從優(yōu)化生產(chǎn)中的物流活動提高生產(chǎn)體系

MaterialMovementinaLeanManufacturingOperation

優(yōu)化生產(chǎn)中的物流活動TotalSystemsDevelopment

全體系生產(chǎn)提高JIT生產(chǎn)(準時,準量生產(chǎn)):Whatismeantbytheterm,“Just-In-Time”?JIT生產(chǎn)意味著什么?DoesitmeanJITSupply?準時,準量供應(yīng)?DoesitmeanJITProduction?準時,準量生產(chǎn)?So,whatisJust-In-Time?

那么,什么是準時準量生產(chǎn)?Theconceptofproducingthenecessaryunitsinthenecessaryquantitiesatthenecessarytimeisdescribedbytheshort-phrase“Just-In-Time”.JIT生產(chǎn)是:在必需時間內(nèi)生產(chǎn)必需數(shù)量的必需部品的概念.Forexample….Inbuildingshoes:Thenecessarysubassembliesoftheproceedingprocess(uppersandbottoms)shouldarriveattheassemblylineatthetimeneededintheamountsneeded.舉例說明:在生產(chǎn)成品鞋的時候:制鞋所必需的部件(鞋幫和鞋底)要準時,準量,準型號地到達制造車間.IfweachieveJIT:

如果我們做到準時,準量生產(chǎn):Unnecessaryinventorieswillbeeliminated.不必要的庫存就會消除Storesandwarehouseswillnotbeneeded.儲存區(qū)和倉庫也可以取消Materialcarryingcostswillbediminished.資材搬運成本降低However….TorelysolelyonacentralplanningapproachthatinstructstheproductionschedulestoallprocessessimultaneouslyisnotlikelytoresultinaJITprocessforalloperations.但是：單純地依賴計劃生產(chǎn)的方法,使所有工序同步生產(chǎn)，并不能完全實現(xiàn)所有環(huán)節(jié)的準時，準量生產(chǎn).TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每周生產(chǎn)計劃Typically,onecontroloperationreceivesthecustomers’ordersanddisseminatesschedules.

通常，生產(chǎn)控制部門接受客戶定單，然后制訂并傳達計劃.

ProductionControl生產(chǎn)控制TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每周生產(chǎn)計劃ProductionControl生產(chǎn)控制IIIIIITheproblemcomeswhenachangeismadeeitherbecausetheorderchangesorequipmentbreaksdown.

但是當定單有變化或設(shè)備出現(xiàn)問題的時候，就會發(fā)生一些問題：庫存庫存庫存庫存Theresultisexcessinventory…

結(jié)果是導致過多的庫存……withintheplantasWork-In-Process…在本車間工序內(nèi)積壓過多的庫存…supplierssendinginpartsthatarenotneeded…上一道工序發(fā)來的并不需要的部件Additionally另外,Weneedextrafloorspacetostorethematerial.我們需要額外的空間來堆放材料Needexpeditorstosatisfythechangesinschedule.需要人力和時間投入來改變生產(chǎn)計劃Runovertimetomakeuppartsthatwenowneed.用加班時間來生產(chǎn)現(xiàn)在所需部件Toyotarethoughthowtocommunicateschedules.豐田公司對調(diào)調(diào)整生產(chǎn)計劃劃做了改進:Toyotadiscoveredadifferentwaytomanagetheirschedule,豐田使用不同同的方法來制制訂調(diào)整生產(chǎn)產(chǎn)計劃Theystoppedtryingtoguesswhatthecustomerwillwant.他們并不去猜猜想客戶的需需求Instead相反..Eachdepartmenthadinstalledasmallinventoryofeachproduct.每個車間都保保持少量的庫庫存Downstreamprocessescometothesupplyingdepartmentsandtakewhatitneeds.下一道工序到到上一道工序序去取他們所所需部件Thisallowstheprocessesupstreamtosimplyreplacewhatwastaken.這樣,上一工工序只要補充充被取走的部部件即可.TheToyotaProductionSystemTPS豐田體系….Islikelytobethemoststudiedanddiscussedoperationsprogramintheworld.是極可能被全全世界研究和和討論的體系系NumerousbooksandpapershavebeenwrittenaboutTPS.出版了了很多多關(guān)于于TPS的書籍籍和其其它資資料ManyhavecometocharacterizeTPSas““l(fā)eanproduction””orNOS.許多人人認為為豐田田體系系(TPS)實際上上就代代表優(yōu)優(yōu)化生生產(chǎn)或或NOSLeanManufacturing(NOS)NOS優(yōu)化生生產(chǎn)Regardlessofanyauthor’’sopinionorrational,allagreethatthefoundationofleanmanufacturing(NOS)isthecontinualpursuittoeliminatewaste.盡管大大家的的觀點點有些些不一一樣,但所所有人人都認認為NOS的基礎(chǔ)礎(chǔ)是持持續(xù)不不斷地地減少少浪費費Wasteisdefinedasanythingthatconsumesresourcesortime,butdoesnotaddvaluetotheproduct.浪費是是任何何耗費費資源源或時時間,但不不增加加產(chǎn)品品價值值的活活動ExcessInventoryisWaste多余的的庫存存是一一種浪浪費Excessinventoryhidesproblems多余的的庫存存會隱隱藏一一些問問題SeaofInventory大量庫存RawMaterial

原資材FinishedGoods

成品LongTransportation過長運輸時間VendorDelivery

供應(yīng)商運送Absenteeism缺勤Commun-icationProblemPoorScheduling計劃不不力MachineBreakdown設(shè)備停停機QualityProblems質(zhì)量問問題LineImbalance線內(nèi)不不平衡衡LongSet-UpTime過長調(diào)調(diào)整時時間LackofHouse-Keeping倉儲管管理問問題溝通問問題OurgoalformaterialsmanagementinNOSNOS資材管管理的的目標標Theidealstateisasmoothflowofmaterialsthroughoutourownfactory理想的的狀態(tài)態(tài)是物物料在在整個個工廠廠內(nèi)順順暢的的流動動.Wewanttotietogetherprocessesthatareseparatedbylargephysicaldistances.使那些些有一一定距距離而而相對對分離離的生生產(chǎn)流流程緊緊密結(jié)結(jié)合起起來Weneedtoimprovecommunicationinregardstomaterialmovement.在物流流方面面要加加強各各工序序間的的溝通通ThePushSystem”推動““生產(chǎn)產(chǎn)體系系Intraditionalmanufacturing,variousproductionschedulesarereleasedtoallprocesses;componentmakingandassembly.在傳統(tǒng)統(tǒng)的生生產(chǎn)中中,各各種生生產(chǎn)計計劃被被傳達達到各各個工工序,部件件生產(chǎn)產(chǎn)和組組裝部部門.ThePushSystem(cont.)”推動““Thesepart-makingprocessesproducethepartsinaccordancetotheirschedulesandtransportthepartstothenextprocess.部件生生產(chǎn)部部門按按照收收到的的計劃劃生產(chǎn)產(chǎn)并把把成品品部件件運送送到下下一道道工序序.ThePushSystem(cont.)”推動““Thismethodmakesitdifficulttopromptlyadapttochanges.這種方方法使使生產(chǎn)產(chǎn)很難難迅速速對變變化作作出反反應(yīng)Eachproductionschedulemustbechangedateachprocesssimultaneously.每個工工序的的生產(chǎn)產(chǎn)計劃劃都必必需同同時變變化以以適應(yīng)應(yīng)同步步生產(chǎn)產(chǎn)ThePushSystem(cont.)”推動””TheResult導致:Thecompanymustholdextrainventoryamongallprocesses.公司不不得不不在各各個工工序保保持額額外的的庫存存Thiscreatesanimbalanceofstockbetweenprocesses.各工序序間的的庫存存達不不到平平衡ThePullSystem“拉動””生產(chǎn)產(chǎn)體系系Incontrast,inaPULLSYSTEM,eachprocesswillwithdrawthepartsitneedsfromtheproceedingprocess.相反,““拉動動”生生產(chǎn)體體系要要求各各個工工序僅僅需從從上一一道工工序提提取自自己所所需要要的部部件.BA“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市SupplyingProcess供應(yīng)工工序CustomerProcess客戶工工序“生產(chǎn)產(chǎn)”指指示板板“拒收收”指指示板板ThePullSystem(cont.)”拉動””體系系Sinceonlythefinal-assemblyprocesscanaccuratelyknowthenecessarytimingandquantityofpartsrequired,theyaretheonlyonestoreceiveaschedule.因為為只只有有制制造造準準確確地地了了解解所所需需時時間間和和部部件件數(shù)數(shù)量量,以以只只要要制制造造收收到到生生產(chǎn)產(chǎn)計計劃劃即即可可.AssemblyStock-fit準備Stitching縫紉Assembly制造Shipping裝船WeeklySchedule每周周生生產(chǎn)產(chǎn)計計劃劃FinalAssemblyreceivesascheduleandpullsfromtheMarketPlace.StitchingandStock-fitreplenishestheMarketPlace.制造接受受生產(chǎn)計計劃,并并借助““供應(yīng)超超市”拉拉動生產(chǎn)產(chǎn).縫紉紉和準備備向“供供應(yīng)超市市”補充充部件.ProductionControl生產(chǎn)控制制ThePullSystem(cont.)”拉動”體體系Withtheschedule,thefinal-assemblygoestothesupplyingdepartmentsandwithdrawswhatpartsareneeded.根據(jù)生產(chǎn)產(chǎn)計劃,制造到到供應(yīng)車車間去提提取所需需部件.ThePullSystem(cont.)”拉動“生生產(chǎn)Theprecedingoperationthenproducesthereplacementsofthepartswithdrawnbythesubsequentprocess.這樣,前前一道工工序開始始生產(chǎn)被被下一道道工序提提走的部部件以補補充所需需.BAssembly制造Stitching縫紉A“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市“生產(chǎn)””指示板板“拒收””指示板板Markets“供應(yīng)超市市”Marketsarethestoragelocationsforallthepartspriortogoingtothenextoperation.“供應(yīng)超市市”是為為下一道道工序儲儲存所需需各種部部件的區(qū)區(qū)域.Marketssimplyareorganizedcollectionsofpurchasedpartsandwork-in-process.組建“供供應(yīng)超市市”只是是為了搜搜集購買買的部件件和線上上的庫存存.Ifpartsarealreadystoredinyourplant,thenyoucanconstructmarkets.如果工廠廠內(nèi)有儲儲存部件件,那就就可以設(shè)設(shè)置此體體系.CautionsaboutMarkets關(guān)于“超超市體系系”的警警告:Don’’tgetcaughtupinotherpeople’sphilosophy.不要受別別的觀點點的影響響:Marketsdonothavetobelocatednexttothereceivingdocks.超市不一一定要靠靠近部件件接受區(qū)區(qū)Marketsdonothavetobelargeinsize.規(guī)模不一一定很大大Youcanhaveseveralmini-marketsifspaceisdifficulttoget.若空間不不夠,可可設(shè)多個個分散的的小超市市.Useyourowncommonsense運用自己己的常識識來解決決問題!RulesfordevelopingMarkets設(shè)立“超超市”的的規(guī)則:Haveastoragelocationforeverypart.為每一部部件設(shè)立立儲存區(qū)區(qū)Determinethemaximumofanyonepartthatwillbestored.為任一需需儲存部部件設(shè)立立最大庫庫存標準準Provideadequatestoragespace.提供合適適的儲存存區(qū)域Safetyisapriority.要優(yōu)先考考慮安全全因素.LessonsLearnedaboutMarkets設(shè)立超市市需注意意的幾點點:Haveanoverflowspotandameanstomonitor.設(shè)立庫存存限制和和監(jiān)控方方法Trytoreservespacesforfutureparts.提前考慮慮，為以以后的部部件留出出儲存空空間Preferably,donotstorethesamepartinmorethanonelocation.同一部件件最好儲儲存在一一個區(qū)域域Makesureaislewayscanaccommodateforklifts.保證過道道可容納納或通行行搬運工工具.Determinecustomerdemand確定客戶戶需求Takttimeisareferencenumberthatgivesyouasenseforthepaceatwhicheachprocessneedstobeproducing.TAKT節(jié)拍時間間為了解解并調(diào)整整各個工工序的生生產(chǎn)速度度提供參參考依據(jù)據(jù)Tocalculatetakttime,dividetheavailabletimebythecustomerdemand.用可利用用的生產(chǎn)產(chǎn)時間除除以客戶戶需求量量，即為節(jié)拍拍時間.Forourplant對我們公公司來說說:Oneshiftisninehoursthereisone60-minutelunch9小時一個個班次,其中有有1個小小時的就就餐休息息時間Work-time工作時間間8Hrs.X60min/hr=480minutes8小時X60=480分鐘480minutespershiftThereis28,800secondspershift480分鐘每個個班次,即28,800秒每每個班次次Customerdemand客戶需求求Thecustomerneeds2,000pairseachday.客戶每天天需要2,000足鞋鞋WeworkoneshifteachdayinAssembly,6daysperweek.制造車間間每天一一個班次次,每周周工作6天Customerdemandis客戶的需需求是:2,000Pairs/28,800sec2,000足/28,800秒or1PAIRevery14.4seconds或每14.4秒秒需要產(chǎn)產(chǎn)一足鞋鞋Marketsetupsandlocations供應(yīng)超市市準備和和位置選選定Locatespacewithintheplantthatcanbeusedasamarket(s).選定公司司可作為為超市的的位置Minimizethenumberofmarkets.Ifmaybenecessarytostartwithseveralsmallones,latertocombineintoone.盡量減少少超市的的數(shù)量,若有必必要可先先設(shè)立幾幾個小的的超市,以后再再合并成成大的超超市.Manpowerandequipmentneeded人員和設(shè)設(shè)備要求求PartsaredeliveredtothelinebyMaterialHandlersusinghand-carts.搬運人員員用手推推車將部部件運到到生產(chǎn)線線TheMaterialHandlerhasadesignatedroutethatcoversallthestationshe(orshe)isresponsiblefor.搬運人員員按照指指定的運運輸路線線負責自自己的工工作區(qū)域域Hedeliversallpartsneededonthatdeliverycycle,retrievesallemptycontainers搬運人員員必須循循環(huán)搬運運所需部部件,并并取回空空的部件件箱Training培訓Thepeoplewhoareaffectedbythenewsystemneedtounderstandwhythecompanyhasimplementedtheprogram.新體系所涉及及到的人員需需要懂得為什什么公司實施施此體系Thosewhoaretosupportitmustunderstandhowitworks.支持新體系的的人員需懂得得體系是怎樣樣運作的Allpeoplemustreceiveadequatetraininginorderforthesystemtobebothrobustandsuccessful.所有相關(guān)人員員需接受培訓訓以保證新體體系的運作效效率和成功。。超市Training(continued)培訓Rememberwhotheaudienceis:Productionworkershavelittleregardforhowmanyturnstheinventorymakes…Materialhandlerswillnotseeinventoryreductionasabenefit….記住誰是培訓訓對象：那些對庫存的的影響不太關(guān)關(guān)心的生產(chǎn)者者…看不到減少庫庫存會帶來收收益的資材管管理者…Training(continued)培訓Designyourtrainingprogram(s)usingtheknowledgeyouwillgaininthesystem’sdevelopment.運用你在實施施NOS的過程中得到到的經(jīng)驗來設(shè)設(shè)計培訓內(nèi)容容，Keepitsimple.使培訓內(nèi)容簡簡潔易懂，Giveyourselfenoughtimetohandlethetoughquestions.Respectthepeople’sconcerns.用足夠的時間間來解決比較較棘手的問題題，尊重別人人的意見。ResultsofaPullSystem生產(chǎn)拉動體系系的結(jié)果Inoperationswheretheimplementationhasbeensuccessful,boththemanagementandworkforcebelievetheworkenvironmenttobe“enhanced”在拉動體系取取得成功的那那些環(huán)節(jié),無無論是管理層層還是工人都都會認為他們們的工作環(huán)境境正在改善。。ResultsofaPullSystem生產(chǎn)拉動體系系的結(jié)果Wheretherehasbeenlittleefforttomakethesystemwork,theplanttypicallyhasshortagesandmissesdeliverywindows.若工廠沒有努努力去實現(xiàn)拉拉動生產(chǎn)，就就會出現(xiàn)部件件投入不足和和不能按照生生產(chǎn)需要來搬搬運部件。9、靜夜夜四無無鄰，，荒居居舊業(yè)業(yè)貧。。。1月-231月-23Friday,January6,202310、雨中黃黃葉樹，，燈下白白頭人。。。13:01:3713:01:3713:011/6/20231:01:37PM11、以以我我獨獨沈沈久久，，愧愧君君相相見見頻頻。。。。1月月-2313:01:3713:01Jan-2306-Jan-2312、故人人江海海別，，幾度度隔山山川。。。13:01:3713:01:3713:01Friday,January6,202313、乍乍見見翻翻疑疑夢夢，，相相悲悲各各問問年年。。。。1月月-231月月-2313:01:3713:01:37January6,202314、他鄉(xiāng)生白白發(fā)，舊國國見青山。。。06一月月20231:01:37下下午13:01:371月-2315、比比不不了了得得就就不不比比，，得得不不到到的的就就不不要要。。。。。。一月月231:01下下午午1月月-2313:01January6,202316、行動出成成果，工作作出財富。。。2023/1/613:01:3713:01:3706January202317、做前前，能能夠環(huán)環(huán)視四四周；；做時時，你你只能能或者者最好好沿著著以腳腳為起起點的的射線線向前前。。。1:01:37下下午1:01下下午午13:01:371月-239、沒有失敗，，只有暫時停停止成功！。。1月-231月-23Friday,January6,202310、很很多多事事情情努努力力了了未未必必有