計(jì)劃生產(chǎn)的精益方法論Heijunka

1、Heijunka Cookbook方案消費(fèi)的精益方法論.1. 選擇消費(fèi)線Analyze Historical Sales DataDetermine Build StrategyCalculate Takt TimeLevel LoadSequenceUnderstand what is made明白要做什么 型號(hào)3000400016種硬件配置 79 個(gè)零件編號(hào)23 個(gè)供應(yīng)商每年14,000臺(tái) DASH2493 種定單組合.2. 識(shí)別特殊型號(hào)或配置 產(chǎn)品有多少種不同的型號(hào)?每種型號(hào)不同在哪里?舉例:Dash 3000/4000 病人監(jiān)護(hù)儀16種不同的硬件配置:3000 or 4000有沒(méi)有復(fù)寫(xiě)

2、器有沒(méi)有RF Nellcor or MasimoAnalyze Historical Sales Data首先搞清楚產(chǎn)品Determine Build StrategyCalculate Takt TimeLevel LoadSequenceUnderstand what is made.3. 做一個(gè)產(chǎn)品系譜Analyze Historical Sales DataDetermine Build StrategyCalculate Takt TimeLevel LoadSequence哪些零件是每個(gè)型號(hào)都要用上的? 哪些零件是用在部分型號(hào)上的?Understand what is made首先

3、搞清楚產(chǎn)品產(chǎn)品系譜不是簡(jiǎn)單的BOM. 它在了解一種零件的組裝頻率上起了很大的作用.4. 要明白哪些零件裝到產(chǎn)品里每個(gè)組件都包括哪些零件(規(guī)格和數(shù)量)Understand what is madeAnalyze Historical Sales DataDetermine Build StrategyCalculate Takt TimeLevel LoadSequence首先搞清楚產(chǎn)品.5. 搜集以往的銷售數(shù)據(jù)不能預(yù)測(cè)未來(lái)歷史是最好的銷售預(yù)言家Understand what is made 分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel LoadCalculate

4、 Takt TimeSequenceAnalyze historical sales data.6. 按照不同的部件分解銷售 數(shù)據(jù)Analyze historical sales dataUnderstand what is made分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel LoadCalculate Takt TimeSequence.7. 總量數(shù)據(jù)Analyze historical sales data 計(jì)算出每個(gè)季度的總量Understand what is made分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel Loa

5、dCalculate Takt TimeSequence.8. 計(jì)算出組件的百分比用總量數(shù)據(jù)來(lái)計(jì)算出每個(gè)季度已銷售組件的百分比Analyze historical sales data舉例: 在2002年第四季度賣出的一切儀表板里66%的產(chǎn)品有Nellcor DAS組件.Understand what is made分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel LoadCalculate Takt TimeSequence.9. 選擇數(shù)據(jù)預(yù)測(cè)未來(lái)的銷售情況如何選擇:市場(chǎng)的變化?產(chǎn)品的穩(wěn)定性?Stage in product life?Analyze histor

6、ical sales data給市場(chǎng)變化下定義2002年第一季度的數(shù)據(jù)不再具有代表性. Understand what is made分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel LoadCalculate Takt TimeSequence.10. Weight PSI 25%, History 75%Analyze historical sales dataOPSI Percentages (Weighting = 25%)方案百分率Historical Percentages (Weighting = 75%)Dealing with mix . . .P

7、SI for volume, Heijunka for mixUnderstand what is made分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel LoadCalculate Takt TimeSequence.11. Multiply Subassembly PercentagesProbability of customer ordering:3000, Nellcor, with Writer, with RF (Part No. = 420000-007)= (.47)(.73)(.41)(.15) = 2.1%Analyze historical

8、 sales dataUnderstand what is made分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel LoadCalculate Takt TimeSequence.12. Create P-Q ChartAnalyze historical sales data2021999-011占了12% 的銷售量%Understand what is made分析以往的銷售數(shù)據(jù)Determine Build StrategyLevel LoadCalculate Takt TimeSequence過(guò)去4個(gè)季度的銷售情況.13. 決議消費(fèi)戰(zhàn)略思索要素:檢測(cè)時(shí)間

9、質(zhì)量問(wèn)題供應(yīng)商周期80/20 rule決議消費(fèi)戰(zhàn)略Level LoadCalculate Takt TimeSequenceAnalyze Historical Sales Data預(yù)測(cè)消費(fèi)Understand what is madeDetermine build strategy定單消費(fèi)%.14. 計(jì)算任務(wù)日Determine Build Strategy平衡消費(fèi)Calculate Takt TimeSequenceAnalyze Historical Sales DataUnderstand what is madeLevel load感恩節(jié)圣誕節(jié)(第四季度68個(gè)任務(wù)日) (4 個(gè)無(wú)方案

10、消費(fèi)日) = 64 有效任務(wù)日.15. 計(jì)算每天/每周的產(chǎn)量Determine Build Strategy平衡消費(fèi)Calculate Takt TimeSequenceAnalyze Historical Sales DataUnderstand what is madeLevel load 每季度需求或是預(yù)測(cè)每季度任務(wù)日 舉例:4288 件/季度64 天/季度=67 件/天335 件/周多少?每天產(chǎn)量 =.16. 計(jì)算出每周產(chǎn)品組合335*20.2% = 68 件/周Level load什么型號(hào)?Determine Build Strategy平衡消費(fèi)Calculate Takt Time

11、SequenceAnalyze Historical Sales DataUnderstand what is made.17.決議每周產(chǎn)量Level loadDetermine Build Strategy平衡消費(fèi)Calculate Takt TimeSequenceAnalyze Historical Sales DataUnderstand what is made什么型號(hào)?.18.a 計(jì)算出消費(fèi)線的節(jié)拍 時(shí)間 節(jié)拍時(shí)間是企業(yè)的心跳 有效時(shí)間 需求量 節(jié)拍時(shí)間=節(jié)拍時(shí)間是一個(gè)數(shù)學(xué)問(wèn)題, 但它是精益消費(fèi)的根本原那么.有效時(shí)間: 安排用來(lái)消費(fèi)的一切消費(fèi)時(shí)間需求量: 在一段時(shí)間內(nèi)預(yù)定零件的消費(fèi)

12、數(shù)量 每個(gè)輪班的有效時(shí)間是6.6個(gè)小時(shí)(延續(xù)性的) 這6.6個(gè)小時(shí)是除去午飯, 休憩等的延續(xù)任務(wù)時(shí)間.舉例工廠每天兩班制顧客的需求是每個(gè)星期1000件產(chǎn)品3960 分鐘/周1000 件/周= 3.96 分鐘/件節(jié)拍時(shí)間 = Calculate Takt time計(jì)算節(jié)拍時(shí)間Determine Build StrategyLevel LoadSequenceAnalyze Historical Sales DataUnderstand what is made.儀表板消費(fèi)線每天一班制 6.6 小時(shí)/天 * 60 分鐘/小時(shí) * 64 天/季度 = 25,344分鐘/季度顧客的需求是每個(gè)季度428

13、8臺(tái)有效時(shí)間 需求量節(jié)拍時(shí)間=4288 臺(tái)/季度25,344 分/季度= 6 分/臺(tái)Dash Line Takt Time = Calculate Takt time計(jì)算節(jié)拍時(shí)間Determine Build StrategyLevel LoadSequenceAnalyze Historical Sales DataUnderstand what is made(每個(gè)車間都會(huì)不同)18.b計(jì)算出消費(fèi)線的節(jié)拍 時(shí)間.我們?cè)?jīng)計(jì)算出了消費(fèi)線的節(jié)拍時(shí)間, 如今我們要為我們的消費(fèi)排序概要 : 任務(wù)天數(shù) 消費(fèi)線的節(jié)拍時(shí)間 = 6 分鐘 12個(gè)不同的型號(hào)Sequencing ProductionLeve

14、l LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made排序消費(fèi)線的節(jié)拍時(shí)間為6分鐘,接著,我們計(jì)算出每個(gè)型號(hào)的節(jié)拍時(shí)間.19. 確定休憩和午飯時(shí)間SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made開(kāi)場(chǎng)任務(wù)時(shí)間: 6:30am終了時(shí)間: 2:00pm早休: 8:45am

15、 9:00am午飯時(shí)間: 12:00pm-12:30pm有效時(shí)間=(8小時(shí)-午飯時(shí)間-休憩時(shí)間-會(huì)議時(shí)間-培訓(xùn)時(shí)間-等等)我們每天6.6個(gè)小時(shí)的延續(xù)任務(wù)時(shí)間.20. 計(jì)算出每個(gè)型號(hào)的節(jié)拍時(shí)間Dash Line T/T = 6 minT/T = 29 min79 min127 minSequence過(guò)去4個(gè)季度的銷售情況節(jié)拍時(shí)間29分鐘Level LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made%.21.a運(yùn)用型號(hào)的節(jié)拍時(shí)間給消費(fèi)排序Seque

16、nceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made2021999-0102021999-0102021999-01030 min30 min每29分鐘消費(fèi)一個(gè) 2021999-010 產(chǎn)品消費(fèi)線的節(jié)拍時(shí)間還6分鐘.21.b運(yùn)用型號(hào)的節(jié)拍時(shí)間給消費(fèi)排序SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales Da

17、taUnderstand what is made2021999-0102021999-0102021999-0102021999-0032021999-0032021999-00330 min36 min每33分鐘消費(fèi)一個(gè) 2021999-003 產(chǎn)品平均33分鐘消費(fèi)線的節(jié)拍時(shí)間還6分鐘.21.c 運(yùn)用型號(hào)的節(jié)拍時(shí)間給消費(fèi)排序SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made2021999-0112021999-0

18、1142 min2021999-0102021999-0102021999-0102021999-0032021999-0032021999-003每42分鐘消費(fèi)一個(gè)2021999-011 產(chǎn)品消費(fèi)線的節(jié)拍時(shí)間還6分鐘.21.d運(yùn)用型號(hào)的節(jié)拍時(shí)間給消費(fèi)排序SequenceLevel LoadDetermine Build StrategyCalculate Takt Time排序Analyze Historical Sales DataUnderstand what is made8:12 AM-0038:18 AM-0148:24 AM-0028:30 AM-0108:36 AM-007 時(shí)

19、間6:30 AM-0106:36 AM-0036:42 AM-0116:48 AM-0026:54 AM-0147:00 AM-0107:06 AM-0037:12 AM-0077:18 AM-0157:24 AM-0117:30 AM-0107:36 AM-0027:42 AM-0037:48 AM-0067:54 AM-0138:00 AM-0108:06 AM-0119:00 AM-0059:06 AM-0039:12 AM-0119:18 AM-0109:24 AM-0159:30 AM-0029:36 AM-0039:42 AM-0129:48 AM-0049:54 AM-01010

20、:00 AM-011BREAK時(shí)間型號(hào)8:12 AM-0038:18 AM-0148:24 AM-0028:30 AM-0108:36 AM-007型號(hào)6:30 AM-0106:36 AM-0036:42 AM-0116:48 AM-0026:54 AM-0147:00 AM-0107:06 AM-0037:12 AM-0077:18 AM-0157:24 AM-0117:30 AM-0107:36 AM-0027:42 AM-0037:48 AM-0067:54 AM-0138:00 AM-0108:06 AM-0119:00 AM-0059:06 AM-0039:12 AM-0119:18

21、 AM-0109:24 AM-0159:30 AM-0029:36 AM-0039:42 AM-0129:48 AM-0049:54 AM-01010:00 AM-011BREAK每天產(chǎn)量=67臺(tái), 12個(gè)型號(hào).22. 制造消費(fèi)時(shí)間表SequenceLevel LoadDetermine Build StrategyCalculate Takt Time拍序Analyze Historical Sales DataUnderstand what is made最終的目的是不延續(xù)消費(fèi)兩個(gè)型號(hào)一樣的產(chǎn)品.定單 消費(fèi)(MTO) 舉例:Determine Build StrategySequenceA

22、nalyze Historical Sales DataUnderstand what is madeLevel LoadCalculate Takt TimeMake to Order%假設(shè)2021999-017產(chǎn)品定單在消費(fèi)方案制定以后才到,那應(yīng)該怎樣辦? 按照預(yù)測(cè)消費(fèi) 按照顧客要求定做.定單 消費(fèi)(MTO) 舉例:Calculate Takt TimeDetermine Build StrategyLevel LoadSequenceAnalyze Historical Sales DataUnderstand what is madeMake to Order21%21%12%11%7

23、%6%5%5%4%2%2%1%1%1%1%1%05001000150020002500300035002021999-0032021999-0102021999-0112021999-0022021999-0072021999-0142021999-0152021999-0042021999-0162021999-0062021999-0052021999-0092021999-0172021999-0082021999-0132021999-0120%5%10%15%20%25%Dash SalesPercent SalesHigh bar on pareto在圖表中較高的柱Real customer order真正的顧客定單用顧客定單來(lái)替代圖表中柱形高的零件.定單 消費(fèi)(MTO) 舉例:Calculate Takt TimeDetermine Build StrategyLevel LoadSequenceAnalyze Hi