優(yōu)化生產(chǎn)中的物流活動

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(zhǔn)時,準(zhǔn)量生產(chǎn)):Whatismeantbytheterm,“Just-In-Time”?JIT生產(chǎn)意味著什么?DoesitmeanJITSupply?準(zhǔn)時,準(zhǔn)量供應(yīng)?DoesitmeanJITProduction?準(zhǔn)時,準(zhǔn)量生產(chǎn)?So,whatisJust-In-Time?

那么,什么是準(zhǔn)時準(zhǔn)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(zhǔn)時,準(zhǔn)量,準(zhǔn)型號地到達(dá)制造車間.IfweachieveJIT:

如果我們做到準(zhǔn)時,準(zhǔn)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(yùn)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(zhǔn)時，準(zhǔn)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(dá)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(dāng)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(dǎo)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)整生產(chǎn)計劃做了改進(jìn):Toyotadiscoveredadifferentwaytomanagetheirschedule,豐田使用不同的方法來制訂調(diào)整生產(chǎn)計劃Theystoppedtryingtoguesswhatthecustomerwillwant.他們并不去猜想客戶的需求Instead相反..Eachdepartmenthadinstalledasmallinventoryofeachproduct.每個車間都保持少量的庫存Downstreamprocessescometothesupplyingdepartmentsandtakewhatitneeds.下一道工序到上一道工序去取他們所需部件Thisallowstheprocessesupstreamtosimplyreplacewhatwastaken.這樣,上一工序只要補(bǔ)充被取走的部件即可.TheToyotaProductionSystem

TPS豐田體系….Islikelytobethemoststudiedanddiscussedoperationsprogramintheworld.是極可能被全世界研究和討論的體系NumerousbooksandpapershavebeenwrittenaboutTPS.出版了很多關(guān)于TPS的書籍和其它資料ManyhavecometocharacterizeTPSas“l(fā)eanproduction”orNOS.許多人認(rèn)為豐田體系(TPS)實際上就代表優(yōu)化生產(chǎn)或NOSLeanManufacturing(NOS)

NOS優(yōu)化生產(chǎn)Regardlessofanyauthor’sopinionorrational,allagreethatthefoundationofleanmanufacturing(NOS)isthecontinualpursuittoeliminatewaste.盡管大家的觀點(diǎn)有些不一樣,但所有人都認(rèn)為NOS的基礎(chǔ)是持續(xù)不斷地減少浪費(fèi)Wasteisdefinedasanythingthatconsumesresourcesortime,butdoesnotaddvaluetotheproduct.浪費(fèi)是任何耗費(fèi)資源或時間,但不增加產(chǎn)品價值的活動ExcessInventoryisWaste

多余的庫存是一種浪費(fèi)Excessinventoryhidesproblems多余的庫存會隱藏一些問題SeaofInventory大量庫存RawMaterial

原資材FinishedGoods

成品LongTransportation過長運(yùn)輸時間VendorDelivery

供應(yīng)商運(yùn)送Absenteeism缺勤Commun-icationProblemPoor

Scheduling計劃不力MachineBreakdown設(shè)備停機(jī)QualityProblems質(zhì)量問題LineImbalance線內(nèi)不平衡LongSet-UpTime過長調(diào)整時間LackofHouse-Keeping倉儲管理問題溝通問題OurgoalformaterialsmanagementinNOS

NOS資材管理的目標(biāo)Theidealstateisasmoothflowofmaterialsthroughoutourownfactory理想的狀態(tài)是物料在整個工廠內(nèi)順暢的流動.Wewanttotietogetherprocessesthatareseparatedbylargephysicaldistances.使那些有一定距離而相對分離的生產(chǎn)流程緊密結(jié)合起來Weneedtoimprovecommunicationinregardstomaterialmovement.在物流方面要加強(qiáng)各工序間的溝通ThePushSystem

”推動“生產(chǎn)體系Intraditionalmanufacturing,variousproductionschedulesarereleasedtoallprocesses;componentmakingandassembly.在傳統(tǒng)的生產(chǎn)中,各種生產(chǎn)計劃被傳達(dá)到各個工序,部件生產(chǎn)和組裝部門.ThePushSystem(cont.)”推動“Thesepart-makingprocessesproducethepartsinaccordancetotheirschedulesandtransportthepartstothenextprocess.部件生產(chǎn)部門按照收到的計劃生產(chǎn)并把成品部件運(yùn)送到下一道工序.ThePushSystem(cont.)”推動“Thismethodmakesitdifficulttopromptlyadapttochanges.這種方法使生產(chǎn)很難迅速對變化作出反應(yīng)Eachproductionschedulemustbechangedateachprocesssimultaneously.每個工序的生產(chǎn)計劃都必需同時變化以適應(yīng)同步生產(chǎn)ThePushSystem(cont.)”推動”TheResult導(dǎo)致:Thecompanymustholdextrainventoryamongallprocesses.公司不得不在各個工序保持額外的庫存Thiscreatesanimbalanceofstockbetweenprocesses.各工序間的庫存達(dá)不到平衡ThePullSystem

“拉動”生產(chǎn)體系Incontrast,inaPULLSYSTEM,eachprocesswillwithdrawthepartsitneedsfromtheproceedingprocess.相反,“拉動”生產(chǎn)體系要求各個工序僅需從上一道工序提取自己所需要的部件.BA“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市SupplyingProcess供應(yīng)工序CustomerProcess客戶工序“生產(chǎn)”指示板“拒收”指示板ThePullSystem(cont.)”拉動”體系Sinceonlythefinal-assemblyprocesscanaccuratelyknowthenecessarytimingandquantityofpartsrequired,theyaretheonlyonestoreceiveaschedule.因為只有制造準(zhǔn)確地了解所需時間和部件數(shù)量,以只要制造收到生產(chǎn)計劃即可.AssemblyStock-fit準(zhǔn)備Stitching縫紉Assembly制造Shipping裝船WeeklySchedule每周生產(chǎn)計劃FinalAssemblyreceivesascheduleandpullsfromtheMarketPlace.StitchingandStock-fitreplenishestheMarketPlace.制造接受生產(chǎn)計劃,并借助“供應(yīng)超市”拉動生產(chǎn).縫紉和準(zhǔn)備向“供應(yīng)超市”補(bǔ)充部件.ProductionControl生產(chǎn)控制ThePullSystem(cont.)”拉動”體系Withtheschedule,thefinal-assemblygoestothesupplyingdepartmentsandwithdrawswhatpartsareneeded.根據(jù)生產(chǎn)計劃,制造到供應(yīng)車間去提取所需部件.ThePullSystem(cont.)”拉動“生產(chǎn)Theprecedingoperationthenproducesthereplacementsofthepartswithdrawnbythesubsequentprocess.這樣,前一道工序開始生產(chǎn)被下一道工序提走的部件以補(bǔ)充所需.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“拒收”指示板Markets“供應(yīng)超市”Marketsarethestoragelocationsforallthepartspriortogoingtothenextoperation.

“供應(yīng)超市”是為下一道工序儲存所需各種部件的區(qū)域.Marketssimplyareorganizedcollectionsofpurchasedpartsandwork-in-process.

組建“供應(yīng)超市”只是為了搜集購買的部件和線上的庫存.Ifpartsarealreadystoredinyourplant,thenyoucanconstructmarkets.

如果工廠內(nèi)有儲存部件,那就可以設(shè)置此體系.CautionsaboutMarkets

關(guān)于“超市體系”的警告:Don’tgetcaughtupinotherpeople’sphilosophy.不要受別的觀點(diǎn)的影響:Marketsdonothavetobelocatednexttothereceivingdocks.超市不一定要靠近部件接受區(qū)Marketsdonothavetobelargeinsize.

規(guī)模不一定很大Youcanhaveseveralmini-marketsifspaceisdifficulttoget.若空間不夠,可設(shè)多個分散的小超市.Useyourowncommonsense運(yùn)用自己的常識來解決問題!RulesfordevelopingMarkets

設(shè)立“超市”的規(guī)則:Haveastoragelocationforeverypart.

為每一部件設(shè)立儲存區(qū)Determinethemaximumofanyonepartthatwillbestored.為任一需儲存部件設(shè)立最大庫存標(biāo)準(zhǔn)Provideadequatestoragespace.

提供合適的儲存區(qū)域Safetyisapriority.

要優(yōu)先考慮安全因素.LessonsLearnedaboutMarkets

設(shè)立超市需注意的幾點(diǎn):Haveanoverflowspotandameanstomonitor.

設(shè)立庫存限制和監(jiān)控方法Trytoreservespacesforfutureparts.

提前考慮，為以后的部件留出儲存空間Preferably,donotstorethesamepartinmorethanonelocation.同一部件最好儲存在一個區(qū)域Makesureaislewayscanaccommodateforklifts.

保證過道可容納或通行搬運(yùn)工具.Determinecustomerdemand確定客戶需求Takttimeisareferencenumberthatgivesyouasenseforthepaceatwhicheachprocessneedstobeproducing.

TAKT節(jié)拍時間為了解并調(diào)整各個工序的生產(chǎn)速度提供參考依據(jù)Tocalculatetakttime,dividetheavailabletimebythecustomerdemand.

用可利用的生產(chǎn)時間除以客戶需求量，即為節(jié)拍時間.Forourplant對我們公司來說:Oneshiftisninehoursthereisone60-minutelunch9小時一個班次,其中有1個小時的就餐休息時間Work-time工作時間8Hrs.X60min/hr=480minutes8小時X60=480分鐘480minutespershiftThereis28,800secondspershift480分鐘每個班次,即28,800秒每個班次Customerdemand客戶需求Thecustomerneeds2,000pairseachday.客戶每天需要2,000足鞋WeworkoneshifteachdayinAssembly,6daysperweek.制造車間每天一個班次,每周工作6天Customerdemandis客戶的需求是:2,000Pairs/28,800sec2,000足/28,800秒or1PAIRevery14.4seconds

或每14.4秒需要產(chǎn)一足鞋Marketsetupsandlocations

供應(yīng)超市準(zhǔn)備和位置選定Locatespacewithintheplantthatcanbeusedasamarket(s).

選定公司可作為超市的位置Minimizethenumberofmarkets.Ifmaybenecessarytostartwithseveralsmallones,latertocombineintoone.

盡量減少超市的數(shù)量,若有必要可先設(shè)立幾個小的超市,以后再合并成大的超市.Manpowerandequipmentneeded

人員和設(shè)備要求PartsaredeliveredtothelinebyMaterialHandlersusinghand-carts.搬運(yùn)人員用手推車將部件運(yùn)到生產(chǎn)線TheMaterialHandlerhasadesignatedroutethatcoversallthestationshe(orshe)isresponsiblefor.搬運(yùn)人員按照指定的運(yùn)輸路線負(fù)責(zé)自己的工作區(qū)域Hedeliversallpartsneededonthatdeliverycycle,retrievesallemptycontainers搬運(yùn)人員必須循環(huán)搬運(yùn)所需部件,并取回空的部件箱Training培訓(xùn)Thepeoplewhoareaffectedbythenewsystemneedtounderstandwhythecompanyhasimplementedtheprogram.新體系所涉及到的人員需要懂得為什么公司實施此體系Thosewhoaretosupportitmustunderstandhowitworks.支持新體系的人員需懂得體系是怎樣運(yùn)作的Allpeoplemustreceiveadequatetraininginorderforthesystemtobebothrobustandsuccessful.所有相關(guān)人員需接受培訓(xùn)以保證新體系的運(yùn)作效率和成功。超市Training(continued)培訓(xùn)Rememberwhotheaudienceis: Productionworkershavelittleregardforhowmanyturnstheinventorymakes… Materialhandlerswillnotseeinventoryreductionasabenefit….記住誰是培訓(xùn)對象：那些對庫存的影響不太關(guān)心的生產(chǎn)者…看不到減少庫存會帶來收益的資材管理者…Training(continued)培訓(xùn)Designyourtrainingprogram(s)usingtheknowledgeyouwillgaininthesystem’sdevelopment.運(yùn)用你在實施NOS的過程中得到的經(jīng)驗來設(shè)計培訓(xùn)內(nèi)容，Keepitsimple.使培訓(xùn)內(nèi)容簡潔易懂，Giveyourselfenoughtimetohandlethetoughquestions.Respectthepeople’sconcerns.用足夠的時間來解決比較棘手的問題，尊重別人的意見。ResultsofaPullSystem

生產(chǎn)拉動體系的結(jié)果Inoperationswheretheimplementationhasbeensuccessful,boththemanagementandworkforcebelievetheworkenvironmenttobe“enhanced”在拉動體系取得成功的那些環(huán)節(jié),無論是管理層還是工人都會認(rèn)為他們的工作環(huán)境正在改善。ResultsofaPullSystem

生產(chǎn)拉動體系的結(jié)果Wheretherehasbeenlittleefforttomakethesystemwork,theplanttypicallyhasshortagesandmissesdeliverywindows.若工廠沒有努力去實現(xiàn)拉動生產(chǎn)，就會出現(xiàn)部件投入不足和不能按照生產(chǎn)需要來搬運(yùn)部件。1、Geniusonlymeanshard-workingallone'slife.(Mendeleyer,RussianChemist)

天才只意味著終身不懈的努力。20.8.58.5.202011:0311:03:10Aug-2011:032、Ourdestinyoffersnotonlythecupofdespair,butthechaliceofopportunity.(RichardNixon,AmericanPresident)命運(yùn)給予我們的不是失望之酒，而是機(jī)會之杯。二〇二〇年八月五日2020年8月5日星期三3、Patienceisbitter,butitsfruitissweet.(JeanJacquesRousseau,Frenchthinker)忍耐是痛苦的，但它的果實是甜蜜的。11:038.5.202011:038.5.202011:0311:03:108.5.202011:038.5.20204、Allthatyoudo,dowithyourmight;thingsdonebyhalvesareneverdoneright.----R.H.Stoddard,Americanpoet做一切事都應(yīng)盡力而為，半途而廢永遠(yuǎn)不行8.5.20208.5.202011:0311:0311:03:1011:03:105、Youhavetobelieveinyourself.That'sthesecretofsuccess.----CharlesChaplin人必須相信自己，這是成功的秘訣。-Wednesday,August5,2020August20Wednesday,August5,20208/5/20206、Almostanysituation---goodorbad---isaffectedbytheattitudewebringto.----LuciusAnnausSeneca差不多任何一種處境---無論是好是壞---都受到我們對待處境態(tài)度的影響。11時3分11時3分5-Aug-208.5.20207、Althoughtheworldisfullofsuffering,itisfullalsooftheovercomingofit.----HellenKeller,Americanwriter雖然世界多苦難，但是苦難總是能戰(zhàn)勝的。20.8.520.8.520.8.5。2020年8月5日星期三二〇二〇年八月五日8、Formanismanandmasterofhisfate.----Tennyson人就是人，是自己命運(yùn)的主人11:0311:03:108.5.2020Wednesday,August5,20209、Whensuccesscomesinthedoor,itseems,loveoftengoesoutthewindow.-----JoyceBrothers成功來到門前時，愛情往往就走出了窗外。11:038.5.202011:038.5.202011:0311:03:108.5.202011:038.5.202010、Lifeismeasuredbythoughtandaction,notbytime.——Lubbock衡量生命的尺度是思想和行為，而不是時間。8.5.20208.5.202011:0311:0311:03:1011:03:1011、Tomakealastingmarriagewehavetoovercomeself-centeredness.要使婚姻長久，就需克服自我中心意識。Wednesday,August5,2020August20Wednesday,August5,20208/5/202012、Treatotherpeopleasyouhopetheywilltreatyou.你希望別人如何對待你，你就如何對待別人。11時3分11時3分5-Aug-208.5.202013、Todowhateverneedstobedoneto