精益生產(chǎn)工具

1、Tenants of Single Piece Flow Do Not Make Defects Do Not Pass Along Defects Do Not Accept DefectsZero Defects = 0 Defects Not 3.4ppmQuality, Quality, QualityDefects are the Worst Kind of Waste 7 Types of Waste Defective Parts Over Production Inventory Motion Transportation Waiting Manual TouchesBatch

2、Single Piece FlowFrom: The Toyota Production SystemBuilding Quality into the ProcessSingle Piece FlowThe next process is the customer never send defects ! Sample Inspect catches Defect too Late When you Finally Find a Defect How many more do you have? Where are they in the process? What is the root

3、Cause? Single Piece Flow catches Defects immediately When you find a Defect You only have one You know where it occurred You Can find/Resolve the Root Cause immediatelyCheck, Do, VerifyCheck - The previous operators work.Do - Your work.Verify - That you did your work correctly.ProcessInspectTranspor

4、tTransportation is integrated into the production processvia automation e.g., moving lineProcessInspectProcessInspectTransportProcessInspectTransportation is integrated into the production processvia human conveyance e.g., Chaku-ChakuBuilding Quality into the Process2 ways to perform SPFThe next pro

5、cess is the customer never send defects !Check, Do, VerifyGets you into Parts Per Million quality-When you verify your work, you catch 1 flaw in 100 parts. The next person checks your work and can catch 1/100 so thats 1/10,000. Then that person Verifies their work and can catch 1/100. Thats 1/1,000,

6、000 errors that can get through. Check, Do, VerifyEvery Customer in a Process has:- a right to expect perfect material- an obligation to inspect the material before use.- an obligation to inform the previous step in the process of any problem.- an obligation to stop the process until any problem has

7、 been resolved.Single piece or one piece flow is a means to primarily buildQuality into the process. This is achieved by establishing a taktTime, developing std work, and swip. The premise is that an Operator can only work on one piece at a time, and performs a Quick quality check on the CTQs of the

8、 process before movingThe part to the following process. If a defect is detected, JidokaIs enactedthe line is stopped, and immediate action is takenTo remediate the situation and take countermeasures to preventreoccurenceTakt timeStd workFlow: work (process) that is done in conjunction with or simul

9、taneous to transportationOne Piece Flow The production is organized into a synchronous chain where each person has a balanced amount of work relative to his/her supplier and customer in the chain. As one person finishes their element, so do all. Work is then moved down the line synchronously. Every

10、person is empowered to stop the production process if a reject is spotted.OrganizationAreaSupervisorNew / RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work SheetTo:TurnsDPUsScope of OperationsFrom:Quality CheckSafety PrecautionStandard Work-in-Process# Lots of Standard Work-in-Pr

11、ocessTakt/Rate TimeTotal Manual & Travel TimeMan/Travel TimeOperatorEnd FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeTubingCFM CellFern BissonnetteCell 6All PartsAll Tubes1 1Mech.CleanRaw materialWeld100/DayFPIX-RayEDM2nd Qtr. 01EndFinishOutside Cell27 - avg lot = 6FlexF

12、inished GoodsACTION WORKOUTgGEMS Global Production SystemThe next process is the customer never send defects !Check, Do, VerifyOne Piece Flow Your customer is the next step in the process. Give to your customer, exactly what they need ( 1 item), exactly when they need it, done perfect every time.Ten

13、ants of 1 pcs Flow Do Not Make Defects Do Not Pass Along Defects Do Not Accept DefectQuality, Quality, QualityDefects are the Worst Kind of WasteSystem of manufacturing in which the final process withdraws the parts it needs from the precedingprocess at exact timing intervals, in the exact standardi

14、zed amount needed.Pull Production Methodology & SequenceDefinitionRef Material Presentation training for explanation on Supermarket definition and useEnd FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeMech.CleanFlexEnd FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech

15、.CleanTorchBrazeMech.CleanFlexParts13456End FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeMech.CleanFlexEnd FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeMech.CleanFlex789102Assembly LineCell or Chaku-Chaku lineSupplierMaterialInformationSupermarketEmp

16、ty containerFull containerLegend1Sequence / TimingPull Production Methodology & SequenceJITJidokaeGPS for GPCHeijunkaLevel LoadingSequencingFinding a balance between the volume of work that your organization needs to do and your capacityAdjusting a production schedule to meet unexpected changes

17、in customer demandOrdering the production in such a fashion to achieve the desired TAKT for all itemstaken from memory JoggerLeveled production meanslowering the peaks amongthe daily production volumesas much as possible and making the production flow smooth and unflucuating. In general, the more fl

18、uctuations you in the production flow, the more muda you end up having. That is because the capacity and capability of a line tends to be set at a level that meets the peak production demand rather than the average demand. If the production line produces only a single product, you may be able to red

19、uce muda simply by adjusting the production schedule and staffing level. But if you want to produce consistently at an average level where you have many different kinds of products to produce in a single line, you have to do the averaging not just in volume but in kinds as well. This way of averagin

20、g both volume and in kinds is called production leveling or heijunka in Japanese.Leveled ProductionAmount of products that can be soldHEIJUNKAAverage by total volumeAverage by model Leveled Load Production Build to forecast Build to FG inv Build after order is received ALL components need to be stoc

21、ked in RM An order from these products takes precedence over 1-2-3 products build this first !Use StocksBuild StocksTAKT0102030405060708090% F1F1F1F1F1F1F2F2F2F2F2F2 TAKT TimeDetermined by PSI2Q3Q4QOk to Build to FGRepeatable ProductsNon-Repeatable Products350300250Total65310663986688777108761089512

22、10104403025380705021701501301200220012000350300250Total6531066398668877710876108951210104403025380705021701501301200220012000Need to Determine . . .How Much20 bulbs per dayWhat Kind15/60 Watts 5/100 WattsWhen5 -60W, 2 100W, 5 60W,2 200W, 5 60W, 1 100W TAKTLevel Load MixLevel Load SequenceIf we were

23、making light bulbs. . . QuarterlyWeeklyWeeklyFrequency6060606060100 1006060606060100 1006060606060100Takt Time = Operating time per dayProduction requirement per dayAssumptions:Machine Breakdown = 0 hourSetup Change = 0 hourDefect Rate = 0%Takt Time EquationFor more information on TAKT Refer to JIT

24、SectionQuick ExampleSetting the production sequence of multiple TRAM RAC Types (Med Systems Product)ProductMonthlyRequirementDailyRequirementTAKT TimeModel 1720 units24 units5 minModel 2360 units12 units10 minModel 3360 units12 units10 minTotal1440 units48 units7.5 minThis is data for 3 products, Mo

25、del 1, Model 2, and Model 3, are produced at GEMS. The chart displays the monthly production level, the daily production level (monthly divided by 30), and the Takt time for each product type.THEY ARE ALL PRODUCED ON THE SAME LINE.How can these units be built in a level production mode using this ex

26、ample? Model 1Model 2Model 3Detailed Example Since these three products are on the same line, you will need to follow the sequence pattern of 1-2-1-3 in your production mix. By doing it this way you are able to level-load your production both in terms of quantity and types.# 1 Prod 1 # 4 Prod 3# 2 P

27、rod 2# 3 Prod 1REPEATMixed Assembly LineProduction Sequence by Type0246810Prod 1Prod 2Prod 3ProductTakt Time0246810121416Prod 1/Prod 2Prod 1/Prod 3ProductsTakt TimeProd 3Prod 2Prod 1If produced in batches, only the Model 1s will meet Takt timesIf produced to a sequence, 2 units will be produced in 2

28、 Takt timesLets show how we validate thisModelLine TaktTakt/Cycle GraphPart - QuantityPart Router13See Std Work Combo Sheet for example. One sheet is created for each operatorAdd RailsAdd BackplAdd 1 SpringAdd 3 SpringAdd CircuiAdd CircuiAdd CircuiAdd CircuiAdd RAC2 Add RAC 4 Add RAU Add R

29、AU Apply Label Apply Label Apply Label Aqpply Label 1XXXXXXXXX2XXXXXXXXX3XXXXXXXXXXSort By Volume02000400060008000100001233123413571946234524682833289434563579385545675678678982489991Part NumberQuantity00.81PercentageSCT=25SCT=40SCT=30766676138127.597.5Step No.Operation NameTimeManualAutoTr

30、avelProduction ReqdTakt/Rate TimeManualAutoTravelWaitOrganizationAreaSupervisorNew / RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work Combination SheetTotalsOperation TimeSec ( ) Min ( ) Hr ( ) 112/6/02AMXShannonX-RayStation 1 & 2J. David1234567Check MotorIssue DHRInstall Ge

31、n. HousingInstall ClipsInstall Term. StripInstall/Wire LatchJumper Wire to Filter10203040506070809074T/T32105641032546463040XStep No.Operation NameTimeManualAutoTravelProduction ReqdTakt/Rate TimeManualAutoTravelWaitOrganizationAreaSupervisorNew / RevPageofDateProduction LinePart NumberPart NameOper

32、atorStandard Work Combination SheetTotalsOperation TimeSec ( ) Min ( ) Hr ( ) 112/6/02AMXShannonX-RayStation 1 & 2J. David1234567Check MotorIssue DHRInstall Gen. HousingInstall ClipsInstall Term. StripInstall/Wire LatchJumper Wire to Filter10203040506070809074T/T32105641032546463040XStep No.Oper

33、ation NameTimeManualAutoTravelProduction ReqdTakt/Rate TimeManualAutoTravelWaitOrganizationAreaSupervisorNew / RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work Combination SheetTotalsOperation TimeSec ( ) Min ( ) Hr ( ) 112/6/02AMXShannonX-RayStation 1 & 2J. David1234567Chec

34、k MotorIssue DHRInstall Gen. HousingInstall ClipsInstall Term. StripInstall/Wire LatchJumper Wire to Filter10203040506070809074T/T32105641032546463040XTakt Build Time= # of Operations * TaktActual Build Time=SCT130230330125240330ModelTBTModelABT1-52+1030ModelObjectives:Produce to Takt Time (understanding no 2 products will have the exact same ABT)The sum of the DTot is zeroEvery product is produce at least onceNo product is produced twice in a rowCreate a prod