精益生产工具英文PPT

TenantsofSinglePieceFlowDoNot

MakeDefectsDoNot

PassAlongDefectsDoNot

AcceptDefectsZeroDefects=0DefectsNot3.4ppmQuality,Quality,Quality…DefectsaretheWorstKindofWaste

7TypesofWaste

DefectivePartsOverProductionInventoryMotionTransportationWaitingManualTouches第一页，共二十三页。BatchSinglePieceFlowFrom:TheToyotaProductionSystemBuildingQualityintotheProcessSinglePieceFlowThenextprocessisthecustomer…neversenddefects!

SampleInspectcatchesDefecttooLateWhenyouFinallyFindaDefectHowmanymoredoyouhave?Wherearetheyintheprocess?WhatistherootCause?

SinglePieceFlowcatchesDefectsimmediatelyWhenyoufindaDefectYouonlyhaveoneYouknowwhereitoccurredYouCanfind/ResolvetheRootCauseimmediately第二页，共二十三页。Check,Do,VerifyCheck-Thepreviousoperatorswork.Do-Yourwork.Verify-Thatyoudidyourworkcorrectly.第三页，共二十三页。ProcessInspectTransportTransportationisintegratedintotheproductionprocessviaautomatione.g.,movinglineProcessInspectProcessInspectTransportProcessInspectTransportationisintegratedintotheproductionprocessviahumanconveyancee.g.,Chaku-ChakuBuildingQualityintotheProcess2waystoperformSPFThenextprocessisthecustomer…neversenddefects!第四页，共二十三页。Check,Do,VerifyGetsyouintoPartsPerMillionquality-Whenyouverifyyourwork,youcatch1flawin100parts.Thenextpersonchecksyourworkandcancatch1/100sothat’s1/10,000.ThenthatpersonVerifiestheirworkandcancatch1/100.That’s1/1,000,000errorsthatcangetthrough.

第五页，共二十三页。Check,Do,VerifyEveryCustomerinaProcesshas:-arighttoexpectperfectmaterial-anobligationtoinspectthematerialbeforeuse.-anobligationtoinformthepreviousstepintheprocessofanyproblem.-anobligationtostoptheprocessuntilanyproblemhasbeenresolved.第六页，共二十三页。SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess.ThisisachievedbyestablishingataktTime,developingstdwork,andswip.ThepremiseisthatanOperatorcanonlyworkononepieceatatime,andperformsaQuickqualitycheckontheCTQsoftheprocessbeforemovingTheparttothefollowingprocess.Ifadefectisdetected,JidokaIsenacted…thelineisstopped,andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurenceTakttimeStdworkFlow:work(process)thatisdoneinconjunctionwithorsimultaneoustotransportation第七页，共二十三页。OnePieceFlow

Theproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis/hersupplierandcustomerinthechain.Asonepersonfinishestheirelement,sodoall.Workisthenmoveddownthelinesynchronously.Everypersonisempoweredtostoptheproductionprocessifarejectisspotted.第八页，共二十三页。OrganizationAreaSupervisorNew/RevPageofDateProductionLinePartNumberPartNameOperatorStandardWorkSheetTo:TurnsDPU'sScopeofOperationsFrom:QualityCheckSafetyPrecautionStandardWork-in-Process#LotsofStandardWork-in-ProcessTakt/RateTimeTotalManual&TravelTimeMan/TravelTimeOperatorEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeTubingCFMCellFernBissonnetteCell6AllPartsAllTubes11Mech.CleanRawmaterialWeld100/DayFPIX-RayEDM2ndQtr.‘01EndFinishOutsideCell27-avglot=6FlexFinishedGoodsACTIONWORKOUTgGEMSGlobalProductionSystemThenextprocessisthecustomer…neversenddefects!Check,Do,Verify第九页，共二十三页。OnePieceFlow

Yourcustomeristhenextstepintheprocess.Givetoyourcustomer,exactlywhattheyneed(1item),exactlywhentheyneedit,doneperfecteverytime.第十页，共二十三页。Tenantsof1pcsFlowDoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectQuality,Quality,Quality…DefectsaretheWorstKindofWaste第十一页，共二十三页。Systemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals,intheexactstandardizedamountneeded.PullProductionMethodology&SequenceDefinitionRefMaterialPresentationtrainingforexplanationonSupermarketdefinitionanduse第十二页，共二十三页。PartssemblyLineCellorChaku-ChakulineSupplierMaterialInformationSupermarketEmptycontainerFullcontainerLegend1Sequence/TimingPullProductionMethodology&Sequence第十三页，共二十三页。JITJidokaeGPSforGPCHeijunkaLevelLoadingSequencingFindingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacityAdjustingaproductionscheduletomeetunexpectedchangesincustomerdemandOrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitemstakenfrommemoryJogger第十四页，共二十三页。Leveledproductionmeans

loweringthepeaksamong

thedailyproductionvolumes

asmuchaspossibleand

makingtheproductionflow

smoothandunflucuating.

Ingeneral,themorefluctuationsyouintheproductionflow,themoremudayouenduphaving.Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand.Iftheproductionlineproducesonlyasingleproduct,youmaybeabletoreducemudasimplybyadjustingtheproductionscheduleandstaffinglevel.Butifyouwanttoproduceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline,youhavetodotheaveragingnotjustinvolumebutinkindsaswell.ThiswayofaveragingbothvolumeandinkindsiscalledproductionlevelingorheijunkainJapanese.LeveledProductionAmountofproductsthatcanbesoldHEIJUNKAAveragebytotalvolumeAverageby

model第十五页，共二十三页。

LeveledLoadProduction

BuildtoforecastBuildtoFGinv

BuildafterorderisreceivedALLcomponentsneedtobestockedinRMAnorderfromtheseproductstakesprecedenceover1-2-3products…buildthisfirst!UseStocksBuildStocksTAKT%F1F1F1F1F1F1F2F2F2F2F2F2TAKTTimeDeterminedbyPSI2Q3Q4QOktoBuildtoFGRepeatableProductsNon-RepeatableProducts第十六页，共二十三页。NeedtoDetermine...HowMuch 20bulbsperdayWhatKind 15/60Watts 5/100WattsWhen 5-60W,2–100W,5–60W, 2–200W,5–60W,1–100WTAKTLevelLoadMixLevelLoadSequence Ifweweremakinglightbulbs...QuarterlyWeeklyWeekly

Frequency606060606010010060606060601001006060606060100TaktTime=OperatingtimeperdayProductionrequirementperdayAssumptions:MachineBreakdown=0hourSetupChange=0hourDefectRate=0%TaktTimeEquationFormoreinformationonTAKT–RefertoJITSectionQuickExample第十七页，共二十三页。SettingtheproductionsequenceofmultipleTRAM–RACTypes(MedSystemsProduct)ProductMonthly

RequirementDaily

RequirementTAKTTimeModel1720units24units5minModel2360units12units10minModel3360units12units10minTotal1440units48units7.5minThisisdatafor3products,Model1,Model2,andModel3,areproducedatGEMS.Thechartdisplaysthemonthlyproductionlevel,thedailyproductionlevel(monthlydividedby30),andtheTakttimeforeachproducttype.THEYAREALLPRODUCEDONTHESAMELINE.Howcantheseunitsbebuiltinalevelproductionmodeusingthisexample?

Model1Model2Model3DetailedExample

第十八页，共二十三页。Sincethesethreeproductsareonthesameline,youwillneedtofollowthesequencepatternof1-2-1-3inyourproductionmix.Bydoingitthiswayyouareabletolevel-loadyourproductionbothintermsofquantityandtypes.#1–Prod1#4–Prod3#2–Prod2#3–Prod1REPEATMixedAssemblyLineProductionSequencebyTypeIfproducedinbatches,onlytheModel1’swillmeetTakttimesIfproducedtoasequence,2unitswillbeproducedin2TakttimesLet’sshowhowwevalidatethis…第十九页，共二十三页。ModelLineTaktTakt/CycleGraphPart-QuantityPartRouter1327.57.57.5SeeStdWorkComboSheetforexample.OnesheetiscreatedforeachoperatorSCT=25SCT=40SCT=30766676138127.597.5第二十页，共二十三页。TaktBuildTime=#ofOperations*TaktActualBuildTime=SCT130230330125240330ModelTBTModelABT1-52+1030ModelObjectives:ProducetoTaktTime(understandingno2productswillhavetheexactsameABT)ThesumoftheDTotiszeroEveryproductisproduceatleastonceNoproductisproducedtwiceinarowCreateaproductsequencewhere:Dtot=S(#ofUnitsinsequence*D)Dtot=-5(#of1’s)+10(#of2’s)+0(#of3’s)0=-5(2)+10(1)+0(1)IneachsequencewillcontainoneModel1,twoModel2s,and1Model3)Accordingtotherulesthesequencemustrun:Model1–Model2–Model1–Model3第二十一页，共二十三页。GuidingPrinciples:GPSLevel-loadingPurpose:Toprovideguidelinesfordevelopingthemethodandtoolstolevel-scheduletheshopfloor.KeyElementsofLevel-scheduling