精益生产工具课件

14三月2024精益生产工具BatchSinglePieceFlowFrom:TheToyotaProductionSystemBuildingQualityintotheProcessSinglePieceFlowThenextprocessisthecustomer…neversenddefects!

SampleInspectcatchesDefecttooLateWhenyouFinallyFindaDefectHowmanymoredoyouhave?Wherearetheyintheprocess?WhatistherootCause?SinglePieceFlowcatchesDefectsimmediatelyWhenyoufindaDefectYouonlyhaveoneYouknowwhereitoccurredYouCanfind/ResolvetheRootCauseimmediatelyCheck,Do,VerifyCheck-Thepreviousoperatorswork.Do-Yourwork.Verify-Thatyoudidyourworkcorrectly.ProcessInspectTransportTransportationisintegratedintotheproductionprocessviaautomatione.g.,movinglineProcessInspectProcessInspectTransportProcessInspectTransportationisintegratedintotheproductionprocessviahumanconveyancee.g.,Chaku-ChakuBuildingQualityintotheProcess2waystoperformSPFThenextprocessisthecustomer…neversenddefects!Check,Do,VerifyGetsyouintoPartsPerMillionquality-Whenyouverifyyourwork,youcatch1flawin100parts.Thenextpersonchecksyourworkandcancatch1/100sothat’s1/10,000.ThenthatpersonVerifiestheirworkandcancatch1/100.That’s1/1,000,000errorsthatcangetthrough.

Check,Do,VerifyEveryCustomerinaProcesshas:-arighttoexpectperfectmaterial-anobligationtoinspectthematerialbeforeuse.-anobligationtoinformthepreviousstepintheprocessofanyproblem.-anobligationtostoptheprocessuntilanyproblemhasbeenresolved.SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess.ThisisachievedbyestablishingataktTime,developingstdwork,andswip.ThepremiseisthatanOperatorcanonlyworkononepieceatatime,andperformsaQuickqualitycheckontheCTQsoftheprocessbeforemovingTheparttothefollowingprocess.Ifadefectisdetected,JidokaIsenacted…thelineisstopped,andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurenceTakttimeStdworkFlow:work(process)thatisdoneinconjunctionwithorsimultaneoustotransportationOnePieceFlow

Theproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis/hersupplierandcustomerinthechain.Asonepersonfinishestheirelement,sodoall.Workisthenmoveddownthelinesynchronously.Everypersonisempoweredtostoptheproductionprocessifarejectisspotted.OrganizationAreaSupervisorNew/RevPageofDateProductionLinePartNumberPartNameOperatorStandardWorkSheetTo:TurnsDPU'sScopeofOperationsFrom:QualityCheckSafetyPrecautionStandardWork-in-Process#LotsofStandardWork-in-ProcessTakt/RateTimeTotalManual&TravelTimeMan/TravelTimeOperatorEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeTubingCFMCellFernBissonnetteCell6AllPartsAllTubes11Mech.CleanRawmaterialWeld100/DayFPIX-RayEDM2ndQtr.‘01EndFinishOutsideCell27-avglot=6FlexFinishedGoodsACTIONWORKOUTgGEMSGlobalProductionSystemThenextprocessisthecustomer…neversenddefects!Check,Do,VerifyOnePieceFlowYourcustomeristhenextstepintheprocess.Givetoyourcustomer,exactlywhattheyneed(1item),exactlywhentheyneedit,doneperfecteverytime.Tenantsof1pcsFlowDoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectQuality,Quality,Quality…DefectsaretheWorstKindofWasteSystemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals,intheexactstandardizedamountneeded.PullProductionMethodology&SequenceDefinitionRefMaterialPresentationtrainingforexplanationonSupermarketdefinitionandusePartssemblyLineCellorChaku-ChakulineSupplierMaterialInformationSupermarketEmptycontainerFullcontainerLegend1Sequence/TimingPullProductionMethodology&SequenceJITJidokaeGPSforGPCHeijunkaLevelLoadingSequencingFindingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacityAdjustingaproductionscheduletomeetunexpectedchangesincustomerdemandOrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitemstakenfrommemoryJoggerLeveledproductionmeans

loweringthepeaksamong

thedailyproductionvolumes

asmuchaspossibleand

makingtheproductionflow

smoothandunflucuating.

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

modelLeveledLoadProductionBuildtoforecastBuildtoFGinvBuildafterorderisreceivedALLcomponentsneedtobestockedinRMAnorderfromtheseproductstakesprecedenceover1-2-3products…buildthisfirst!UseStocksBuildStocksTAKT%

F1F1F1F1F1F1F2F2F2F2F2F2

TAKTTimeDeterminedbyPSI2Q3Q4QOktoBuildtoFGRepeatableProductsNon-RepeatableProductsNeedtoDetermine...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–RefertoJITSectionQuickExampleSettingtheproductionsequenceofmultipleTRAM–RACTypes(MedSystemsProduct)ProductMonthly

RequirementDaily

RequirementTAKTTimeModel1720units24units5minModel2360units12units10minModel3360units12units10minTotal1440units48units7.5minThisisdatafor3products,Model1,Model2,andModel3,areproducedatGEMS.Thechartdisplaysthemonthlyproductionlevel,thedailyproductionlevel(monthlydividedby30),andtheTakttimeforeachproducttype.THEYAREALLPRODUCEDONTHESAMELINE.Howcantheseunitsbebuiltinalevelproductionmodeusingthisexample?Model1Model2Model3DetailedExample

Sincethesethreeproductsareonthesameline,youwillneedtofollowthesequencepatternof1-2-1-3inyourproductionmix.Bydoingitthiswayyouareabletolevel-loadyourproductionbothintermsofquantityandtypes.#1–Prod1#4–Prod3#2–Prod2#3–Prod1REPEATMixedAssemblyLineProductionSequencebyTypeIfproducedinbatches,onlytheModel1’swillmeetTakttimesIfproducedtoasequence,2unitswillbeproducedin2TakttimesLet’sshowhowwevalidatethis…Mod