推式與拉式系統(tǒng)jit

推式與拉式系統(tǒng)jitJIT目標(biāo)和建築架構(gòu)的歸納產(chǎn)品設(shè)計(jì)流程設(shè)計(jì)人員因素製造規(guī)劃避免中斷使系統(tǒng)有彈性排除浪費(fèi)平衡迅速的流程最終目標(biāo)支援目標(biāo)建築架構(gòu)2及時(shí)化生產(chǎn)系統(tǒng)常見的資源浪費(fèi)1超額生產(chǎn)(overproduction)等候時(shí)間(waitingtime)不必要的運(yùn)送(unnecessarytransporting)存貨(inventory)加工浪費(fèi)(processingwaste)不必要的生產(chǎn)步驟產(chǎn)出瑕疵品3及時(shí)化生產(chǎn)系統(tǒng)常見的資源浪費(fèi)2無效的工作方法(inefficientworkmethod)不佳的佈置和物料搬運(yùn)模式，增加在製品存貨產(chǎn)品不良再製成本消費(fèi)者不滿意造成銷售損失4及時(shí)化生產(chǎn)系統(tǒng)WasteinOperations5及時(shí)化生產(chǎn)系統(tǒng)WasteinOperations6及時(shí)化生產(chǎn)系統(tǒng)WasteinOperations7及時(shí)化生產(chǎn)系統(tǒng)ThePrinciplesoftheTOYOTAProductionSystem(TPS)1Allworkmustbecompletelyspecifiedastocontent,sequence,timing,andoutcome.Everycustomer-supplierconnectionmustbedirect,unambiguouslyspecifyingthepeopleinvolved,theformandquantityoftheservicesorgoodstobeprovided,thewaytherequestsaremadebyeachcustomer,andtheexpectedtimeinwhichtherequestswillbemet.8及時(shí)化生產(chǎn)系統(tǒng)ThePrinciplesoftheTOYOTAProductionSystem(TPS)2Thepathwayforeveryserviceandproductmustbesimpleanddirect.Anyimprovementtothesystemmustbemadeinaccordancewiththescientificmethod,undertheguidanceofateacher,atthelowestpossibleorganizationallevel.9及時(shí)化生產(chǎn)系統(tǒng)BasicElementsofJIT1標(biāo)準(zhǔn)的零件(產(chǎn)品設(shè)計(jì))模組化設(shè)計(jì)(產(chǎn)品設(shè)計(jì))高產(chǎn)能的系統(tǒng)(產(chǎn)品設(shè)計(jì))可同時(shí)生產(chǎn)(產(chǎn)品設(shè)計(jì))將員工視為資產(chǎn)(人員/組織的要素)訓(xùn)練員工，使其變成多能工(人員/組織的要素)持續(xù)改善(人員/組織的要素)成本會(huì)計(jì)(人員/組織的要素)領(lǐng)導(dǎo)與專案管理(人員/組織的要素)10及時(shí)化生產(chǎn)系統(tǒng)BasicElementsofJIT2Cellularlayouts(製程設(shè)計(jì)Pullproductionsystem(製造規(guī)劃與控制)Flexibleresources(製程設(shè)計(jì))Kanbanproductioncontrol(製造規(guī)劃與控制)Small-lotproduction(製程設(shè)計(jì))Quicksetups(製程設(shè)計(jì))Uniformproductionlevels(製造規(guī)劃與控制)Qualityatthesource(製程設(shè)計(jì))Totalproductivemaintenance(製造規(guī)劃與控制)Suppliernetworks(製造規(guī)劃與控制)11及時(shí)化生產(chǎn)系統(tǒng)FlexibleResourcesMultifunctionalworkers(多能工)PerformmorethanonejobGeneralpurposemachines(通用設(shè)備)PerformseveralbasicfunctionsStudyoperators&improveoperations12及時(shí)化生產(chǎn)系統(tǒng)CellularLayoutsGroupdissimilarmachinesinmanufacturingcelltoproducefamilyofpartsWorkflowsinonedirectionthroughcellCycletimeadjustedbychangingworkerpaths13及時(shí)化生產(chǎn)系統(tǒng)ManufacturingCellwithWorkerRoutesWorker1Worker2Worker3Cell114及時(shí)化生產(chǎn)系統(tǒng)WorkerRoutesLengthenedasVolumeDecreasesCell5Worker2Cell2Worker1Cell1Worker3Cell3Cell415及時(shí)化生產(chǎn)系統(tǒng)推式與拉式系統(tǒng)推式系統(tǒng)(pushsystem)(例如，MPR)當(dāng)工作在某工作站完成時(shí)，產(chǎn)出就被推往下一站。拉式系統(tǒng)(pullsystem)(例如，JIT)工作移動(dòng)的控制落於下一站;每一工作站從前一站拉拔所需產(chǎn)出。16及時(shí)化生產(chǎn)系統(tǒng)KanbanProductionControlSystem

(看板生產(chǎn)管制系統(tǒng))KanbancardindicatesstandardquantityofproductionDerivedfromtwo-bininventorysystem(雙倉(cāng)制)KanbanmaintainsdisciplineofpullproductionProductionkanban(生產(chǎn)看板)authorizesproductionWithdrawalkanban(提領(lǐng)看板)authorizesmovementofgoods17及時(shí)化生產(chǎn)系統(tǒng)ASampleKanban18及時(shí)化生產(chǎn)系統(tǒng)TheOriginofKanbana)Two-bininventorysystem b)KanbaninventorysystemReordercardBin1Bin2Q-RKanbanRRQ=orderquantityR=reorderpoint-demandduringleadtime19及時(shí)化生產(chǎn)系統(tǒng)TypesofKanbans—

Dualkanbans20及時(shí)化生產(chǎn)系統(tǒng)Single-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2StorageareaEmptycontainersFullcontainersAssemblyline1Assemblyline221及時(shí)化生產(chǎn)系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline222及時(shí)化生產(chǎn)系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline223及時(shí)化生產(chǎn)系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline224及時(shí)化生產(chǎn)系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline225及時(shí)化生產(chǎn)系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline226及時(shí)化生產(chǎn)系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline227及時(shí)化生產(chǎn)系統(tǒng)看板系統(tǒng)—

singlekanban28及時(shí)化生產(chǎn)系統(tǒng)Dualkanbanvs.singlekanbanDualkanbanIsusedwhenmaterialisnotnecessarilymovingbetweentwoconsecutiveprocesses,orwhenthereismorethanoneinputtoaprocessandtheinputsaredispersedthroughoutthefacility.SinglekanbanIsusedwhentheprocessesaretightlylinked.29及時(shí)化生產(chǎn)系統(tǒng)TypesofKanbansKanbanSquareMarkedareadesignedtoholditemsSignalKanbanTriangularkanbanusedtosignalproductionatthepreviousworkstationMaterialKanbanUsedtoordermaterialinadvanceofaprocessSupplierKanbansRotatebetweenthefactoryandsuppliers30及時(shí)化生產(chǎn)系統(tǒng)TypesofKanbans—

kanbansquareandkanbanracks31及時(shí)化生產(chǎn)系統(tǒng)TypesofKanbans—

signalkanbans32及時(shí)化生產(chǎn)系統(tǒng)看板管理系統(tǒng)之規(guī)則不要把不良品交給後製程。由後製程到前製程來領(lǐng)取零件。前製程僅生產(chǎn)將被後製程領(lǐng)用去的數(shù)量。生產(chǎn)必須平衡?？窗逯蛔鰹槲⒄{(diào)整的手段，其張數(shù)必須減到最少。製程必須安定化、合理化。33及時(shí)化生產(chǎn)系統(tǒng)Single-CardKanbanSystemKANBANPartNumber: 1234567ZLocation: Aisle5 Bin47LotQuantity: 6Supplier: WS83Customer: WS116EachcontainermusthaveacardAssemblyalwayswithdrawsfromfabrication(pullsystem)ContainerscannotbemovedwithoutakanbanContainersshouldcontainthesamenumberofpartsOnlygoodpartsarepassedalongProductionshouldnotexceedauthorization34及時(shí)化生產(chǎn)系統(tǒng)看板(容器)數(shù)量之決定1K=容器數(shù)量。d=工作中心之計(jì)劃使用率(預(yù)期每日需求)。p=每箱容器零件之平均加工時(shí)間。W=在生產(chǎn)過程中之平均等候時(shí)間，加上每箱物料的搬運(yùn)時(shí)間。C=標(biāo)準(zhǔn)容器之零件容量。X=政策變數(shù)。反應(yīng)生產(chǎn)系統(tǒng)的效率(10%以內(nèi))35及時(shí)化生產(chǎn)系統(tǒng)看板(容器)數(shù)量之決定2k=在前置時(shí)間期間的平均需求+安全庫(kù)存每箱內(nèi)的單位數(shù)量=d(w+p)(1+x)c36及時(shí)化生產(chǎn)系統(tǒng)看板(容器)數(shù)量之決定3where N =numberofkanbansorcontainers d =averagedemandoversometimeperiod L =leadtimetoreplenishanorder S =safetystock C =containersizeNo.ofKanbans=averagedemandduringleadtime+safetystockcontainersizeN=dL+SC37及時(shí)化生產(chǎn)系統(tǒng)容器數(shù)量決定—範(fàn)例某汽車零件公司生產(chǎn)4輪傳動(dòng)車的方向盤及暫停系統(tǒng)中的搖桿手臂組合。一般1箱零件在製造週期中需要0.02天的加工及0.08天的物料處理和等候時(shí)間。零件每日的需求為2000個(gè)單位。管理部門認(rèn)為搖桿手臂組合的需求不確定，所以其安全庫(kù)存為需求量的10%。若每箱內(nèi)各有22個(gè)零件，則應(yīng)授權(quán)的箱子數(shù)量為多少。38及時(shí)化生產(chǎn)系統(tǒng)小批量(Small-lotproduction)的效益降低在製品存貨減少因品質(zhì)發(fā)生問題時(shí)所產(chǎn)生的檢驗(yàn)和重加工成本減少儲(chǔ)存空間問題更容易顯現(xiàn)增加生產(chǎn)彈性易於進(jìn)行作業(yè)平衡39及時(shí)化生產(chǎn)系統(tǒng)InventoryHidesProblems40及時(shí)化生產(chǎn)系統(tǒng)LowerLevelsofInventoryExposeProblems41及時(shí)化生產(chǎn)系統(tǒng)ComponentsofLeadTime

(前置時(shí)間的元素)ProcessingtimeReducenumberofitemsorimproveefficiencyMovetimeReducedistances,simplifymovements,standardize

routingsWaitingtimeBetterscheduling,sufficientcapacitySetuptimeGenerallythebiggestbottleneck42及時(shí)化生產(chǎn)系統(tǒng)快速籌置(Quicksetups)Single-digitsetupThegoalofhavingasetuptimeoflessthan10minutes.快速換模又稱一分鐘換模術(shù)(single-minuteexchangeofdies,SMED)43及時(shí)化生產(chǎn)系統(tǒng)快速籌置的實(shí)施步驟1.將換模作業(yè)流程劃分外部整備作業(yè)與內(nèi)部整備作業(yè)。2.儘可能把內(nèi)部整備作業(yè)改變成外部整備作業(yè)。3.消除內(nèi)部整備所需的調(diào)整作業(yè)。4.外部整備作業(yè)的標(biāo)準(zhǔn)化。5.推動(dòng)平行作業(yè)。6.利用機(jī)械提高換模效率。7.其他管理部門的充分配合。44及時(shí)化生產(chǎn)系統(tǒng)CommonTechniquesforReducingSetupTime145及時(shí)化生產(chǎn)系統(tǒng)CommonTechniquesforReducingSetupTime246及時(shí)化生產(chǎn)系統(tǒng)CommonTechniquesforReducingSetupTime347及時(shí)化生產(chǎn)系統(tǒng)平準(zhǔn)化生產(chǎn)(UniformProduction)ResultsfromsmoothingproductionrequirementsKanbansystemscanhandle+/-10%demandchangesThewaytoreducevariabilityinproductionSmoothsdemandacrossplanninghorizonMixed-modelassemblysteadiescomponentproduction48及時(shí)化生產(chǎn)系統(tǒng)平準(zhǔn)化—範(fàn)例1TheAPPofTOYOTA:4500vehiclesperweek.Twofullshifts,fivedaysperweek→450pershift(480minutes)Threemodelsareproduced:Camry(C),Avalon(A),andSienna(S).200Camry,150Avalons,and100SiennaspershiftCycletime:480/450=1.067(min)49及時(shí)化生產(chǎn)系統(tǒng)平準(zhǔn)化—範(fàn)例2First200C’s→150A’s→100S’sHighaveragecycleinventorylevelLumpyrequirementsSecond4C’s→3A’s→2S’sThecycle=9(1.067)=9.60(50timespershift)50及時(shí)化生產(chǎn)系統(tǒng)平準(zhǔn)化—範(fàn)例3ThirdC→S→C→A→C→A→C→S→AThesetuptimesmustbeveryshort.ComponentrequirementsissteadyCapacityrequirementsaresmoothed51及時(shí)化生產(chǎn)系統(tǒng)QualityattheSource1Jidoka(自働化)在生產(chǎn)過程中自動(dòng)偵測(cè)缺點(diǎn)Andon(安童)在每個(gè)工作站裝置燈號(hào)系統(tǒng)，以指示問題及落後狀態(tài)。Undercapacityschedulingallowsforplanning,problemsolving&maintenance52及時(shí)化生產(chǎn)系統(tǒng)QualityattheSource2防呆裝置日文發(fā)音為POKAYOKE

，是指在模具，工具，機(jī)器設(shè)備上設(shè)計(jì)防止錯(cuò)誤(不良)發(fā)生的裝置，一旦作業(yè)員做錯(cuò)或需要作業(yè)上的警示時(shí)，防呆裝置可以預(yù)防或使機(jī)器停下來，確保不產(chǎn)生不良品。目視管理系統(tǒng)(visualcontrol)：係透過顯示板之顯示得以快速且明顯地發(fā)現(xiàn)異常、浪費(fèi)、故障、斷料等現(xiàn)場(chǎng)不順暢之情形，而達(dá)到能速謀對(duì)策的一種管理系統(tǒng)。53及時(shí)化生產(chǎn)系統(tǒng)VisualControl54及時(shí)化生產(chǎn)系統(tǒng)VisualControl55及時(shí)化生產(chǎn)系統(tǒng)VisualControl56及時(shí)化生產(chǎn)系統(tǒng)Kaizen(改善)ContinuousimprovementRequirestotalemploymentinvolvementEssenceofJITiswillingnessofworkerstoSpotqualityproblemsHaltproductionwhennecessaryGenerateideasforimprovementAnalyzeproblemsPerformdifferentfunctions57及時(shí)化生產(chǎn)系統(tǒng)TotalProductiveMaintenance(TPM)BreakdownmaintenanceRepairstomakefailedmachineoperationalPreventivemaintenanceSystemofperiodicinspection&maintenancetokeepmachinesoperatingTPMcombinespreventivemaintenance&totalqualityconcepts58及時(shí)化生產(chǎn)系統(tǒng)TPMRequiresManagementto:DesignproductsthatcanbeeasilyproducedonexistingmachinesDesignmachinesforeasieroperation,changeover,maintenanceTrain&retrainworkerstooperatemachinesPurchasemachinesthatmaximizeproductivepotentialDesignpreventivemaintenanceplanspanninglifeofmachine59及時(shí)化生產(chǎn)系統(tǒng)導(dǎo)入JIT的基礎(chǔ)—5S運(yùn)動(dòng)定義功能整理(seiri,organization)把東西分成必要與不必要，將不必要的東西撤走。排除資源空間的浪費(fèi)。整頓(seiton,tidiness)需要的東西排放整齊以便取用。排除尋找，縮短作業(yè)或產(chǎn)品線切換、準(zhǔn)備時(shí)間。清掃(seiso,cleanliness)把工作場(chǎng)所掃除清潔，去除雜物及灰塵。提升效率，排除隱藏的工業(yè)災(zāi)害與品質(zhì)不良。清潔(seiketsu,maintenance)保持整理、整頓、清掃所建立之成果。確保作業(yè)安全，延長(zhǎng)設(shè)備壽命，提升產(chǎn)品品質(zhì)。修養(yǎng)(shitsuke,discipline)對(duì)於規(guī)定的事項(xiàng)確實(shí)遵守並養(yǎng)成習(xí)慣。加強(qiáng)小團(tuán)體之自主性活動(dòng)。60及時(shí)化生產(chǎn)系統(tǒng)SupplierPolicies1Locate