精益生产推行之原材料看板采购系统.ppt

1、,Raw Material Kanban 原材料看板Reorder Board System 再订购面板系统,JCMS Facilitator Training JCMS 推行者培训 May 24th - 28th, 2004 2004年5月24日,ReorderBoard_SHW_E_Oct 2003.ppt,2,Module Objectives模块目标,Explain the function of a Raw Material Kanban Reorder Board System 解释原材料看板再订购板系统的功能 Identify the Kanban card flow in th

2、e plant 明确看板卡在工厂内的流动 Identify key components for successful implementation of the Raw Material Kanban Reorder Board System 明确原材料看板重新排列面板系统顺利实施的关键因素 Explain the benefits of a Kanban system 解释看板系统的优点,ReorderBoard_SHW_E_Oct 2003.ppt,3,What does a Reorder Board Show?重新再订购板展示什么内容？,Inventory as it gets pu

3、lled and consumed原材料变化和消耗的详细记录 Quantity left 剩余量 Number of totes remaining in inventory when triggered 记录剩余库存的数量,ReorderBoard_SHW_E_Oct 2003.ppt,4,The Kanban Card System 看板卡系统,How does a Kanban Card System for external components support flow and JCMS? 外部零件的看板卡系统如何支持流动和JCMS？,The order for replenishm

4、ent is based on actual inventory usage 补充订购是建立在实际库存的基础上的 The details for ordering are made visual for the team on the shop floor 订购的详细情况在工厂向小组可视化展示,ReorderBoard_SHW_E_Oct 2003.ppt,5,Reorder Board: Current State再订购板：现有状态,Develop current state map of the area identified 为已确定区域制定现有状态图 Examples例如: Ship

5、Windows 运输窗口 Inventory Levels 库存水平 Inventory Storage 库存总量 Ordering Method 订购方法 Communication flow 交流流动 Other examples? 其他实例,ReorderBoard_SHW_E_Oct 2003.ppt,6,Reorder Board: Future State再订购板：未来状态,Develop Future State Map of the area identified 为已明确区域制定未来状态图 One Piece Flow is the foundation driving ch

6、ange 单片流动是推动变革的基础 Elimination of Waste! 消除浪费,ReorderBoard_SHW_E_Oct 2003.ppt,7,Kanban Signal Flow 看板信号流动,Relation of board location to inventory 看板位置与库存的关系 Method of signal attachment 信号附件方法 Determine how many production lines handle the inventory 决定使用库存的生产线数量,ReorderBoard_SHW_E_Oct 2003.ppt,8,Card

7、Flow example卡片流动实例,ReorderBoard_SHW_E_Oct 2003.ppt,9,Responsibilities 责任,Floor Layout 地面布局 Defined inventory storage area 定义库存存储区域 Inventory sizing 库存大小 Designated receiving area 指定接收区域 Training 培训 Leadership 领导 Support staff 支持力量 Production teams 生产小组 Documentation 文件 Card Audit 卡片审核 Gemba Audit Ge

8、mba 审核 Inventory Checklist 库存检验清单 Contact List 联系单 Work Instructions 工作指导书,ReorderBoard_SHW_E_Oct 2003.ppt,10,Responsibilities责任 (cont.),Board Construction 面板结构 Material acquisition 材料获得 Mapping 绘图 Board layout 面板布局 Board location 面板位置 Board 面板 5S 5S Cards 卡片 Process 过程 Audits 审核 Handling of Cards 卡

9、片的处理,ReorderBoard_SHW_E_Oct 2003.ppt,11,Pull card as soon as team breaks into a standard pack 在产品分装入标准包装后立即取卡 Place card on reorder board starting at the bottom and working up 在再订购面板上自下向上放置卡片,Consumption 消耗,ReorderBoard_SHW_E_Oct 2003.ppt,12,Ordering 订购,商品计划员Commodity Scheduler Pulls consumed cards

10、at fixed time 在固定的时间取出消耗卡片 Scans cards onto order sheet 查看订购表上的卡片 Places card in appropriate due date pouch or area on receiving board according to delivery lead time 根据订货至交货提前期，将卡片放入合适的到期日的口袋中或接收板上的合适区域。,ReorderBoard_SHW_E_Oct 2003.ppt,13,Receiving Board接收板,Delivery Time 发货时间 Supplier or scheduler

11、specific 供应商或日程细节 Past Due 过期,Expedite 快运 Documentation 文件 Make it VISUAL ! 可视化,ReorderBoard_SHW_E_Oct 2003.ppt,14,Receiving 接收,Pull card from date due pouch 从到期袋中取出卡片 Match cards to components 将卡片与组件相对应 Identify past dues based on delivery time 根据发运时间确认出过期数量 Identify over-shipments based on cards a

12、vailable 根据现有卡片明确过量运输 Place temp cards in front of the rack to be consumed first 在首先使用材料的货架前放置临时卡片 Put inventory in the rack according to the FIFO system 根据FIFO系统将库存产品放入货架中,ReorderBoard_SHW_E_Oct 2003.ppt,15,Past Due过期处理,Notify Team Leader 通知团队领导者 Initial, time and date on back of card 在卡片的背面标记时间与日期

13、 Place card in past due pouch 将卡片置于过期袋中 Team leader follow check list 团队领导者按照检查表进行检查,ReorderBoard_SHW_E_Oct 2003.ppt,17,Over-shipment过量发运,Notify Commodity scheduler 通知商品计划员 Place in the over-ship area 将材料置入过量发运区 Commodity Scheduler to follow checklist 商品计划员按照检查表检查,ReorderBoard_SHW_E_Oct 2003.ppt,18,

14、Expedite加速,Check arrival time and date on back of card 检查卡片背后的到达时间与日期 If parts are late, refer to past due instructions 如果到达时间延迟，请参照过期处理方法 Put card back in expedite pouch 将卡放回到快运期袋中,ReorderBoard_SHW_E_Oct 2003.ppt,19,On Hold暂留,Temporary decrease in loop size or to account for parts being sorted 暂时降低

15、回路大小，或暂被分拣出的部分 Notify Team Leader 通知团队领导者 Place parts in non-conforming with completed label if a quality issue Initial, time, and date back of card 如出现质量问题，将部件连同填写完毕的标签一现放在不合格区。在卡片背标记时间与日期 Team Leader follow checklist 团队领导者按照检查表检查,ReorderBoard_SHW_E_Oct 2003.ppt,20,Temp Cards 临时卡片,Temporary cards a

16、re used for a temporary increase of loop size, e.g.usage increase or Saturday production 临时卡用于回路大小暂时性增大。如：产品使用量增加或星期六生产 Use FIFO method to ensure temp cards are used first 使用FIFO（先进先出）方法，以保证临时卡片被首先使用,ReorderBoard_SHW_E_Oct 2003.ppt,21,Card Audit 卡片审查,Understand the purpose of performing audits: to v

17、erify accurate orders or correct issues with lost cards 理解实施审查的目的：检查订购是否准确或纠正丢失卡片的相关问题。 Designate the person responsible for completing audit 指定专人负责完成审查。 Frequency of audits, dependent upon successful handling of cards, is determined by the Commodity Scheduler. Generally starts at 1 per day. 审查的频率是由

18、商品计划员决定的，这取决于卡片的成功处理与否。通常每天审查1次。 Using the card audit sheet, confirm total # of cards in loop to cards present on ROB and on the floor. 使用卡片审查单，确认ROB与车间的每个卡片的总数。 If card is missing, determine which one it is and notify CS 如果卡片丢失，找出是哪一个丢失并通知CS。,ReorderBoard_SHW_E_Oct 2003.ppt,22,ReorderBoard_SHW_E_Oc

19、t 2003.ppt,23,Card Audit Sheet卡片审查表,ReorderBoard_SHW_E_Oct 2003.ppt,24,Gemba Audits Gemba审查,Gemba审查的目的是确认工厂的活动是否符合计划的过程或程序The purpose of the Gemba Audit is to verify the activity on the shop floor is matching the planned process or procedures. 这是加强理解与追踪系统的重要性的一个好方法This is a good tool to reinforce th

20、e understanding and importance of following the systems. 审查的频率由CS决定，并取决于是否能够严格地遵循系统， Frequency of audits, dependent on successful adherence to systems, determined by CS。,ReorderBoard_SHW_E_Oct 2003.ppt,26,Maintenance 维护,Reprint and laminate any cards that are damaged or lost 重新打印毁坏了的或丢失的卡片，并塑封 Repla

21、ce damaged pouches, containers 更换毁坏的口袋或容器 Replenish supply pouch (rubber bands, China pen, cleaning cloth) 补充供应袋中的物品（橡胶圈、笔、清洁布） Maintain updated info on all posted labels and reference sheets 更新所有标签与参考表上的信息,ReorderBoard_SHW_E_Oct 2003.ppt,27,Supplier Contact List供应商联系单,Tool to help verify past dues

22、or over ships 是帮助确认过期或过量发运的工具 For each supplier the following info is listed: receive time/day(s), carrier 对于每个供应商应列出以下信息：接收时间/天数、承运人 If a true shipment discrepancy is found, contact assigned CS 如果发现发运出现差异，应通知指定的CS,ReorderBoard_SHW_E_Oct 2003.ppt,29,Benefits of Kanban / Reorder Board看板/再订购板实施的益处,Dec

23、rease in inventory $, this helps our profit margin and bonus! 降低库存成本，这将有助于获取利润与红利！ Ordering based on consumption, not forecast, prevents pile-ups of inventory 根据消费订购，不是根据预测，这样就能防止库存的积压。 Suppliers know exactly what to ship, discrete qty. vs. min/max 供应商明确知道发运的货物、不连续订单数量VS最小/最大量。 Cleaner, safer, more organized environment 更加清洁、安全，并且更加有组织性的环境。,ReorderBoard_SHW_E_Oct 2003.ppt,30,Benefits (contd)实施的益处,High visibility of component status, more efficient flow of information 零件的状态具有较高的可视性，并且信息流动的效率更高。 Total loop size for specific V # 具体V#的总回路