精益生產(chǎn)之普通拉系統(tǒng)GenericPullSysem-課件

GenericPullSystemDefinitionofGenericPullBestPracticeCaseExamplesHowtoDetermineGenericPullLevelsExerciseAntennaSimulationRD010402GenericPullSystemDefinition普通拉系統(tǒng)定義普通拉系統(tǒng)的最佳實(shí)踐

案例舉例如何去決定普通拉水準(zhǔn)練習(xí)天線模擬RD010402普通拉系統(tǒng)定義普通拉系統(tǒng)的最佳實(shí)踐RD010402LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-023GenericPullSystemLeanSixSigma

ImprovementPrLearningObjectivesUnderstandthebestpracticedefinitionHowtoapplythisbestpracticeinvariousenvironmentsAbletodeterminethelevelsofinventoryusingthefivestepsDemonstratethisbestpracticethroughexercisesandsimulation4GenericPullSystemLearningObjectivesUnderstand課程目的理解最佳實(shí)踐的定義如何在多變的環(huán)境中應(yīng)用這個(gè)最佳實(shí)踐能夠去決定庫存的水平用5個(gè)步驟通過練習(xí)和模擬來示范這一最佳實(shí)踐5GenericPullSystem課程目的理解最佳實(shí)踐的定義5GenericPullSysWhat’sinItforMe?UnderstandthereasonforthistoolindifferentenvironmentsHowtousethistoolforpotentialblackbeltprojects6GenericPullSystemWhat’sinItforMe?Understand我學(xué)到了什么?理解在不同環(huán)境中使用這個(gè)工具的原因?qū)τ诤趲撛陧?xiàng)目如何去使用這個(gè)工具7GenericPullSystem我學(xué)到了什么?理解在不同環(huán)境中使用這個(gè)工具的原因7GenerGenericPullSystemsGenericPullSystemslimittheamountofWork-In-Processinventoryinordertocontrolcycletime.8GenericPullSystemGenericPullSystemsGenericPu普通拉系統(tǒng)普通拉系統(tǒng)為了控制周轉(zhuǎn)時(shí)間限制了制程庫存的數(shù)量（Work-In-Process）.9GenericPullSystem普通拉系統(tǒng)普通拉系統(tǒng)為了控制周轉(zhuǎn)時(shí)間限制了制程庫存的數(shù)量（WIPCapExitsStartsTriggerGenericPullSystemDefinedDefinition:AGenericPullSystemestablishesaWIPcapontheamountofinventorywithinapredefinedphysicalworkarea(setofworkstations)orprocess.TomaintaintheWIPcap,exitsfromtheprocesstriggerstartsintotheprocess.EstablishingWIPcapisthekeytocycletimereduction!!10GenericPullSystemWIPCapExitsStartsTriggerGenerWIPCapExitsStartsTrigger普通拉系統(tǒng)的定義定義:一個(gè)普通拉系統(tǒng)是在一個(gè)預(yù)先確定的物理工作區(qū)域（工作站）或流程中，在存貨金額上建立了一個(gè)WIPcap.來維護(hù)WIPcap,從流程中的“出口”（exits）來觸發(fā)進(jìn)入流程的“出發(fā)”（Starts).建立WIPcap是降低周轉(zhuǎn)時(shí)間的關(guān)鍵11GenericPullSystemWIPCapExitsStartsTrigger普通拉系統(tǒng)WhentoUseGenericPullAlwaysGenericPullsystemscanbeusedinanyofthefollowingmanufacturing/transactionalenvironments:Repetitiveprocess/repetitiveproductSimilarproducts/partsrunwithinsameprocessflowExample:Automotiveassemblyline,customerorderprocessingRepetitiveprocess/non-repetitiveproduct Dissimilarproducts/partsrunwithinsameprocessflowExample:Buildtoorderprintedcircuitboardmanufacturer,customercomplaintprocessingNon-repetitiveprocess/non-repetitiveproductDissimilarproducts/partsrunwithinadissimilarprocessflowExample:Machinemodel/prototypeshop,NPIprocessesGenericPullsystemsshouldalwaysbeusedwhenareplenishmentpullsystemisimplemented12GenericPullSystemWhentoUseGenericPullAlways何時(shí)使用普通拉系統(tǒng)永遠(yuǎn)普通拉系統(tǒng)可以被使用在下列任何制造/事務(wù)處理的環(huán)境中:重復(fù)的流程/重復(fù)的產(chǎn)品類似的產(chǎn)品/零件在同一個(gè)流程中運(yùn)行例如:汽車的組裝線,客戶定單流程重復(fù)的流程/不重復(fù)的產(chǎn)品

不同的產(chǎn)品/零件在同一個(gè)流程中運(yùn)行例如:根據(jù)定單定制的電路板制造商,客戶投訴流程不重復(fù)的流程/不重復(fù)的產(chǎn)品不重復(fù)的產(chǎn)品/零件在不同的流程里運(yùn)行例如:機(jī)器模型/原型制作車間,NPI流程當(dāng)補(bǔ)充拉系統(tǒng)被實(shí)施時(shí)，普通拉系統(tǒng)將永遠(yuǎn)被使用13GenericPullSystem何時(shí)使用普通拉系統(tǒng)永遠(yuǎn)13GenericPullSystWhenflyingfromDFWtoO’Hare,weoftenwindupwaitingonthegrounddueto“flowcontrol.”SinceO’Hareisoverloaded,airtrafficcontrolkeepsusinDallasuntilthecongestionoverO’Hareclears,versusgettingthereandcirclingChicago.Eitherway,weenduplate.However,usingthe“flowcontrol”(fixedWIP)method,weuselessfuelandreducetheriskofanaccident.Inaddition,wekeepouroptionsopen(suchas

re-routingiftheweatherbecomestoobad).Inapullsystem,maintaininga“fixedWIP”keepsworkordersinpaperformaslongaspossible.Thisprovidesthegreatestflexibilitytoschedule/engineeringchanges.Inaddition,lowWIPmeansafastercycletime,whichincreasestheprobabilityreleasesarebasedonactualcustomerordersversusforecast.“FixedWIP”ImprovesFlexibility14GenericPullSystemWhenflyingfromDFWtoO’Hare當(dāng)航班從DFW到O’Hare,我們通常由于“流控制”而在地面上緊張的等待。因?yàn)镺’Hare機(jī)場超負(fù)荷了,空中交通控制要求我們?cè)谶_(dá)拉斯等待，直到O’Hare的堵塞清除掉；與在芝加哥上空盤旋相比，任何一條路都注定會(huì)讓我們晚點(diǎn)?？墒牵褂谩傲骺刂啤?固定WIP)方式,我們用的燃油更少且降低了事故的風(fēng)險(xiǎn).此外,我們?nèi)匀幌碛形覀兊倪x擇權(quán)(例如重新選擇路線如果天氣變的更糟的話).在一個(gè)拉系統(tǒng)中，維護(hù)一個(gè)“固定WIP”可以使工作指令盡可能的在計(jì)劃階段。這樣為制定計(jì)劃/工藝變更提供了最大的彈性。此外，底WIP意味著更快的周轉(zhuǎn)時(shí)間，這樣可以增加基于客戶的訂單而不是根據(jù)預(yù)測“固定的WIP”改善彈性15GenericPullSystem當(dāng)航班從DFW到O’Hare,我們通常由于“流控制”ThePowerofaWIPCapWIPCap–CycletimeisreducedandstableNoWIPCap–Cycletimefluctuateswithamountof

WIP16GenericPullSystemThePowerofaWIPCapWIPCapWIPCap的能力WIPCap–周轉(zhuǎn)時(shí)間被降低了且穩(wěn)定沒有WIPCap–周轉(zhuǎn)時(shí)間隨WIP的金額而波動(dòng)17GenericPullSystemWIPCap的能力WIPCap–周轉(zhuǎn)時(shí)間被降低了且穩(wěn)UnitedTechnologies:

HoseandFittingsDivision(PTG)BeforeMetalwareflarerunninglargebatcheswithlargeamountsofWIP18GenericPullSystemUnitedTechnologies:

Hoseand聯(lián)合技術(shù):

HoseandFittings分部(PTG)之前金屬器械運(yùn)行大批次并伴隨大的WIP19GenericPullSystem聯(lián)合技術(shù):

HoseandFittings分部(PTUnitedTechnologies:

HoseandFittingsDivision(PTG)AfterMetalwareflareareawithcontrolsplacedonmaterialreleasestothedepartment20GenericPullSystemUnitedTechnologies:

Hoseand聯(lián)合技術(shù):

HoseandFittings分部(PTG)之后金屬器械區(qū)域?qū)Πl(fā)料到部門的材料放置進(jìn)行控制21GenericPullSystem聯(lián)合技術(shù):

HoseandFittings分部(PTTeledyneContinentalMotorsBeforeNointernallimitsexistedforthenumberofcylindersasuppliercouldpushtoitscustomer,resultinginlargeamountsofWIPintheline.22GenericPullSystemTeledyneContinentalMotorsBefTeledyneContinentalMotors之前對(duì)于缸體數(shù)量沒有內(nèi)部限制，供應(yīng)商向客戶推動(dòng)供應(yīng)，導(dǎo)致生產(chǎn)線有大量WIP.23GenericPullSystemTeledyneContinentalMotors之前2TeledyneContinentalMotorsAfterLimitswereestablishedworkstationsandthelinewasdrainedofexcessWIP24GenericPullSystemTeledyneContinentalMotorsAftTeledyneContinentalMotors之后建立限制數(shù)量，過多的WIP從工位和生產(chǎn)線清除25GenericPullSystemTeledyneContinentalMotors之后2HowtoSizeaGenericPullSystem1.DeterminecurrentManufacturingCycleTime(MCT)2.DeterminecurrentManufacturingCycleEfficiency(MCE)3.IdentifyappropriatetargetMCE4.CalculatetheoreticalbestMCT5.CalculateWIPcap26GenericPullSystemHowtoSizeaGenericPullSys如何確定普通拉系統(tǒng)的規(guī)模1.確定目前的制造周期時(shí)間(MCT)2.確定目前的制造周轉(zhuǎn)效率(MCE)3.識(shí)別適合的MCE目標(biāo)4.計(jì)算理論上的最佳MCT5.計(jì)算WIPcap27GenericPullSystem如何確定普通拉系統(tǒng)的規(guī)模1.確定目前的制造周期時(shí)間(MManufacturingCycleTimeMCT–Thetimefromworkorderreleaseintomanufacturinguntilcompletion/movementintoshipping/finishedgoods.Itismeasuredas:WIPistheinventorylevelatagivenpointintimeEXITSistheamountofworkcompletedoveragivenperiodoftime(Weekly,Daily)28GenericPullSystemManufacturingCycleTimeMCT–制造周期時(shí)間MCT–從工作單的下發(fā)到制造，直到完成/移動(dòng)到成品的時(shí)間.他被量測如:WIP是在給定時(shí)間點(diǎn)的存貨水平EXITS是在一個(gè)給定的時(shí)間內(nèi)(每周，每天)工作完成的金額29GenericPullSystem制造周期時(shí)間MCT–從工作單的下發(fā)到制造，直到完成/移動(dòng)MCTExits=20units/dayWIP

=SumofallInventorywithinPhysicalworkarea=100unitsMCT=100units/20unitsperdayMCT=5daysExample:

CalculatingMCT30GenericPullSystemMCTExits=WIP=SumofallInMCTExits=20單位/天WIP

=在物理工作區(qū)域里所有存貨的總和=100單位MCT=100單位/20單位每天MCT=5天舉例:

計(jì)算MCT31GenericPullSystemMCTExits=WIP=在物理工作區(qū)域里所有存貨的ManufacturingCycleEfficiencyMCEisameasureoftherelativeefficiencyinaproductionsystem.Itrepresentsthepercentageofvalueaddtime(changingform,fit,function)ofaproductdownthecriticalpath.Itismeasuredas:MCEistheperformanceindicatorforGenericPullSystems.32GenericPullSystemManufacturingCycleEfficiency制造周轉(zhuǎn)效率MCE是在生產(chǎn)系統(tǒng)中相關(guān)聯(lián)的效率量測.它代表關(guān)鍵路徑中的增值時(shí)間（改變形狀，尺寸，功能）的比率.

MCE是對(duì)于普通拉系統(tǒng)的績效指示器.33GenericPullSystem制造周轉(zhuǎn)效率MCE是在生產(chǎn)系統(tǒng)中相關(guān)聯(lián)的效率量測.它代表Example:

CalculatingMCE.2hrs.3

hrs.2hrs.2

hrs.6hrs1hrsBake7.0hrs.5hrsReworkInspect*CriticalPath=

ValueAddTotal = 10.0hours ValueAddCriticalPath = 8.5hours*MCT = 5.0days MCE = (8.5-7)/((5x8)-7)** = 1.5/33 = 4.5%FinishedGoodsRawMaterial*

TimeattheInspectworkstationdoesnotcontributetotheCriticalPathcalculationsbecauseinspectionisnotvalueadd.** Bake/MachinetimesarenotincludedinMCEcalculations34GenericPullSystemExample:

CalculatingMCE.2hr舉例:

計(jì)算MCE.2hrs.3

hrs.2hrs.2

hrs.6hrs1hrsBake7.0hrs.5hrsReworkInspect*CriticalPath=

ValueAddTotal = 10.0hours ValueAddCriticalPath = 8.5hours*MCT = 5.0days MCE = (8.5-7)/((5x8)-7)** = 1.5/33 = 4.5%FinishedGoodsRawMaterial* 在檢驗(yàn)工作站中的時(shí)間沒有算到關(guān)鍵路徑的計(jì)算中，因?yàn)闄z驗(yàn)不是增值的.** 烘烤/機(jī)器時(shí)間沒有包含在MCE的計(jì)算中35GenericPullSystem舉例:

計(jì)算MCE.2hrs.3hrs.2hrs.TargetMCETableofManufacturingCycleEfficiencyBenchmarksbasedonprocessapplication36GenericPullSystemTargetMCETableofManufacturi目標(biāo)MCE制造周轉(zhuǎn)效率表是基于流程應(yīng)用的基準(zhǔn)應(yīng)用

低端MCE

高端MCE

加工

1%

25%

裝配

10%

30%

組裝(用批傳輸

)

15%

40%

組裝

20%

50%

(不用批傳輸

)37GenericPullSystem目標(biāo)MCE制造周轉(zhuǎn)效率表是基于流程應(yīng)用的基準(zhǔn)應(yīng)用低端MCTheoreticalBestMCTTheoreticalBestMCTis:The“best”orlowestmanufacturingcycletimeachievablebasedontheprocesscharacteristics.Itismeasuredas:VA(CriticalPath)isthevalueaddtimealongthecriticalpath.Itdoesnotincludethevalueaddtimeofparallelprocesses.38GenericPullSystemTheoreticalBestMCTTheoretica理論的最佳MCT理論的最佳MCT是:基于過程特性可以達(dá)到的“最佳”或最低的制造周期時(shí)間.它可以由下列公式計(jì)算:VA(CriticalPath)

是沿關(guān)鍵路徑的增值時(shí)間，它并不包括并行工序的增值時(shí)間39GenericPullSystem理論的最佳MCT理論的最佳MCT是:39GenericMCTTB=1.5hrs/.2=7.5hrs=1dayExample:

TheoreticalBestMCT40GenericPullSystemMCTTB=1.5hrs/.2Example:

ThMCTTB=1.5hrs/.2=7.5hrs=1day舉例:

理論的最佳MCT41GenericPullSystemMCTTB=1.5hrs/.2舉例:

理論的最佳MCWIPCapTheWIPcapdeterminesthemaximumWIPallowedwithintheprocessatanytime.Itismeasuredas:42GenericPullSystemWIPCapTheWIPcapdeterminesWIPCapWIPcap決定在任意時(shí)間內(nèi)過程允許的最大WIP.它可以由下列公式計(jì)算:43GenericPullSystemWIPCapWIPcap決定在任意時(shí)間內(nèi)過程允許的最大WIPCap =1dayx20units/day =20unitsExample:

WIPCap44GenericPullSystemWIPCap =1dayx20units/dayWIPCap =1dayx20units/day =20units舉例:

WIPCap45GenericPullSystemWIPCap =1dayx20units/dayExample:

SummaryCurrentState:DesiredState:MCT

=5daysWIP

=100unitsExits

=20units/dayValueAddtime=1.5hrsMCE=4.5%MCT

=1dayWIP

=20unitsExits

=20units/day

ValueAddtime=1.5hrsMCE=20%46GenericPullSystemExample:

SummaryCurrentState舉例:

摘要目前的狀況:期望的狀況:MCT

=5daysWIP

=100unitsExits

=20units/day增值時(shí)間=1.5hrsMCE=4.5%MCT

=1dayWIP

=20unitsExits

=20units/day增值時(shí)間=1.5hrsMCE=20%47GenericPullSystem舉例:

摘要目前的狀況:期望的狀況:MCT=5daysAchievingWIPCapTypicallythecurrentWIPlevelwillbesignificantlygreaterthantheWIPCaplevel.Therefore,aplanmustbedevelopedtoreducetheWIP.48GenericPullSystemAchievingWIPCapTypicallyth時(shí)間增值

ExitsWIPPCTPCECurrentMonth01.5hrs20/day10054.5%步驟1Month11.5hrs20/day8046.0%步驟2Month21.5hrs20/day6038.8%步驟3Month31.5hrs20/day40216.7%步驟4Month41.5hrs20/day20120.0%WIP降低計(jì)劃達(dá)到WIPCap目前的WIP水平明顯高于WIPCap的水平.因此，必須制定計(jì)劃減少WIP.49GenericPullSystem時(shí)間增值ExitsWIPPCTPCECurrentMontHowtoReleaseWIPinto

aGenericPullSystemReleaselogicforGenericPullSystemsActualWIP>=WIPCapDonotreleaseanymoreworkintothisprocessflow.ActualWIP<WIPCapMoreworkshouldbereleasedintotheprocess(giventhatdemand>0).TheamountofworkreleasedshouldmakeActualWIPapproximatelyequaltoWIPcap.ActionRequiredWIPStatus50GenericPullSystemHowtoReleaseWIPinto

aGen如何將WIP發(fā)放到普通拉系統(tǒng)中普通拉系統(tǒng)的發(fā)放邏輯實(shí)際WIP>=WIPCap不發(fā)放任何的工單到流程中.實(shí)際WIP<WIPCap應(yīng)該發(fā)放更多的工單到流程中去(給定的需求>0).發(fā)放的工單將讓實(shí)際的WIP和WIPcap大致相等。需要采取的行動(dòng)WIP狀況51GenericPullSystem如何將WIP發(fā)放到普通拉系統(tǒng)中普通拉系統(tǒng)的發(fā)放邏輯實(shí)際WIPGenericPullExercise:PartAGiventhefollowingInformation:AverageDemandis10units/dayCurrentMCTis20daysValueAddTime=8hoursFabricationShop1shiftoperationthatworks5daysperweekAnswerthefollowingquestions:WhatshouldmyWIPcap(inunits)be?HowmuchinventoryshouldIdrainfromtheoperation?52GenericPullSystemGenericPullExercise:PartAG普通拉系統(tǒng)的練習(xí):零件A已知下列信息:平均的需求是10單位/天目前的MCT是20天增值時(shí)間=8小時(shí)裝配車間每周工作5天，一班運(yùn)作回答下列問題:我的WIPcap(單位)將會(huì)是什么?應(yīng)該從工序中減少多少庫存？53GenericPullSystem普通拉系統(tǒng)的練習(xí):零件A已知下列信息:53GenericGenericPullExercise:PartBUsingthecalculatedWIPcapfromPartAanswerthefollowingquestions:CurrentWIPlevelis105unitsandmyMRPsystemwantsmetoreleaseaquantityof5unitsintothelinewhatshouldIdo?Why?CurrentWIPlevelis95unitsandmyMRPsystemwantsmetoreleaseaquantityof5unitsintothelinewhatshouldIdo?Why?CurrentWIPlevelis98unitsandmyMRPsystemwantsmetoreleaseaquantityof5unitsintothelinewhatshouldIdo?Why?54GenericPullSystemGenericPullExercise:PartBU普通拉系統(tǒng)的練習(xí):零件B用零件A部分的WIPCap計(jì)算結(jié)果回答下列問題:目前的WIP水平是105單位，我的MRP系統(tǒng)要求我發(fā)放一個(gè)數(shù)量為50單位的工單到生產(chǎn)線上，我應(yīng)該做什么？為什么？目前的WIP水平是95單位，我的MRP系統(tǒng)要求我發(fā)放一個(gè)數(shù)量為5單位的工單到生產(chǎn)線上，我應(yīng)該做什么？為什么？目前的WIP水平是98單位，我的MRP系統(tǒng)要求我發(fā)放一個(gè)數(shù)量為5單位的工單到生產(chǎn)線上，我應(yīng)該做什么？為什么？55GenericPullSystem普通拉系統(tǒng)的練習(xí):零件B用零件A部分的WIPCap計(jì)算HowtoDetermineUnitof

MeasureforWIPControlConceptuallyallGenericPullSystemsareidentical,theprimarydifferencebeingtheWIPcontrolparameter.TheWIPcontrolparameteristheunitofmeasureforWIPusedtocontrolthepipeline.Threetypesofparametersareused:QuantityEquivalentUnitsTimeThemosteffectivemethodfordeterminingtheproperparameterisusingthe“CoefficientofVariation(CV)”fortheproductvalueaddtimes.56GenericPullSystemHowtoDetermineUnitof

Meas如何決定WIP控制的量測單位概念性的普通拉系統(tǒng)都是同樣的，主要的不同點(diǎn)在于WIP的控制參數(shù).WIP的控制參數(shù)是指用來控制整個(gè)路徑的WIP的度量參數(shù).三種類型的指標(biāo)被使用:數(shù)量等價(jià)單位時(shí)間確定適合參數(shù)的最有效的方法是將“變量系數(shù)”用于產(chǎn)品增值時(shí)間。57GenericPullSystem如何決定WIP控制的量測單位概念性的普通拉系統(tǒng)都是同樣的，主CoefficientofVariation(CV)TheCVoftheValueAddTimesisusedtodeterminehowtheworkloadinaprocessisaffectedbychangesinproductmix.Itismeasuredas:“CVisareasonablerelativemeasureofthevariabilityinaprocess.”–FactoryPhysics,Hopp&Spearman58GenericPullSystemCoefficientofVariation(CV)T變量系數(shù)(CV)增值時(shí)間的CV用來確定過程中的工作量是如何受混型產(chǎn)品變化影響的，按下式計(jì)算：“CV是過程變異性相對(duì)合理的量測方法.”–FactoryPhysics,Hopp&Spearman59GenericPullSystem變量系數(shù)(CV)增值時(shí)間的CV用來確定過程中的工作量是如何Example2:

CalculatingCVStd.Dev.(s)=Coeff.Var.(CV)=Mean(x)=Formulas:60GenericPullSystemExample2:

CalculatingCVStd.舉例2:

計(jì)算CVStd.Dev.(s)=Coeff.Var.(CV)=Mean(x)=公式:61GenericPullSystem舉例2:

計(jì)算CVStd.Dev.(s)=CoefSelectingWIPControlParameter62GenericPullSystemSelectingWIPControlParamete選擇WIP控制參數(shù)63GenericPullSystem選擇WIP控制參數(shù)63GenericPullSystemExample3:

IdentifyingWIPControlParameterReferenceHandoutsforanalyticaldetailLowVariabilityMediumVariabilityHighVariabilityMean(x):1.673.704.56StdDev(s):0.713.916.59CV(s/x):0.421.061.44Parameter:QuantityEquiv.Units/TimeTimeResizingFrequency:QuarterlyMonthlyWeekly64GenericPullSystemExample3:

IdentifyingWIPCon舉例3:

確定WIP控制參數(shù)詳細(xì)分析參考分發(fā)的資料低變異中等變異高變異Mean(x):1.673.704.56StdDev(s):0.713.916.59CV(s/x):0.421.061.44參數(shù):數(shù)量等價(jià)單位/時(shí)間時(shí)間調(diào)整規(guī)模大小的頻次:每季度每月每周65GenericPullSystem舉例3:

確定WIP控制參數(shù)詳細(xì)分析參考分發(fā)的資料低變Example4:

CalculatingEquivalentUnitsHighestvolumeproductrepresentsequivalentunit66GenericPullSystemExample4:

CalculatingEquiva舉例4:

計(jì)算等價(jià)單位最高產(chǎn)量的產(chǎn)品代表等價(jià)單位67GenericPullSystem舉例4:

計(jì)算等價(jià)單位最高產(chǎn)量的產(chǎn)品代表等價(jià)單位67GenPerformanceMeasurementsofaGenericPullSystemPullSystemeffectivenessmeasurementsMCTandMCTVarianceMCEActualvs.TargetWIPAdditionalmeasurementsWIPTurnsBacklogbyOrder,PartandAgeOn-TimeDeliveryQuantityofDailyCompletionsRefertoDashboardbestpracticeforspecifics68GenericPullSystemPerformanceMeasurementsofa普通拉系統(tǒng)的績效評(píng)估拉系統(tǒng)的效力量測MCT和MCT的變化量MCE實(shí)際的WIPvs.目標(biāo)的WIP其他的量測WIP周轉(zhuǎn)次數(shù)按訂單、零件及期限分類訂貨準(zhǔn)時(shí)交貨日完成數(shù)量詳細(xì)信息查閱最佳實(shí)踐的宣傳板69GenericPullSystem普通拉系統(tǒng)的績效評(píng)估拉系統(tǒng)的效力量測69GenericPuTakeawaysUnderstandtheimportanceofGenericPullAbletosize(calculate)aGenericPullSystemHowtoapplythisbestpractice70GenericPullSystemTakeawaysUnderstandtheimport總結(jié)理解普通拉系統(tǒng)的重要性能夠去計(jì)算一個(gè)普通拉系統(tǒng)的規(guī)模如何去應(yīng)用這一最佳實(shí)踐71GenericPullSystem總結(jié)理解普通拉系統(tǒng)的重要性71GenericPullSyAntennaExerciseRunExercises1-4RecordResultsandObservationsDiscussExercises1-4AntennaExerciseRunExercises天線練習(xí)練習(xí)1-4記錄結(jié)果和觀察信息討論練習(xí)1-4天線練習(xí)練習(xí)1-4LearningObjectivesDemonstratethefundamentalrelationshipbetweenWIP,CycleTime,andThroughputDemonstratetheWIPimpactonaprocessDemonstratethebottleneckimpactonaprocessRecordeachsimulationresult/observationanddiscussindetail74GenericPullSystemLearningObjectivesDemonstrate課程目的示范WIP、周轉(zhuǎn)時(shí)間和生產(chǎn)能力的基本關(guān)系原理示范在流程中WIP的影響示范在流程中的瓶頸影響記錄每個(gè)模擬的結(jié)果/觀察和討論細(xì)節(jié)75GenericPullSystem課程目的示范WIP、周轉(zhuǎn)時(shí)間和生產(chǎn)能力的基本關(guān)系原理75GeWhat’sinItforMe?Visuallyseetheimpactofbarriers(WIPandBottleneck)onaprocessHowtocalculatecycletimeinthisexerciseandotherapplications76GenericPullSystemWhat’sinItforMe?Visuallys我學(xué)到了什么?真實(shí)的看到在流程中瓶頸的影響（WIP和瓶頸）如何去計(jì)算在這個(gè)練習(xí)和其他應(yīng)用中的周轉(zhuǎn)時(shí)間77GenericPullSystem我學(xué)到了什么?真實(shí)的看到在流程中瓶頸的影響（WIP和瓶頸）7TeamExercise:

AntennaFactoryExercise#1Startwithemptyline

(WIP=0)BuildoneantennaRecordresultsExercise#2StartwithWIP=4BuildfourantennasRecordresultsExercise#3StartwithWIP=8BuildeightantennasRecordresultsExercise#4StartwithWIP=0Operation#2-BottleneckRunsimulationfortwominutesRecordresults78GenericPullSystemTeamExercise:

AntennaFactory團(tuán)隊(duì)練習(xí):

天線工廠練習(xí)#1從零開始

(WIP=0)建一個(gè)天線記錄結(jié)果練習(xí)#2從WIP=4開始建4個(gè)天線記錄結(jié)果練習(xí)#3從WIP=8開始建8個(gè)天線記錄結(jié)果練習(xí)#4從WIP=0開始操作員#2–瓶頸運(yùn)行模擬2分鐘記錄結(jié)果79GenericPullSystem團(tuán)隊(duì)練習(xí):

天線工廠練習(xí)#1練習(xí)#2練習(xí)#3練習(xí)#4ExerciseCycleTime#1 #2 #3 #4Team1Team2Team3Team4Team5Team6WIPExitsExerciseResults80GenericPullSystemExerciseCycleTime#1 練習(xí)的周轉(zhuǎn)時(shí)間#1 #2 #3 #4隊(duì)1隊(duì)2隊(duì)3隊(duì)4隊(duì)5隊(duì)6WIPExits練習(xí)結(jié)果81GenericPullSystem練習(xí)的周轉(zhuǎn)時(shí)間#1 #2 #3 Operators1through4ProductionSupervisorrecordsthecycletimeandthroughputofeachrunExerciseRolesInsertScrewAttachAntennaBaseOperatorperformsthetaskoftheoperationassignedAttachSideLeg1AttachSideLeg282GenericPullSystemOperators1through4Productio操作員從1到4生產(chǎn)主管記錄每次的周轉(zhuǎn)時(shí)間和生產(chǎn)能力練習(xí)的角色嵌入螺絲裝上基礎(chǔ)天線操作員按照給定的任務(wù)去完成裝上腳1裝上腳283GenericPullSystem操作員從1到4生產(chǎn)主管練習(xí)的角色嵌入裝上基礎(chǔ)操作員按照ExerciseObservationsAslongasthereisnoqueuetime(WIP=1-4),thecycletimeisroughlyequaltothesumoftheprocesstimesorvalueaddtime(VA).TherateatwhichAntennasarecompleted(throughput)ismaximizedwhenthereisnoidletime(WIP=4-8),anditisgovernedbytheslowestoperation.WhenWIP=4antennas,thereisnoqueuetime(minimumcycletime)andnoidletime(maximumthroughput),thisisthecriticalWIPlevel.ForanyWIP>CriticalWIP,cycletimewillincreasewithnoincreaseinthroughput(assumingnovariability).Thereexistsafundamental

relationshipbetweenWIP,Cycle

TimeandThroughput.Whatisit?WIP CT Exits1 60sec 1/min4 60sec 4/min8 120sec 4/min84GenericPullSystemExerciseObservationsAslonga練習(xí)的觀測報(bào)告在這里是沒有排隊(duì)等待時(shí)間(WIP=1-4),周轉(zhuǎn)時(shí)間大約等于工序時(shí)間的總和或者增值時(shí)間(VA).當(dāng)沒有空閑時(shí)間時(shí)(WIP=4-8)，天線的完成比率（生產(chǎn)能力）是最大的,并且比率被最慢的那個(gè)工位所控制.當(dāng)WIP=4個(gè)天線時(shí),流程中沒有等待時(shí)間(最小的周轉(zhuǎn)時(shí)間)并且沒有空閑時(shí)間(最大的產(chǎn)能),這就是關(guān)鍵WIP水平.對(duì)于任何WIP>關(guān)鍵WIP,周轉(zhuǎn)時(shí)間將被延長而生產(chǎn)能力并沒有被提升(假設(shè)沒有可變性).在WIP、周轉(zhuǎn)時(shí)間和生產(chǎn)能力間存在這一個(gè)基本的關(guān)系。它是什么？WIP CT Exits1 60sec 1/min4 60sec 4/min8 120sec 4/min85GenericPullSystem練習(xí)的觀測報(bào)告在這里是沒有排隊(duì)等待時(shí)間(WIP=1-TakeawaysUnderstandtherelationshipbetweenCycleTime,WIP,andThroughputBetterunderstandinghowtoimpactcycletime86GenericPullSystemTakeawaysUnderstandtherelati總結(jié)理解周轉(zhuǎn)時(shí)間、WIP和生產(chǎn)能力間的相互關(guān)系更好的理解如何去影響周轉(zhuǎn)時(shí)間87GenericPullSystem總結(jié)理解周轉(zhuǎn)時(shí)間、WIP和生產(chǎn)能力間的相互關(guān)系87GenerChapterRevisionHistoryHiddenSlide88GenericPullSystemChapterRevisionHistoryHiddenGenericPullSystemDefinitionofGenericPullBestPracticeCaseExamplesHowtoDetermineGenericPullLevelsExerciseAntennaSimulationRD010402GenericPullSystemDefinition普通拉系統(tǒng)定義普通拉系統(tǒng)的最佳實(shí)踐

案例舉例如何去決定普通拉水準(zhǔn)練習(xí)天線模擬RD010402普通拉系統(tǒng)定義普通拉系統(tǒng)的最佳實(shí)踐RD010402LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-0291GenericPullSystemLeanSixSigma

ImprovementPrLearningObjectivesUnderstandthebestpracticedefinitionHowtoapplythisbestpracticeinvariousenvironmentsAbletodeterminethelevelsofinventoryusingthefivestepsDemonstratethisbestpracticethroughexercisesandsimulation92GenericPullSystemLearningObjectivesUnderstand課程目的理解最佳實(shí)踐的定義如何在多變的環(huán)境中應(yīng)用這個(gè)最佳實(shí)踐能夠去決定庫存的水平用5個(gè)步驟通過練習(xí)和模擬來示范這一最佳實(shí)踐93GenericPullSystem課程目的理解最佳實(shí)踐的定義5GenericPullSysWhat’sinItforMe?UnderstandthereasonforthistoolindifferentenvironmentsHowtousethistoolforpotentialblackbeltprojects94GenericPullSystemWhat’sinItforMe?Understand我學(xué)到了什么?理解在不同環(huán)境中使用這個(gè)工具的原因?qū)τ诤趲撛陧?xiàng)目如何去使用這個(gè)工具95GenericPullSystem我學(xué)到了什么?理解在不同環(huán)境中使用這個(gè)工具的原因7GenerGenericPullSystemsGenericPullSystemslimittheamountofWork-In-Processinventoryinordertocontrolcycletime.96GenericPullSystemGenericPullSystemsGenericPu普通拉系統(tǒng)普通拉系統(tǒng)為了控制周轉(zhuǎn)時(shí)間限制了制程庫存的數(shù)量（Work-In-Process）.97GenericPullSystem普通拉系統(tǒng)普通拉系統(tǒng)為了控制周轉(zhuǎn)時(shí)間限制了制程庫存的數(shù)量（WIPCapExitsStartsTriggerGenericPullSystemDefinedDefinition:AGenericPullSystemestablishesaWIPcapontheamountofinventorywithinapredefinedphysicalworkarea(setofworkstations)orprocess.TomaintaintheWIPcap,exitsfromtheprocesstriggerstartsintotheprocess.EstablishingWIPcapisthekeytocycletimereduction!!98GenericPullSystemWIPCapExitsStartsTriggerGenerWIPCapExitsStartsTrigger普通拉系統(tǒng)的定義定義:一個(gè)普通拉系統(tǒng)是在一個(gè)預(yù)先確定的物理工作區(qū)域（工作站）或流程中，在存貨金額上建立了一個(gè)WIPcap.來維護(hù)WIPcap,從流程中的“出口”（exits）來觸發(fā)進(jìn)入流程的“出發(fā)”（Starts).建立WIPcap是降低周轉(zhuǎn)時(shí)間的關(guān)鍵99GenericPullSystemWIPCapExitsStartsTrigger普通拉系統(tǒng)WhentoUseGenericPullAlwaysGenericPullsystemscanbeusedinanyofthefollowingmanufacturing/transactionalenvironments:Repetitiveprocess/repetitiveproductSimilarproducts/partsrunwithinsameprocessflowExample:Automotiveassemblyline,customerorderprocessingRepetitiveprocess/non-repetitiveproduct Dissimilarproducts/partsrunwithinsameprocessflowExample:Buildtoorderprintedcircuitboardmanufacturer,customercomplaintprocessingNon-repetitiveprocess/non-repetitiveproductDissimilarproducts/partsrunwithinadissimilarprocessflowExample:Machinemodel/prototypeshop,NPIprocessesGenericPullsystemsshouldalwaysbeusedwhenareplenishmentpullsystemisimplemented100GenericPullSystemWhentoUseGenericPullAlways何時(shí)使用普通拉系統(tǒng)永遠(yuǎn)普通拉系統(tǒng)可以被使用在下列任何制造/事務(wù)處理的環(huán)境中:重復(fù)的流程/重復(fù)的產(chǎn)品類似的產(chǎn)品/零件在同一個(gè)流程中運(yùn)行例如:汽車的組裝線,客戶定單流程重復(fù)的流程/不重復(fù)的產(chǎn)品

不同的產(chǎn)品/零件在同一個(gè)流程中運(yùn)行例如:根據(jù)定單定制的電路板制造商,客戶投訴流程不重復(fù)的流程/不重復(fù)的產(chǎn)品不重復(fù)的產(chǎn)品/零件在不同的流程里運(yùn)行例如:機(jī)器模型/原型制作車間,NPI流程當(dāng)補(bǔ)充拉系統(tǒng)被實(shí)施時(shí)，普通拉系統(tǒng)將永遠(yuǎn)被使用101GenericPullSystem