精益生產(chǎn)之2箱補(bǔ)充拉系統(tǒng)2BinReplenishmentPull中課件

03十二月2022精益生產(chǎn)之2箱補(bǔ)充拉系統(tǒng)2BinReplenishmentPull(中01十二月2022精益生產(chǎn)之2箱補(bǔ)充拉系統(tǒng)2BinRep12-Bin

補(bǔ)充拉系統(tǒng)2-箱補(bǔ)充拉系統(tǒng)的介紹線旁VS使用點(diǎn)庫存2-箱數(shù)據(jù)的要求和計(jì)算庫存部署選擇卡觸發(fā)2-箱流程1-箱系統(tǒng)附錄RD0112022-Bin

補(bǔ)充拉系統(tǒng)2-箱補(bǔ)充拉系統(tǒng)的介紹RD011202LeanSixSigma

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ImprovementPr3LearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentouseabinSystemBeabletosize(calculate)alltheparametersforabinsystem4LearningObjectivesUnderstand4課程目的理解箱補(bǔ)充系統(tǒng)的不同類型知道一個(gè)箱系統(tǒng)的好處理解何時(shí)使用一個(gè)箱系統(tǒng)能夠去計(jì)算一個(gè)箱系統(tǒng)的所有參數(shù)5課程目的理解箱補(bǔ)充系統(tǒng)的不同類型55What’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystem6What’sinItforMe?Beableto6我學(xué)到了什么?能夠在黑帶項(xiàng)目中應(yīng)用這個(gè)工具能夠?qū)嵤┮粋€(gè)箱系統(tǒng)7我學(xué)到了什么?能夠在黑帶項(xiàng)目中應(yīng)用這個(gè)工具772-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofastandardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedpartsPurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartreplenishmentis“triggered”basedonconsumption82-BinReplenishmentPullIntro82-箱補(bǔ)充拉系統(tǒng)的介紹2-箱補(bǔ)充拉系統(tǒng)是一個(gè)標(biāo)準(zhǔn)的補(bǔ)充拉系統(tǒng)的簡化版本，其好處是：在一個(gè)流程中建立戰(zhàn)略性的零件緩沖區(qū)原材料制造的零件采購的零件成品通過緩沖庫存將供應(yīng)過程和消耗過程聯(lián)系起來零件的補(bǔ)充是基于消耗而觸發(fā)的92-箱補(bǔ)充拉系統(tǒng)的介紹2-箱補(bǔ)充拉系統(tǒng)是一個(gè)標(biāo)準(zhǔn)的補(bǔ)充拉系統(tǒng)9WhatIsa2-BinReplenishment?Formanypartsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedperiodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe“1st”isbeingrefilled/replenished.Therearetwoprimaryreplenishmentlocations:Line-SideandPointofUse10WhatIsa2-BinReplenishment?102-箱補(bǔ)充拉系統(tǒng)是什么?對于在流程中的眾多零件而言，一個(gè)2-箱系統(tǒng)可以被用來補(bǔ)充零件相對于同步供應(yīng):一箱有足夠零件/供應(yīng)品以滿足在使用點(diǎn)上已計(jì)算出的用量周期。當(dāng)?shù)谝幌溆猛炅撕螅谘a(bǔ)充/重新裝料時(shí)，第二箱取代第一箱的位置繼續(xù)滿足使用。有兩個(gè)主要的補(bǔ)充地點(diǎn)：線旁和使用點(diǎn)112-箱補(bǔ)充拉系統(tǒng)是什么?對于在流程中的眾多零件而言，一個(gè)2-11Benefitsof2-BinReplenishmentOrganizedandoverallcleanerappearanceofstoredmaterialsReducedfrequencyoforderssubmittedtothestockroom/vendorReducednumberoftripsforre-supplyBettermanagementofinventoryontheshopfloorMorepredictableinventorycostsImproveemployeeproductivityby:Eliminatingpart/supplyshortagesatthepoint-of-useReducetimewastedbypersonnel/supervisionretrievingsupplies/inventoryfromthestockroomand/orvendorsEliminatelostormisplacedmaterial2-BinReplenishmentcanbeusedforoffice/safetysupplies,productioninventory,productionsupplies–evenathome!12Benefitsof2-BinReplenishmen122-箱補(bǔ)充拉系統(tǒng)的好處存儲的材料外觀非常清潔和有條理提交給庫房/供應(yīng)商的頻率減少重復(fù)供應(yīng)的差錯(cuò)數(shù)量減少了現(xiàn)場庫存的管理更好庫存成本更具有預(yù)測性提高員工生產(chǎn)率:排除在使用點(diǎn)的零件/供應(yīng)短缺減少由于人員/管理等，從庫房和/或供應(yīng)商重新找回供應(yīng)/庫存的時(shí)間浪費(fèi)排除材料的丟失或放錯(cuò)地方2-箱補(bǔ)充可以被使用在辦公室，安全供應(yīng)，生產(chǎn)庫存，生產(chǎn)供應(yīng)—甚至在家里!132-箱補(bǔ)充拉系統(tǒng)的好處存儲的材料外觀非常清潔和有條理1313WhentoUse2-BinReplenishmentPullRepetitiveproductoffering/processRelativelyconsistentdemand/volume(lowvariability)Part/supplyshortagesareaconsistent/costlyproblemPart/supplyinventorycostsare“outofcontrol”dueto:Lostormisplacedparts/suppliesLackofissue/dispersaldisciplineorcontrol14WhentoUse2-BinReplenishmen14何時(shí)使用2-箱補(bǔ)充拉系統(tǒng)重復(fù)的產(chǎn)品供應(yīng)/流程重復(fù)穩(wěn)定的需求(底變異)零件/供應(yīng)短缺是常事，且是一個(gè)代價(jià)很大的問題零件/供應(yīng)庫存成本是失控的，由于：零件/供應(yīng)品丟失或放錯(cuò)地方缺乏投料/分發(fā)的一致性或控制15何時(shí)使用2-箱補(bǔ)充拉系統(tǒng)重復(fù)的產(chǎn)品供應(yīng)/流程1515WhatIsaBin?Doesn’tnecessarilylooklikea“bin”Canbeastandardplasticbin(Acro-bin)Canalsobethebox/containerthepart/supplyisshippedin(alsocalleda“standardpack”–purchasingdefinition)Whenthebox/containermethodisused,a“bin”canbeonestandardpackorseveralstandardpacks.Examples:1boxofscrews2boxesofscrews1drumofoil30bagsofconnectors1rolloflabels4tubesofsealant16WhatIsaBin?Doesn’tnecessar16一箱是什么?這并不是說一定要看上去像個(gè)“箱子”它可以是一個(gè)標(biāo)準(zhǔn)的塑料箱它也可以是用于零件運(yùn)輸?shù)囊粋€(gè)盒子或容器(也可以用采購的定義被稱為一個(gè)“標(biāo)準(zhǔn)包”)當(dāng)盒子/容器方式使用了后,一個(gè)“箱”可以是一個(gè)標(biāo)準(zhǔn)的包或幾個(gè)標(biāo)準(zhǔn)包。例如：1盒螺釘2盒螺釘1打油30包連接器1卷標(biāo)貼4管子密封劑17一箱是什么?這并不是說一定要看上去像個(gè)“箱子”17172-BinReplenishmentDataParameters/NeedsDemand/Usage(DMD)TypicallyexpressedintermsofAverageDailyUsage(ADU)inunitsLeadTime(LT)ThetimeittakesfromwhenatriggerissenttowhenreplenishmentarrivesInthiscase,canalsobethoughtofas“RestockingTime”O(jiān)rderFrequency(OF)Iforders/triggersaresentatscheduledtimes(i.e.,noteveryday,suchasonceperweek)Typical2-BinsystemsdonotuseanOrderFrequency,asreplenishmentcanoccureveryday/shift(ormore)Box/ContainerQuantityIfstock/supplyroomorvendordoesnotbreakdownshippingquantity,thenthebinquantitymaybesetequaltosomemultipleofthebox/containerquantity(standardpack)thatthepart/supplyisshippedinSafetyStockTypically1/2themax(LT,OF)*DMD,maybesetotherwisedependentonindividualconditions182-BinReplenishmentDataParam182-箱補(bǔ)充系統(tǒng)數(shù)據(jù)

參數(shù)/要求需求/使用(DMD)一般來說用平均每天用量（ADU）來表達(dá)交貨期(LT)從補(bǔ)充需求觸發(fā)到補(bǔ)充品到達(dá)的時(shí)間。在這里，也可以被認(rèn)為是“再進(jìn)貨時(shí)間”。訂單頻率(OF)如果訂單/觸發(fā)信號的發(fā)放是按預(yù)定時(shí)間（如：并不是每天，而是每周一次）2-箱系統(tǒng)是不需要用訂單頻率的。補(bǔ)充可以發(fā)生在每天、每班（或更多）盒子/容器數(shù)量如果庫房或供應(yīng)商沒有列出運(yùn)輸數(shù)量的明細(xì)分類，那么箱數(shù)量可以設(shè)定為等于運(yùn)送零件/供應(yīng)品的若干盒子/容器數(shù)量安全庫存一般來說的設(shè)定為1/2max(LT,OF)*DMD,否則根據(jù)獨(dú)立的情況來看192-箱補(bǔ)充系統(tǒng)數(shù)據(jù)

參數(shù)/要求需求/使用(DMD)1919StockRoomorVendor12FullBin/CardMove1to2when2ispulled,Send

TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)2-BinReplenishment

(“Line-Side”Stocking)Reducespart/supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresultinsignificantproductivityimprovementsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF220StockRoomorVendor12FullMove20庫房或供應(yīng)商12添滿的箱/卡當(dāng)2被拉動(dòng)時(shí)，移動(dòng)1到2，發(fā)送觸發(fā)信號使用的部件空的箱/卡使用點(diǎn)位置(POU)或工作庫存(WIP)2-箱補(bǔ)充

(“線旁”庫存)減少零件/供應(yīng)品庫存，增加生產(chǎn)效率促進(jìn)WIP的降低將導(dǎo)致在庫房里的顯著的生產(chǎn)力提高降低/消除庫房在批數(shù)量上的影響可以簡單化存貨/周轉(zhuǎn)的計(jì)算流程線旁庫存LTOF2SS/2DMDOF),LTmax(箱數(shù)量

+*=21庫房或12添滿的當(dāng)2被拉動(dòng)時(shí)，移動(dòng)1到使用的空的使21FullBin/CardPullfrom1untilempty,sendtriggerandpullfrom2untilempty,sendtrigger,etc.UseComponentsEmptyBin/Card2-BinReplenishment

(“Point-ofUse”Stocking)LTOF12-BinPOUstockingisusedwhenre-stockingisnotanissue.StockRoomorVendorPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)222FullPullfrom1untilempty,U22拉動(dòng)從1開始直到用完為止,發(fā)送觸發(fā)信號，然后拉動(dòng)從2開始直到用完為止，發(fā)送觸發(fā)信號,等等.使用部件2-箱補(bǔ)充

(“使用點(diǎn)”庫存)LTOF1SS/2DMDOF),LTmax(箱數(shù)量+*=當(dāng)重新備庫存不是一個(gè)問題時(shí)，使用2-箱POU庫存庫房或供應(yīng)商2添滿的箱/卡空的箱/卡使用點(diǎn)位置(POU)或工作庫存(WIP)23拉動(dòng)從1開始直到用完為止,發(fā)送觸發(fā)信號，然后拉動(dòng)從2開始直232-BinReplenishmentCalculationsBinQuantity=Max(LT,OF)+SS/2Ifreplenishinginstandardpacks,BinQuantityisroundeduptotheneareststandardpackmultipleExample:CalculatetheBinQuantityforthefollowing(standardpackreplenishment):PartNumber: 40567Description: RubberGlovesDemand/Usage: 25pairs/dayLeadTime: 2days(trigger-stock/supplyroom-replenishment)OrderFrequency: N/ABoxQuantity: 50pairsBinQuantity=[Max(2days,N/A)*25pairs/day]+.5*[Max(2days,N/A)*25pairs/day]/2=63pairsButwehavetorounduptotheneareststandardpack,so:BinQuantity=100pairs=2boxes242-BinReplenishmentCalculatio242-箱補(bǔ)充的計(jì)算箱數(shù)量=Max(LT,OF)+SS/2如果是標(biāo)準(zhǔn)包的補(bǔ)充，箱數(shù)量應(yīng)該是近似于標(biāo)準(zhǔn)包的倍數(shù)舉例:計(jì)算下列數(shù)據(jù)的箱數(shù)量(標(biāo)準(zhǔn)包補(bǔ)充):零件號碼: 40567描述: 橡膠手套需求/用量: 25雙/天交貨時(shí)間: 2天(觸發(fā)–庫房–補(bǔ)充)訂單頻率: 不適用箱數(shù)量: 50雙箱數(shù)量=[Max(2天,N/A)*25雙/天]+.5*[Max(2天,N/A)*25雙/天]/2=63雙但是我們要取一個(gè)近似標(biāo)準(zhǔn)箱的數(shù)量，所以:箱數(shù)量=100對=2箱252-箱補(bǔ)充的計(jì)算箱數(shù)量=Max(LT,OF)+SS25Exercise#1:

2-BinReplenishmentCalculatetheBinQuantityforthefollowingsupplyitemina2-BinLine-SideReplenishmentprocessdirectlylinkedtothesupplier:PartNumber: 80886Description: PrinterPaperDemand/Usage: 22reams/dayLeadTime: 4days(trigger-purchasing-supplier-receiving-replenishment)OrderFrequency: 5daysBoxQuantity: 10reamsBinQuantity=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.Butwehavetorounduptotheneareststandardpack,so:BinQuantity=

=

.26Exercise#1:

2-BinReplenishme26練習(xí)#1:

2-箱補(bǔ)充如下供應(yīng)品的2-箱線旁補(bǔ)充流程直接連接著供應(yīng)商，計(jì)算箱數(shù)量:零件號碼: 80886描述: 打印紙需求/用量: 22令/天交貨時(shí)間: 4天(觸發(fā)–采購–運(yùn)輸–收貨–補(bǔ)充)訂單頻率: 5天箱數(shù)量: 10令箱數(shù)量=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.但是我們要取一個(gè)近似標(biāo)準(zhǔn)包的數(shù)量，所以:箱數(shù)量=

=

.27練習(xí)#1:

2-箱補(bǔ)充如下供應(yīng)品的2-箱線旁補(bǔ)充流程直接連27Exercise#2:

2-BinReplenishmentCalculatetheBinQuantityforthefollowingassemblyitemina2-BinLine-SideReplenishmentprocesslinkedtothewarehouse:PartNumber: A44B2Description: 4"Dia.SteelExtrusionDemand/Usage: 225ft/dayLeadTime: 1day(trigger-warehouse-replenishment)OrderFrequency: N/AExtrusionLength: 30ftBinQuantity=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.Butwehavetorounduptotheneareststandardpack,so:BinQuantity=

=

.28Exercise#2:

2-BinReplenishme28練習(xí)#2:

2-箱補(bǔ)充如下組裝線2-箱線旁補(bǔ)充流程直接連接著供應(yīng)商，計(jì)算箱數(shù)量:零件號碼: A44B2描述: 直徑4“的鋼鐵拉絲需求/用量: 225英尺/天交貨時(shí)間: 1天(觸發(fā)–倉庫–補(bǔ)充)訂單頻率: 不適用拉絲長度: 30英尺箱數(shù)量=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.但是我們要取一個(gè)近似標(biāo)準(zhǔn)包的數(shù)量，所以:箱數(shù)量=

=

.29練習(xí)#2:

2-箱補(bǔ)充如下組裝線2-箱線旁補(bǔ)充流程直接連接2912-BinReplenishment

BinLabelingandInformationEachBin/StorageLocationshouldhaveabarcodelabelortag.Makesurenottouseapermanentlabelappliedtoarack/bin,becauseyouwilleventuallywanttoresizeandmayhavetomakenewlabels!LabelsforLineSideBins/TagsforResupplyBinsPartNumber,Description,andLocationarePrinted.BinQuantityshouldnotbeprinted(requirestoomanylabelchangeswhenresizing–triggermechanismorsystemwillhaveBinQuantity)EachBinLocationshouldbeuniquetoavoidconfusionwhenrestocking.ExamplesareintheAppendix.LocationPartNumberDescription2LocationPartNumberDescription3012-BinReplenishment

BinLabe3012-箱補(bǔ)充

箱標(biāo)貼和信息每個(gè)箱/庫存地點(diǎn)都應(yīng)該有一個(gè)條碼標(biāo)貼或標(biāo)簽確保不要用永久的標(biāo)簽貼在一個(gè)貨架/箱。因?yàn)槟銓{(diào)整大小，且貼上一個(gè)新的標(biāo)貼！在線旁的需要重新補(bǔ)充的箱上的標(biāo)貼被打印的零件號碼,描述,地點(diǎn)等箱數(shù)量不應(yīng)該被打印出來(當(dāng)調(diào)整大小時(shí)需要太多的標(biāo)簽變化–觸發(fā)機(jī)制或系統(tǒng)將有箱數(shù)量)每個(gè)箱地點(diǎn)必須是獨(dú)一無二的以避免在重新補(bǔ)充庫存時(shí)混淆舉例在附件里.地點(diǎn)零件號碼描述2地點(diǎn)零件號碼描述3112-箱補(bǔ)充

箱標(biāo)貼和信息每個(gè)箱/庫存地點(diǎn)都應(yīng)該有一個(gè)條31Notesona1-BinSystemAonebinsystemisanexceptiontothe2-binforveryslowmovingparts/supplies.1-binpartsarenotstoredin2-binsbecauseof:HighinventorycostSpacerequirementsRacking/storagecost1-binsarereplenisheduponstockoutattheLine-Sidelocation.Stockoutimpactshouldbelowbecause:Parts/suppliesareverylowusers.Parts/suppliesarealsoatpointofusewhenLine-Sidestockoutoccurs.Parts/suppliesarestockedinnearbystock/supplyroom–easytoreplace.32Notesona1-BinSystemAoneb321-箱系統(tǒng)的注意對于流動(dòng)非常緩慢的零件/供應(yīng)品來說，一個(gè)1-箱系統(tǒng)是2-箱系統(tǒng)的例外.1-箱零件不象2-箱那樣被存儲，因?yàn)?高庫存成本空間需要貨架/倉儲成本在線旁的地點(diǎn)庫存短少時(shí)，1-箱被補(bǔ)充。庫存短少的影響應(yīng)該是微弱的，因?yàn)?零件/供應(yīng)品是非常少的使用者。當(dāng)線旁的存貨短缺發(fā)生時(shí)，零件/供應(yīng)品也同樣在使用點(diǎn).零件/供應(yīng)品被存放在庫房附近—容易補(bǔ)充.331-箱系統(tǒng)的注意對于流動(dòng)非常緩慢的零件/供應(yīng)品來說，一個(gè)1-33StockRoomorVendor11FullBin/CardMove1to2when2ispulled,Send

TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)1-BinReplenishment

(Typicallyfrom“Line-Side”)Reducespart/supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresultinsignificantproductivityimprovementsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF134StockRoomorVendor11FullMove34庫房或供應(yīng)商111-箱補(bǔ)充

(特別是從“線旁”)LTOF1添滿的箱/卡空的箱/卡當(dāng)2被拉動(dòng)時(shí)，移動(dòng)1到2，發(fā)送觸發(fā)信號使用點(diǎn)位置(POU)或工作庫存(WIP)減少零件/供應(yīng)品庫存，增加生產(chǎn)效率促進(jìn)WIP的降低將導(dǎo)致在庫房里的顯著的生產(chǎn)力提高降低/消除庫房在批數(shù)量上的影響可以簡單化存貨/周轉(zhuǎn)的計(jì)算流程線旁庫存SS/2OF),LTmax(箱數(shù)量

+*=使用的部件DMD35庫房或111-箱補(bǔ)充

(特別是從“線旁”)LT1添滿的空的當(dāng)35StockroomorVendor1LinePOU1-BinReplenishmentTransactions1-BinSysteminventorytransactionsmirrorthoseofthe2-BinsystemFrontflushforreducingtransactionsbutreduceoverallinventoryaccuracyBackflushforincreasinginventoryaccuracy(slightly)butincreasenumberofsystemtransactions11-binCardPartXYZTriggerReplenishment1-binCardPartXYZ36Stockroom1LinePOU1-BinReple36庫房或供應(yīng)商1線POU1-箱補(bǔ)充事務(wù)處理1-箱系統(tǒng)庫存交接與2-箱系統(tǒng)相似前端堆積減少交接過程但降低總體庫存量的準(zhǔn)確性后端堆積增加了庫存準(zhǔn)確性（幅度輕微）但增加了系統(tǒng)處理的事務(wù)量11-箱卡零件XYZ觸發(fā)補(bǔ)充1-箱卡零件XYZ37庫房或1線POU1-箱補(bǔ)充事務(wù)處理1-箱系統(tǒng)庫存交接與237TakeawaysKnowthethevarioustypesofBinReplenishmentsystemsBeabletodescribethebenefitsofaBinsystemHowtosize(calculate)alltheparametersforaBinsystem38TakeawaysKnowthethevarious38總結(jié)知道箱補(bǔ)充系統(tǒng)的不同類型能夠描述一個(gè)箱系統(tǒng)的利益能夠去計(jì)算一個(gè)箱系統(tǒng)的所有參數(shù)39總結(jié)知道箱補(bǔ)充系統(tǒng)的不同類型3939APPENDIX

2-BinReplenishmentPullAPPENDIX

2-BinReplenishmentP40附錄

2-箱補(bǔ)充拉系統(tǒng)附錄

2-箱補(bǔ)充拉系統(tǒng)41InstructionsforTypicalCard

Triggered2-BinReplenishmentThisprocessusesgreenandredcardstotriggerreplenishment;“bins”areactuallythebox/containerthepart/supplyisshippedin.1. Employeeremovesabinanddropsitsgreen2-bincardintothemailbox:Pullpartsfrom“bin”withgreencardbeforeusinganywiththeredcard.2. Atsametime(s)eachday,thecardsarepickedupfromthemailboxandreturnedtothestock/supplyroom.3. Thestock/supplyroompullsproperamountofparts/material(notedoncard,setequaltothecalculated“bin”quantity).4. Inventorytransactionsareperformed(dependingonissuemethod),andthematerialsandcardsaredeliveredtothestoragelocation.5. Employeestocksmaterialinstoragelocationandreturnscardtoitsproperplace.Whenstock/supplyroomreplacesthematerial,ensurethattheredcardisplacedonthefullbin.Alwaysleavesyouafullredbinremainingwhengreenbinrunsout.Ifnot,youcouldrundownbothbinsandstockoutbeforeeitherisreplaced;ifaredcardisinthereplenishmentprocess,apartshortageisimminent–actfast!42InstructionsforTypicalCard42典型的卡觸發(fā)2-箱補(bǔ)充的介紹這個(gè)流程用綠色和紅色卡來觸發(fā)補(bǔ)充；“箱”是實(shí)際用來發(fā)貨零件/供應(yīng)品的盒子/容器.1. 員工清掉一個(gè)箱后，將綠色的2-箱卡放入郵箱:在使用有紅色卡的零件前，先從有綠卡的箱中拉零件2. 每天的同一時(shí)候,郵箱卡片被收集并返回到庫房中.3. 庫房拉動(dòng)零件/材料的適合數(shù)量(在卡上注明，將之設(shè)定為計(jì)算出的“箱”數(shù)量).4. 庫存處理被執(zhí)行了(根據(jù)發(fā)放的方式),然后材料和卡被傳送到倉儲地點(diǎn).5. 員工將物料放在倉儲地點(diǎn)然后將卡返回到適合的地方.當(dāng)庫房補(bǔ)充材料時(shí)，確保紅色卡被放在添滿的箱上.當(dāng)綠箱被放出去使用時(shí)，始終保持紅卡箱中的零件已經(jīng)被填滿.如果不是這樣，在任一箱補(bǔ)充前你將用盡每個(gè)箱存貨；如果紅卡在補(bǔ)充過程中，零件短缺現(xiàn)象即將出現(xiàn)—盡快采取行動(dòng)。43典型的卡觸發(fā)2-箱補(bǔ)充的介紹這個(gè)流程用綠色和紅色卡來觸發(fā)補(bǔ)充43MaintainingaCardTriggered2-BinProcessCheckperiodicallyforlostcardsandreplace.Besttimeisrightafterreplenishment;anycardsnotreplacedorinthemailboxarelost.Policetheproperuseofcards:Supervisor/Leaddropgreencardswhengreenbinisempty.Supervisor/Leaddropredcardsonstockout–investigate!Supervisor/Leadensurecardsarereplacedwhenpartsarerestocked.Greenbinsarecompletelyusedbeforeredbins.Resizebinswhendemandchanges.Addcardsfornewparts,deletecardsforobsoleteparts.44MaintainingaCardTriggered244保持卡觸發(fā)2-箱系統(tǒng)的過程定期檢查卡片是否丟失并更換.最佳時(shí)間是在補(bǔ)充之后，如果卡片未被更換或未在郵箱都視為丟失維持卡片的合理使用:當(dāng)綠卡箱用完變空時(shí)，主管/組長投放綠卡.當(dāng)存貨用完時(shí)，主管/組長投放紅卡–調(diào)查!當(dāng)零件重新補(bǔ)充時(shí)，主管/組長確?？ㄆ桓鼡Q.在用紅卡箱前，確保綠卡箱已經(jīng)被用完.當(dāng)需求改變時(shí)需要重新調(diào)整箱的數(shù)量.新增的零件要增加不同的卡，過期的死庫存零件要將卡片毀尸滅跡.45保持卡觸發(fā)2-箱系統(tǒng)的過程定期檢查卡片是否丟失并更換.4545Bin1Bin2ExampleCardTriggered

Line-Side2-BinRackBin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-Bin

MailboxOrderCards1. AlwayspullmaterialfrombinwithGREEN

cardifitisthere.2. Store/supplyroomreplacesmaterialandswitchesREDcardtomaterialjustreplaced.3. Thecardsareattachedtomagneticstriplabels(foreaseofmovementforresizing).Bin1Bin1Bin246Bin1Bin2ExampleCardTrigger46Bin1Bin2舉例：

由卡觸發(fā)的線旁2-箱貨架Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-箱郵箱訂單卡片1. 如果這里有綠卡箱，那么必須要從綠卡箱里拉材料.2. 庫房補(bǔ)充材料并將紅卡換到剛補(bǔ)充的材料里.3. 卡片最好是有磁性的(這樣在調(diào)整數(shù)量時(shí)可以方便移動(dòng)).Bin1Bin1Bin247Bin1Bin2舉例：

由卡觸發(fā)的線旁2-箱貨架Bin47ExampleCardTriggered

Line-Side2-BinSystem48ExampleCardTriggered

Line-S48舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)49舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)4949ExampleCardTriggered

Line-Side2-BinSystem2-BinCardsareGreenandRed,pertheprocess.Cardsareplacedintoplasticsheathstoprotectthemfromgettingknockedofftheracking.Clearplasticsheathsareattachedtometalrackingviastickymagneticstripmakeresizingeasier.Binlabelsarewhitestickybackedandplacedinsideofplasticsheathforprotection.Aclearplasticsheathoverawhitelabelindicatesthatthebinisbeingreplenished.50ExampleCardTriggered

Line-S50舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)根據(jù)流程的需要，2-箱卡是綠卡和紅卡.卡片可裝入塑料套中以防止摩擦磕碰.透明塑料套通過磁性體吸附到金屬貨架上以便容易的調(diào)整數(shù)量.料箱標(biāo)簽為白色的，貼在塑料套內(nèi)背面加以保護(hù).塑料套顯示出白色時(shí)表明料箱正在補(bǔ)充.51舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)根據(jù)流程的需要，2-箱卡是綠51Ifaclearplasticsheath/pouchisusedtohousethelabelandthecard,thenaclearpouchovertheracklabelindicatesthatthepartisonorder–aneasywaytoPoka-Yoketheprocess.Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:box UnitsperPack: 6000STOCKOUT4Box(es)HaveBeenOrderedLocation=A25Physical=S-10002-BinR1-L3-S3CommonNamePartNumberPartDescriptionIndicatesPartisonOrderIndicatesQuantityonOrderLine-SideLocationRackandSpaceLocationSampleBin/RackLabel52Ifaclearplasticsheath/pouc52如果一個(gè)空塑料套/袋用來收集標(biāo)貼或卡片時(shí)，那么它在貨架上表示該零件已經(jīng)是在途訂單，這是很好的防錯(cuò)措施擋風(fēng)膠條40130W/STRIP.270HT.187BKFSW標(biāo)準(zhǔn)包裝:盒 每包件數(shù)： 6000用完4箱已訂貨地點(diǎn)=A25物理位置=S-10002-BinR1-L3-S3名稱零件號碼零件描述指示零件在訂貨中顯示訂貨數(shù)量線旁場所貨架和空間位置箱/貨架標(biāo)簽實(shí)例53如果一個(gè)空塑料套/袋用來收集標(biāo)貼或卡片時(shí)，那么它在貨架上表示53Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:box UnitsperPack: 6000Order:4Box(es)WhenNobox(es)AreLeftLocation=A252-BinSpace=S-10002-BinR2-A-4CommonNamePartNumberPartDescriptionIndicatesQuantityonOrderLine-SideLocationRackandBinLocationCardsaretypicallycoloredlightredor

lightgreenandlaminatedforprotection.Sample2-BinCard54WeatherstripCommonNamePartNu54擋風(fēng)膠條40130W/STRIP.270HT.187BKFSW標(biāo)準(zhǔn)包:盒子 每包數(shù)量: 6000訂貨:當(dāng)無剩余時(shí)，需要4箱訂貨地點(diǎn)=A252-箱空間=S-10002-BinR2-A-4卡片一般是亮紅或亮綠顏色，并有壓膜保護(hù)。2-箱卡樣板名稱零件號碼零件描述顯示訂貨數(shù)量線旁場所貨架和空間位置55擋風(fēng)膠條卡片一般是亮紅或亮綠顏色，2-箱卡樣55SampleRackLayout–FrontRacklayoutsdrawninExcel/othermakeexcellentimplementationandupkeepmapstoguidestocking/restockingefforts.Manytimesitisgoodtohaveparts/suppliesononlyonesideofarack–thatwayyoucan“pullfromoneside”and“replenishfromtheother.”56SampleRackLayout–FrontRack56貨架排布的樣板–前面貨架布置一般可用EXCEL或其他工具來做優(yōu)秀的實(shí)施，畫張圖來指導(dǎo)庫存/再次補(bǔ)充庫存的努力，大多數(shù)是一側(cè)取用零件/供應(yīng)品，你可以“從一側(cè)拉”并“從另一側(cè)補(bǔ)充”。57貨架排布的樣板–前面貨架布置一般可用EXCEL或其他工具57SampleRackLayout–BackIfarackhasafrontandabackside,makesuretolabelboth.Also,ifapart/supplystandardpackcanbeseenfrombothsidesoftherack(largebox/container),labelONLYonesidetoavoidconfusion.58SampleRackLayout–BackIfa58貨架排布的樣板–前面如果貨架是分正反面時(shí)，兩面都要有標(biāo)貼。同樣，如果零件/供應(yīng)品的包裝箱在貨架兩側(cè)都可以看見，標(biāo)簽只在一側(cè)標(biāo)識，以防止混淆.59貨架排布的樣板–前面如果貨架是分正反面時(shí)，兩面都要有標(biāo)貼59Measurementof2-BinEffectiveness2-BinEffectivenessismeasuredby:Stockoutswhenmaterialwasinthestock/supplyroomNumberofpartsperday/week/month/yearIndicatesthatthebinisnotsizedcorrectly,ORthereplenishmentleadtimeisincorrect,oralackofdisciplineintheprocessArepartsorganized?Yes/NoTypicallyavisualcheckoftheprocesswillsuffice,BUTtheprocessmustbeauditedatperiodicintervals(once/month)Areunscheduledreplenishmentsbeingmade?Howmanyperday/week/month?Consistentunscheduledreplenishmentsmayindicatethatdemandhasincreasedandthebinneedstoberesized.60Measurementof2-BinEffective602-箱效果的量測2-箱效果可以由下列方法量測:當(dāng)材料在庫房時(shí)的物料短缺每天/周/月/年的零件數(shù)量指出箱數(shù)量不正確，或補(bǔ)充交貨時(shí)間不正確，或過程缺乏組織性零件是否有組織的?是/否一般可以目視檢查過程的執(zhí)行能力，但應(yīng)定期對過程進(jìn)行審核（每月一次）是否有計(jì)劃外補(bǔ)充現(xiàn)象?每天/周/月有多少次?持續(xù)的計(jì)劃外補(bǔ)充表明需求增加，箱數(shù)量需調(diào)整。612-箱效果的量測2-箱效果可以由下列方法量測:6161StockroomorVendor2-BinLine-SideReplenishment

BackflushingInventory1. PartsarepulledfromlinePOUlocation,backflushingrelievesconsumedinventoryfromline-sidelocation.2. Binispulledfromline-sidestoragetore-supplyPOUlocation.3. Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4. Binisrefilledwithappropriatequantity.5. Inventoryistransferredfromstockroomtoline-sidelocation.6. Fullbinwithtriggerreturnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryTransferOccursHere1Line-SideStorage2InventoryBackflush(Charge-Off)OccursHereLinePOU262Stockroom2-BinLine-SideReple62庫房/供應(yīng)商2-箱線旁補(bǔ)充

后端堆積庫存1. 零件從線使用點(diǎn)（POU）的位置被拉動(dòng),后端堆積減輕了從線旁消耗的庫存.2. 箱被拉動(dòng)著從線旁庫存到使用點(diǎn)（POU）補(bǔ)充位置.3. 觸發(fā)信號(卡,箱,等.)被返回到庫房或供應(yīng)商.4. 箱被重新添滿到適合的數(shù)量.5. 庫存被轉(zhuǎn)移從庫房到線旁位置.6. 滿箱將回到線旁.2-箱卡零件XYZ觸發(fā)補(bǔ)充2-箱卡零件XYZ庫存轉(zhuǎn)移發(fā)生在這里1線旁庫存2庫存后端積壓(Charge-Off)發(fā)生在這里線POU263庫房/供應(yīng)商2-箱線旁補(bǔ)充

后端堆積庫存1. 零件從線使用點(diǎn)63StockroomorVendor2-BinLine-SideReplenishment

FrontflushingInventory1. PartsarepulledfromlinePOUlocation.2. Binispulledfromline-sidestoragetore-supplyPOUlocation.3. Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4. Binisrefilledwithappropriatequantity.5. Inventoryisfront-flushedoutofstockroomtoWIPorexpenseaccount.6. Fullbinwithtriggerreturnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryFrontflush(Charge-Off)OccursHere1Line-SideStorage2LinePOU264Stockroom2-BinLine-SideReple6403十二月2022精益生產(chǎn)之2箱補(bǔ)充拉系統(tǒng)2BinReplenishmentPull(中01十二月2022精益生產(chǎn)之2箱補(bǔ)充拉系統(tǒng)2BinRep652-Bin

補(bǔ)充拉系統(tǒng)2-箱補(bǔ)充拉系統(tǒng)的介紹線旁VS使用點(diǎn)庫存2-箱數(shù)據(jù)的要求和計(jì)算庫存部署選擇卡觸發(fā)2-箱流程1-箱系統(tǒng)附錄RD0112022-Bin

補(bǔ)充拉系統(tǒng)2-箱補(bǔ)充拉系統(tǒng)的介紹RD0112066LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-0267LeanSixSigma

ImprovementPr67LearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentouseabinSystemBeabletosize(calculate)alltheparametersforabinsystem68LearningObjectivesUnderstand68課程目的理解箱補(bǔ)充系統(tǒng)的不同類型知道一個(gè)箱系統(tǒng)的好處理解何時(shí)使用一個(gè)箱系統(tǒng)能夠去計(jì)算一個(gè)箱系統(tǒng)的所有參數(shù)69課程目的理解箱補(bǔ)充系統(tǒng)的不同類型569What’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystem70What’sinItforMe?Beableto70我學(xué)到了什么?能夠在黑帶項(xiàng)目中應(yīng)用這個(gè)工具能夠?qū)嵤┮粋€(gè)箱系統(tǒng)71我學(xué)到了什么?能夠在黑帶項(xiàng)目中應(yīng)用這個(gè)工具7712-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofastandardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedpartsPurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartreplenishmentis“triggered”basedonconsumption722-BinReplenishmentPullIntro722-箱補(bǔ)充拉系統(tǒng)的介紹2-箱補(bǔ)充拉系統(tǒng)是一個(gè)標(biāo)準(zhǔn)的補(bǔ)充拉系統(tǒng)的簡化版本，其好處是：在一個(gè)流程中建立戰(zhàn)略性的零件緩沖區(qū)原材料制造的零件采購的零件成品通過緩沖庫存將供應(yīng)過程和消耗過程聯(lián)系起來零件的補(bǔ)充是基于消耗而觸發(fā)的732-箱補(bǔ)充拉系統(tǒng)的介紹2-箱補(bǔ)充拉系統(tǒng)是一個(gè)標(biāo)準(zhǔn)的補(bǔ)充拉系統(tǒng)73WhatIsa2-BinReplenishment?Formanypartsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedperiodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe“1st”isbeingrefilled/replenished.Therearetwoprimaryreplenishmentlocations:Line-SideandPointofUse74WhatIsa2-BinReplenishment?742-箱補(bǔ)充拉系統(tǒng)是什么?對于在流程中的眾多零件而言，一個(gè)2-箱系統(tǒng)可以被用來補(bǔ)充零件相對于同步供