevel LoadCalculate Takt TimeSequence.11. Multiply Subassembly PercentagesProbability of customer ordering:3000, Nellcor, with Writer, with RF (Part No. = 420000-007)= (.47)(.73)(.41)(.15) = 2.1%Analyze historical

8、 sales dataUnderstand what is made分析以往的销售数据Determine Build StrategyLevel LoadCalculate Takt TimeSequence.12. Create P-Q ChartAnalyze historical sales data2021999-011占了12% 的销售量%Understand what is made分析以往的销售数据Determine Build StrategyLevel LoadCalculate Takt TimeSequence过去4个季度的销售情况.13. 决议消费战略思索要素:检测时间

9、质量问题供应商周期80/20 rule决议消费战略Level LoadCalculate Takt TimeSequenceAnalyze Historical Sales Data预测消费Understand what is madeDetermine build strategy定单消费%.14. 计算任务日Determine Build Strategy平衡消费Calculate Takt TimeSequenceAnalyze Historical Sales DataUnderstand what is madeLevel load感恩节圣诞节(第四季度68个任务日) (4 个无方案

10、消费日) = 64 有效任务日.15. 计算每天/每周的产量Determine Build Strategy平衡消费Calculate Takt TimeSequenceAnalyze Historical Sales DataUnderstand what is madeLevel load 每季度需求或是预测每季度任务日 举例:4288 件/季度64 天/季度=67 件/天335 件/周多少?每天产量 =.16. 计算出每周产品组合335*20.2% = 68 件/周Level load什么型号?Determine Build Strategy平衡消费Calculate Takt Time

11、SequenceAnalyze Historical Sales DataUnderstand what is made.17.决议每周产量Level loadDetermine Build Strategy平衡消费Calculate Takt TimeSequenceAnalyze Historical Sales DataUnderstand what is made什么型号?.18.a 计算出消费线的节拍 时间 节拍时间是企业的心跳 有效时间 需求量 节拍时间=节拍时间是一个数学问题, 但它是精益消费的根本原那么.有效时间: 安排用来消费的一切消费时间需求量: 在一段时间内预定零件的消费

12、数量 每个轮班的有效时间是6.6个小时(延续性的) 这6.6个小时是除去午饭, 休憩等的延续任务时间.举例工厂每天两班制顾客的需求是每个星期1000件产品3960 分钟/周1000 件/周= 3.96 分钟/件节拍时间 = Calculate Takt time计算节拍时间Determine Build StrategyLevel LoadSequenceAnalyze Historical Sales DataUnderstand what is made.仪表板消费线每天一班制 6.6 小时/天 * 60 分钟/小时 * 64 天/季度 = 25,344分钟/季度顾客的需求是每个季度428

13、8台有效时间 需求量节拍时间=4288 台/季度25,344 分/季度= 6 分/台Dash Line Takt Time = Calculate Takt time计算节拍时间Determine Build StrategyLevel LoadSequenceAnalyze Historical Sales DataUnderstand what is made(每个车间都会不同)18.b计算出消费线的节拍 时间.我们曾经计算出了消费线的节拍时间, 如今我们要为我们的消费排序概要 : 任务天数 消费线的节拍时间 = 6 分钟 12个不同的型号Sequencing ProductionLeve

14、l LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made排序消费线的节拍时间为6分钟,接着,我们计算出每个型号的节拍时间.19. 确定休憩和午饭时间SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made开场任务时间: 6:30am终了时间: 2:00pm早休: 8:45am

15、 9:00am午饭时间: 12:00pm-12:30pm有效时间=(8小时-午饭时间-休憩时间-会议时间-培训时间-等等)我们每天6.6个小时的延续任务时间.20. 计算出每个型号的节拍时间Dash Line T/T = 6 minT/T = 29 min79 min127 minSequence过去4个季度的销售情况节拍时间29分钟Level LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made%.21.a运用型号的节拍时间给消费排序Seque

16、nceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made2021999-0102021999-0102021999-01030 min30 min每29分钟消费一个 2021999-010 产品消费线的节拍时间还6分钟.21.b运用型号的节拍时间给消费排序SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales Da

17、taUnderstand what is made2021999-0102021999-0102021999-0102021999-0032021999-0032021999-00330 min36 min每33分钟消费一个 2021999-003 产品平均33分钟消费线的节拍时间还6分钟.21.c 运用型号的节拍时间给消费排序SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made2021999-0112021999-0

18、1142 min2021999-0102021999-0102021999-0102021999-0032021999-0032021999-003每42分钟消费一个2021999-011 产品消费线的节拍时间还6分钟.21.d运用型号的节拍时间给消费排序SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made8:12 AM-0038:18 AM-0148:24 AM-0028:30 AM-0108:36 AM-007 时

19、间6:30 AM-0106:36 AM-0036:42 AM-0116:48 AM-0026:54 AM-0147:00 AM-0107:06 AM-0037:12 AM-0077:18 AM-0157:24 AM-0117:30 AM-0107:36 AM-0027:42 AM-0037:48 AM-0067:54 AM-0138:00 AM-0108:06 AM-0119:00 AM-0059:06 AM-0039:12 AM-0119:18 AM-0109:24 AM-0159:30 AM-0029:36 AM-0039:42 AM-0129:48 AM-0049:54 AM-01010

20、:00 AM-011BREAK时间型号8:12 AM-0038:18 AM-0148:24 AM-0028:30 AM-0108:36 AM-007型号6:30 AM-0106:36 AM-0036:42 AM-0116:48 AM-0026:54 AM-0147:00 AM-0107:06 AM-0037:12 AM-0077:18 AM-0157:24 AM-0117:30 AM-0107:36 AM-0027:42 AM-0037:48 AM-0067:54 AM-0138:00 AM-0108:06 AM-0119:00 AM-0059:06 AM-0039:12 AM-0119:18

21、 AM-0109:24 AM-0159:30 AM-0029:36 AM-0039:42 AM-0129:48 AM-0049:54 AM-01010:00 AM-011BREAK每天产量=67台, 12个型号.22. 制造消费时间表SequenceLevel LoadDetermine Build StrategyCalculate Takt Time拍序Analyze Historical Sales DataUnderstand what is made最终的目的是不延续消费两个型号一样的产品.定单 消费(MTO) 举例:Determine Build StrategySequenceA

22、nalyze Historical Sales DataUnderstand what is madeLevel LoadCalculate Takt TimeMake to Order%假设2021999-017产品定单在消费方案制定以后才到,那应该怎样办? 按照预测消费 按照顾客要求定做.定单 消费(MTO) 举例:Calculate Takt TimeDetermine Build StrategyLevel LoadSequenceAnalyze Historical Sales DataUnderstand what is madeMake to Order21%21%12%11%7

23、%6%5%5%4%2%2%1%1%1%1%1%05001000150020002500300035002021999-0032021999-0102021999-0112021999-0022021999-0072021999-0142021999-0152021999-0042021999-0162021999-0062021999-0052021999-0092021999-0172021999-0082021999-0132021999-0120%5%10%15%20%25%Dash SalesPercent SalesHigh bar on pareto在图表中较高的柱Real customer order真正的顾客定单用顾客定单来替代图表中柱形高的零件.定单 消费(MTO) 举例:Calculate Takt TimeDetermine Build StrategyLevel LoadSequenceAnalyze Hi