GMS-缩短制造周期.ppt

1、缩短制造周期SHORT LEAD TIME,不断改进 Continuous Improvement,制造质量 Built-In- Quality,员工参与 经营 People Involvement,标准化 Standardization,缩短制造周期定义： Short Lead Time Definition:,Definition: Reduce the time from the placement of an order by the final customer to the delivery of the product and receipt of payment. There

2、are three types of lead time that contribute to the short lead time concept. They are: (1) Total Lead Time (receive order to receive payment) (2) Product Development Lead Time (from Document of Strategic Intent DSI to Start of Production - SOP) (3) Process Lead Time (from raw material to final assem

3、bly) (4) From factory to customer.,定义：缩短从最终客户下订单到交货收款的时间。在缩短制造周期的概念中有四种类型：(1) 完整的制造周期（从收到定单到收到货款） (2) 产品开发周期（从概念设计到生产开始） (3) 工艺制造周期（从原材料到最后装配）(4) 从生产基地到客户。,缩短制造周期目的： Short Lead Time Purpose :,Purpose: To achieve customer enthusiasm by delivering the customer his/her product more quickly, while maint

4、aining good quality. Ultimately, our Company benefits through cost reduction and increased customer loyalty.,目的：在保证高质量的同时，通过更快地传递产品来获得客户热诚。最终，公司将受益于降低的成本和提升的客户忠诚。,9.供应链的管理 Supply Chain Management (4),7.拉动式系统 Pull Systems (6),5.有计划的发运 /收货Schedule Shipping/Receiving (8),3.固定周期订货系统Fixed Period Ordering

5、 System (5),1.简易的工艺流程 Simple Process Flow (7),缩短制造周期的9个要素Nine Element of Short Lead Time,2.少批量包装 Small Lot Packaging (15),4.受控的外部运输 Controlled External Transportation (14),6.临时物料储存 Temporary Material Storage CMA (9),8.均衡定购车辆的生产计划 Level Vehicle Orders Schedules(3),2008 GMS SLT要素,1-1、简易的工艺流程 Simple Pr

6、ocess Flow (6),定义：以获得一个简易的物料与信息流为目的的流程 Definition: A process which incorporates a constant drive to attain a simple sequential process flow of material and information.,目的：设计和实施这样一种工艺,这种工艺在优化成本,降低工序内库存和易发现问题的同时坚持“先进先出”这一原则并且具有可跟踪性,可视性,能缩短制造周期. Purpose: To design and implement processes that maintain

7、 FIFO, allow trace ability, are visual, reduce lead time, easily detects problems while optimizing cost, and reduces inventory and work in process.,2、在制品及缓冲区受控, 并被优化及目视化。（例如零件、装配、零部件等）Work-in-process and buffers are controlled, optimized and visualized (e.g. parts, assemblies, components, etc.),1、先进

8、先出这一原则体现在所有物料存储操作中 First In First Out is practiced in ALL Material Storage operations.,1-2、简易的工艺流程 Simple Process Flow (6),3、目前的布局和流程利于直接,连续及简洁的生产/物料流转。. Layouts and processes facilitate a direct, continuous and simple product/material flow,4、为操作工设置安全、高效的零件摆放环境。Team member envelopes are set to allow

9、 safe and efficient parts presentation,要求 Requirements:,1-3、简易的工艺流程 Simple Process Flow (6),先进先出须在所有的物料存储操作中实施。 在制品缓冲区物料必须保持先进先出。 在制品和缓冲区必须正确目视并与最大/最小控制流程相一致。 所有按批生产的零件（如工位上预装分总成），其每次批量应近可能减少。 在制品必须经常检查以确保其数量上的最小化与最优化。,1-4、简易的工艺流程 Simple Process Flow (6),5、制造/仓储目视辅助设施(清单,屏幕,拉动卡等)要以简洁的格式存放于车间现场Manufa

10、cturing/warehousing visual aids (i.e. manifest, build schedules/runsheets, inside rack labels, etc.) are present on the shop floor in a simple format.,6、移动设备和生产/仓储设备支持简洁流程 Mobile equipment and production/warehousing equipment facilitate simple flowProduction visual aids (manifest,2-1、少量包装 Small Lot

11、Packaging (7),定义： 确定,分配或设计合适的标准数量和料箱 Definition: Determining, assigning or designing the appropriate standard quantity and container. 目的: 以易于操作的包装方式为操作工提供零部件,这种包装使部件在运送,储存和发货过程中不易受损,且易操作. Purpose: To provide parts to the operator in a user-friendly package that facilitates damage-free and economical

12、 handling during shipment, storage and delivery.,2-2、少量包装 Small Lot Packaging (7),c.在搬运时，零件质量得到维护，且衬隔操作最小化 Part quality is maintained while dunnage and dunnage handling are minimized,b.料箱尺寸必须模块化和可堆放，以便支持运输效率，空间利用率和装载稳定性Container sizes should be modular and stackable to support transportation efficie

13、ncies, cube utilization and load stability.,1.料箱设计： Container Design: a.在料箱/料架订购之前，所有料箱设计提案由物料、生产、质量、安全和附加小组根据需求进行回顾和批准 All container design proposals are reviewed and approved by material, production, quality, safety/ergo and additional groups as required before containers/racks are ordered.,要求 Req

14、uirements:,2-3 、少量包装 Small Lot Packaging (7),2.料箱内装有的物品须在经核准的标签上明确显示(零件号，名称，数量等) Container contents are identified on an approved label (part number, quantity, etc.),3、料箱选择过程文件化且确保选择最高效的料箱。 Container selection process is documented and ensures that the most effective container is selected.,A,关注于使用手工

15、搬运的料箱。 B,频繁运输（例如通常每班数次）决定标准包装数量，且零件必须放满料箱（没有剩余空间）。 C,要保护完整性的零件需指定使用衬隔。 D,手工搬运/移动的料箱的重量必须在本地规范以内。 E,从质量、制造和物料操作提出的需求被收集和反馈。每个班都需要纳入这个过程中。 F,分层审核用于检验包装需求和为持续改进寻（即提高料箱装载率、正确尺寸的料箱和标准包装数量）寻找机会。 G,有流程设置定期检查（例如最少每六个月车型年转换）指定的包装是否达到频繁搬运的要求。 H,每个零件都有一个标准包装数量。 I,备用料箱/一次性使用料箱的尺寸等于或小于可回用料箱。 G,对于提供同一个零件的多加供应商必须使

16、用经过审批的包装。 K,对于备用料箱，标准包装数量必须相同。 - Focus on using hand-manageable containers. - Standard pack quantity provides for frequent delivery (e.g. multiple times per shift in most cases) and should fill the container (no air). - Dunnage is assigned where needed to protect the integrity of the part. - Weight

17、of hand-carried/hand-moved containers is within local specification. - Input from quality, manufacturing, and material handling is collected and feedback given. All shifts are involved in the process. - Layered audits are used for verifying packaging requirements and identifying opportunities for co

18、ntinuous improvement (i.e. full containers, right size container and standard pack quantity). - A process is installed to check on a regular basis (at least every 6 months) whether assigned packaging fulfills the guidelines for frequent delivery. - One standard pack quantity per part number exists.

19、- Dimensions for back-up/expendable are the same or less than the returnable. - Dual suppliers providing the same part must use the approved packaging. - For the backup container, the standard pack quantity must be the same.,2-4 、少量包装 Small Lot Packaging (7),2-5 、少量包装 Small Lot Packaging (7),5、尽可能减少

20、或者消除重新包装（翻包装） Repacking is minimized/eliminated.,4、对于正常生产和所有可销售的生产活动，使用指定生产料箱运输物料。在仓储操作中，对于所有工厂而言，最终使用料箱运输物料。要尽可能使用通用的可回用料箱。 Material is shipped in the designated production container for regular production and all saleable build events. In warehousing operations, material is shipped in the end-use

21、container for all plant events. Use of common returnable containers is optimized. .,料箱型号： SC,2-6 、少量包装 Small Lot Packaging (7),c.有清楚的标记便于返回供应商（例如料箱型号，供应商名称，料箱对应零件规格，堆高等） clearly marked to facilitate return to suppliers (e.g. container type, supplier name, part specific containers, stack heights, etc

22、.,b.大小合适，且能提供事先的料箱计划 sized properly and able to accommodate planned quantities of containers,d.减少运输距离和标准化作业流程 located to minimize travel distance and standardize the work flow,6、空箱返回区域： Empty container return areas: a.经过目视化清楚的标识（即区域类型“筛选”、“存储”、供应商、返回计划、准备指示等） clearly identified with visual controls

23、(i.e. type of area Sort, Stage, supplier, return schedule, preparation instructions, etc.),2-7 、少量包装 Small Lot Packaging (7),f.确认损坏的料箱并制定修理/处置的方式 identify and route damaged containers for repair/disposal,e. 确保在发送供应商之前，空箱中无杂物 assure empty containers are free of debris before shipping them to supplier

24、,7、空箱处理准则 Empty container handling practices: a.确保操作工把空箱放置在合适的返回装置中 assure operator places empty container on appropriate return device b.遵循已有的内部衬垫处理流程 conform to a written process for handling internal dunnage c.遵循已有的分类，分级，装卸流程 conform to a written process for proper sorting, staging, loading, and

25、unloading,d.防止料错箱用 prevent misuse of containers,3-1 、固定周期订货系统 Fixed Period Ordering System (5),定义：为了能够在均衡基础上有效地提供物料而预先确定零部件定购的固定周期 Definition: Pre-determined, fixed period for parts ordering allowing for the effective supply of material on a leveled basis 目的：确保物流供应既可以预知又可靠 Purpose: To ensure predict

26、able, reliable flow of materials through the pipeline,3-2 、固定周期订货系统 Fixed Period Ordering System (5),2、有合适的流程避免零件报废 A documented process is in place to avoid obsolete parts,1、建立零部件订货和发运的固定周期 A fixed period is established for parts ordering and delivery.,5、有合适的流程确定系统库存和实际库存一致，以便维护零件计划的真实性。A process i

27、s in place to ensure record balance matches physical inventory to maintain part schedule integrity.,3、有处理紧急事件的特殊流程 An exception process exists to cover emergencies.,4、本地管理和维护供应商计划和物料的后续跟踪 Supplier schedules and Material follow-up are managed and maintained locally.,要求 Requirements:,4-1 、受控的外部运输 Cont

28、rolled External Transportation (8),定义:精益物流供应商管理有计划的可控的物流流程 Definition: Scheduled logistics pipeline with established controls managed by a lead logistics provider.,目的:为重复性物料的运送提供可预测的方法并达到各种资源的最优化 purpose: To provide a predictable method for frequent material movement that maximizes use of resources.

29、,4-2 、受控的外部运输 Controlled External Transportation (8),a. Provides business plan which is integrated with the Plant Material BPD and includes performance criteria. 提供业务计划，应与工厂物料BPD结合并包含绩效标准,e.张贴BPD和绩效标准，并定期与工厂回顾（最少每月一次） Posts BPD and performance criteria which is reviewed with the plant (minimum month

30、ly).,2.物流联系点负责物流运作。 Point of contact for Logistics is responsible for operational logistics,物流对口部门负责对关键绩效进行考量（例如：准时配送表现、成本降低、空间利用率等） Point of contact for Logistics is responsible for and measures key performance criteria (e.g. On time delivery, cost reduction, cube utilization etc.).,要求 Requirements

31、:,4-3、受控的外部运输 Controlled External Transportation (8),6.在正确的时间按照正确的数量从供应商处提取物料 Material is picked up from the supplier at the right time and in the right quantity,5.每条路线上是采用即时卸货法还是拖挂车厢抛停卸货法是根据经济和交通可靠性来决定的 Staging trailers in a marshaling area vs. live unloading is determined for each route based on e

32、conomics and transportation reliability.,7.有文件流程并被执行来协调特殊或紧急的运输和来正确区分由额外运输费用. A documented process is in place and followed to coordinate special or emergency shipments and to properly classify premium transportation.,4.为平衡人员工作量，设备需求及将库存最小化，发运计划应该是均衡的（例如：每周，每天，每小时 Planned delivery windows are level

33、(i.e.hour-to-hour,shift to shift,day-to-day,week-to-week) to balance workload and equipment as well as minimize inventory.,3.外部物流对口部门向承运人或运输供应商提供培训 Point of contact for Logistics provides training for all carriers and/or transportation providers.,4-4、受控的外部运输 Controlled External Transportation (8),8.

34、为了物流的运行质量的战略路线规划，联系点要将未来的影响列入考虑，以达到最低的物流成本。 Point of contact for Logistics is performing strategic route planning taking future impact into consideration to achieve lowest logistic costs.,5-1 、有计划的发运 /收货 Schedule Shipping/Receiving (5),定义：货物运输根据指定的时间达到/离开 Definition: Transportation carriers arrive /

35、 depart at designated time. 目的：均衡和标准化发运/收货活动以及资源要求 Purpose: To level and standardize shipping / receiving activities and resource requirements.,不能早到也不能晚到,5-2 、有计划的发运 /收货Schedule Shipping/Receiving (5),2、标准操作流程建立并展示，该流程明确承运商和工厂的任务和职责Standard operating procedures are established, displayed, and adhere

36、d to which describe the roles and responsibilities for the carrier and the plant.,1、承运人按计划的窗口时间到达/离开指定地点以平衡工作量、器械、以及最小化库存Carriers arrive/depart at the designated locations during scheduled window times to balance workload, equipment, and minimize inventory.,要求 Requirements:,3、使用标准化的目视信息栏（如，仓库信息墙），公布

37、每次运输的计划和状态 Standard visuals (e.g. dock boards) are in place to communicate the schedule and actual status of each delivery.,3、接收和发运区域应隔离并且要目视化 Receiving and shipping material areas are segregated and visual.,5-3 、有计划的发运 /收货 Schedule Shipping/Receiving (5),5、根据需要返回的计划，正确数量的料箱返回到正确的供应商处。Containers are

38、 returned to the right supplier in the right quantity based on the required return schedule.,4、有适当的流程用于确定、隔离、处理和补充损坏的料箱和物料。 A documented process is in place to identify, segregate, process and replenish damaged containers or material. .,6-1、临时物料储存 Temporary Material Storage (9),定义：在货运至使用地之前在指定区域的固定零

39、部件放置位置 Definition: A fixed part location in a designated area before delivery to the point of use. 目的：安排和控制库存以便满足制造和物流的需求 Purpose: To organize and control inventory to meet manufacturing and material flow needs.,X,6-1、临时物料储存 Temporary Material Storage (8),TMS: A=纸箱存储区 Carton Storage B=大件存储区 Bulk Sto

40、rage C=排序件存储区 Sequence Staging D=工程更改或和溢库区 Eng.Change and Overflow”Zone” E=报废和废弃物料区 Scrap and Obsolescence “Zone” F-空箱和废品区 Returnable and Waste”Zone”,6-2、临时物料储存 Temporary Material Storage (8),2、每一零件号有一个固定的库位。库位场地能够满足预计的最大值 Each part number has one fixed storage location. Storage location is sized to

41、 cover calculated maximum.,1、物料堆放区的数量和位置支持当前使用物料送料流程。Number and location of material storage areas support efficient material delivery processes,3、所有零件库位被目视化识别（标识，标签，使用说明等）All part locations are visually identified (signs, labels, instructions, etc.).,4.使用目视化控制，确保车间现场的安全（安全堆放高度），库存控制（最小最大库存，先进现出，溢库）

42、得到有效管理。 Visual controls are used to ensure that safety (safe stacking height), material flow process, and inventory control (min./max. FIFO, overflow) is managed on the shop floor.,6-3、临时物料储存 Temporary Material Storage (8),8、有流程存在用于隔离工程更改零件、断点老零件、待处理零件、包装更改测试零件和废旧物区域的设置。 A process exists to segregat

43、e engineering change material, obsolete material, non-conformance / scrap, package trials, and service parts areas,6、维护最小和最大库存，有文件流程来控制例外情况（违反最小最大库存，零库存，溢库等）。 Min/max quantities are maintained and a documented process is in place to manage exceptions (min and max violations, out of stock conditions,

44、 overflow, etc.).,思考 Think,?,5、 通道：a）清楚地标识出物料的进出，b）为所有人员提供流畅的交通c）便于叉车和拖车的通道的最小化4）清楚地标识设备和行人的通道和限制。(a) are clearly identified for store/in and retrieve/out, (b) provide for smooth traffic flow for all users (c) minimize the use of common aisles for forklift and tugged traffic and (d) clearly identify

45、 pedestrian paths / restrictions.,7、溢库区尽量小且受控，清晰标明，便于先进先出 Overflow areas are minimized, controlled, clearly identified and facilitate FIFO.,7-1、拉动式系统 Pull Systems (5),定义：由用户根据某产品的用量授权在特定时间,地点以一定的数量制造 和/或运输某一产品的补充系统 Definition: A replenishment system where the user authorizes the manufacture and / or

46、 delivery of a product at a specific time, place and quantity based on consumption.,目的：在使用户满意的前提下管理物流和减少库存 Purpose: To manage the flow of material and minimize inventory while satisfying the user.,7-2、拉动式系统 Pull Systems (5),3.当每个循环送满料箱上线的时，从使用的线旁工位取走空料箱和衬垫Empty containers and dunnage are removed fro

47、m the point of use location on each cycle when replenishment parts are delivered.,1、有适当的文件流程用于选择适当的拉动系统，从而最好的补充每个物料消耗。 A documented process is in place to select the appropriate pull system to be used for each part number to best replenish the material at point of use.,2、拉动信号由物料消耗所触发。要做到补料及时，工位正确，数量

48、正确，物料完好，以及向团队成员做最详细的介绍拉动信号由物料消耗所触发。要做到补料及时，工位正确，数量正确，物料完好，以及向团队成员做最详细的介绍 The pull signal is initiated by material consumption. Replenishment is timely, to the right location, in the right quantity, free of damage, and in the best presentation to the team member.,要求 Requirements:,Or,KANBAN,ANDON,7-3、

49、拉动式系统 Pull Systems (5),看板卡拉动流程 Pull Card Process 暗灯拉动系统（EPS） Electronic Pull System (EPS) PPS拉动 PPS Pull,Production Pull System,Small Parts Application Space Lineside for loopsize number,7-4、拉动式系统 Pull Systems (5),5、目视化控制被用作过程管理（min/max,看板卡数量，拉动触发点等） Visual controls are used for process management (

50、min/max, number of cards in loop, reorder points, etc.),4、合理的文件流程应该是在有规律的基础上对每一拉动触发信号进行监控、维护和改进的（例如：看板卡，线旁MIN/MAX，拇指数等）。 A documented process is in place for monitoring, maintaining and improving each pull signal (pull cards, lineside min/max levels, reorder points) on a regular basis.,8-1、均衡定购车辆的生产

51、计划 Level Vehicle Orders (3),定义：包括预定定购车辆均衡生产标准限制和不变更时间表在内的定单计划方法 Definition: Order scheduling method incorporating predetermined vehicle order leveling criteria limits and no change schedule time horizon. 目的：通过均衡工作量和推行标准化工作来增强精益生产的效率，从而达到支持精益生产物料管理和客户满意度的目的 Purpose: To enhance efficient lean manufact

52、uring by leveling out the workload and enabling standardized work to support lean materials management and customer satisfaction.,8-2、均衡定购车辆的生产计划 Level Vehicle Orders (3),益处：Benefits： 防止制造流程中的过度生产浪费 Prevents waste of over-production in the manufacturing process 平衡零件的供应 Level part supply 建立生产计划，能在适当的

53、时间生产合适的车辆 Creates a production plan that produces the right car at the right time. 改进制造流程及设备使用率 Improves building and equipment utilization 当有阻碍时，提高决策能力 Improves decision making when interruptions occur.,8-3、均衡定购车辆的生产计划 Level Vehicle Orders (3),8-4、均衡定购车辆的生产计划 Level Vehicle Orders (3),2、有流程保证检查在工厂会议上每个订单都按照规定的时间和数量被接收，有适当的计划规范（比如约束条