流程標準化ppt課件

1、流程規(guī)范化Routing Standardization議程 Agenda目的 / 結(jié)果 Purpose / results與流線消費有關的問題 Issues relating to flow流程規(guī)范化六步驟 6 steps to routing standardization學習內(nèi)容 What Youll Learn根據(jù)類似流程，將廢品 (零件) 分類How to group products (parts) into families according to common routings如何簡化零件流程How to simplify part routings根據(jù)零件系列，將流線消費單

2、元文件化，并予以實施How to implement and document flow production cells around part family groups及時消費原理 JIT Principles跟上“節(jié)拍時間Pace to “takt time 達成流線消費Create flow production 結(jié)合“拉動系統(tǒng)Incorporate “pull system 流程規(guī)范化的目的Purpose of Routing Standardization減少獨特流程的數(shù)量Reduce the number of unique routings簡化個別零件的流程Simplify

3、individual part routings制定規(guī)范化任務Develop standard work貴司的流程象哪個？ Which Is Your Process?流線型非流線型零件零件零件零件零件零件零件零件不良流線的緣由 Causes of Poor Flow演化式增長 Evolutionary growth人員安排變化 Staffing changes規(guī)范本錢會計 Standard cost accounting產(chǎn)能頂峰 Capacity peaks共用設備 Shared equipment數(shù)量變化 Quantity variations流程技術 Process technology

4、流程變化 Routing variations外部交接點 External handoffs回環(huán)工序 Loopbacks換模時間太長 Setups too long不同零件的數(shù)量 Number of different parts超級機器 Super machine大批量 Large batches流程思想 Process thinking必要的操作 (修繕) As-required operations (repair)變化的種類 Types of Variation數(shù)量變化 Quantity variation產(chǎn)品變化 Product variation變化的程度 Degree Of Va

5、riation產(chǎn)量比例 零件數(shù)量比例特征種類很少制造業(yè)里最常見，種類非常多種類極多，變化極大 (很稀有)流程規(guī)范化六步驟6 Steps To Routing Standardization進展零件-數(shù)量 (P-Q) 分析Prepare part-quantity (P-Q) analysis2.進展流程分析Prepare process route analysis3.根據(jù)類似流程，對零件進展分類Group parts by routing similarity4.定義設備可用性Define equipment availability5.簡化零件流程Simplify part routing

6、s6.實施新的流程系列，并將其文件化Implement and document new process family groups零件-數(shù)量 (P-Q) 分析Part-Quantity (P-Q) Analysis* 由于圓整問題，各個比例之和并不等于100% Individual percentages dont equal 100 % due to rounding零件代號Part Number數(shù)量Quantity數(shù)量比例% of Quantity累計數(shù)量比例Cumulative Quantity (%)ABCD5684152524%24%2316848022%46%2351536017

7、%63%9851228513%76%756511457%83%216981306%89%189961055%94%45646804%98%15695653%100%*零件-數(shù)量 (P-Q) 關系圖 Part-Quantity (P-Q) Chart數(shù)量零件代號累計數(shù)量比例流程分析 Process Route Analysis任務中心 Work Center零件 Part #數(shù)量 Quantity車削Lathe鏜Bore機加工Mach焊 Weld磨Grind機加工Mach銑Mill檢驗Insp5684152523168480235153609851228575651145216981301899

8、6105456468015695651111111112342222222333333334454444442零件系列 (1) Part Family Group (1)任務中心 Work Center零件 Part #數(shù)量 Quantity車削Lathe鏜Bore機加工Mach焊Weld磨Grind機加工Mach銑Mill平衡Bal檢驗Insp56811506510100423390321080453350123457643215746899832156987123457689987653421零件系列 (2) Part Family Group (2)= 外部工序 Outside proc

9、ess任務中心 Work Center零件Part #數(shù)量Quantity車削Lathe磨Grind熱處置HT Treat滾光Tumble噴涂Coating內(nèi)圓磨ID Grind機加工Mach檢驗Insp1289175765110064447516585111122223333444455556666777788889999定義設備可用性 Define Equipment Availability識別現(xiàn)有設備Identify existing available equipment分配設備予各個流程組別Allocate equipment to process groups識別潛在瓶頸問題Id

10、entify potential bottlenecks簡化零件流程 Simplify Part Routings簡化操作順序Simplify the sequence of operations同一系列的一切零件都制定規(guī)范化流程Develop a standard route for all parts in a family減少工序數(shù)量Reduce the number of operations消除單元外的交接點Eliminate out-of-cell handoffs防止回環(huán)工序Eliminate loop-backs防止共用裝卸中心Eliminate shared load centers思索運用規(guī)范化流程模塊Consider using standard routing templates消除交換流程Eliminate alternative routings將新的系列文件化，并