精益制造質量管理系統(tǒng)縮短制造周期模塊課件

1、縮短制造周期SHORT LEAD TIME 縮短制造周期SHORT LEAD TIME 縮短制造周期定義： Short Lead Time Definition: The desired reduction in time from the placement of an order by the final customer to the delivery of the product and receipt of payment. There are four types of lead time which contribute to the short lead time concep

2、t: 1.Total Lead Time 2.Product Development Lead Time 3.Process Lead Time 4.From factory to customer.從最終用戶訂貨至交貨收款之間期望能減少的時間，它包含四種類型：1、總的制造周期（收到訂單至收到貨款）2、產(chǎn)品開發(fā)周期（從概念設計至SORP）3、工藝制造周期（從原材料至SORP）4、裝配廠至用戶?？s短制造周期定義： Short Lead Time De9.供應鏈的管理 Supply Chain Management (3)7.內部拉動/交貨Internal Pull/Delivery (7)5.有

3、計劃的發(fā)運 /收貨Schedule Shipping/Receiving (7)3.固定周期訂貨系統(tǒng)Fixed Period Ordering System (5)1.簡易的工藝流程Simple Process Flow (8)縮短制造周期的9個要素Nine Element of Short Lead Time2.少量包裝 Small Lot Packaging (19)4.受控的外部運輸 Controlled External Transportation (18)6.臨時物料儲存 Temporary Material Storage CMA (9)8.均衡定購車輛的生產(chǎn)計劃 Level V

4、ehicle Orders (4)9.供應鏈的管理 Supply Chain Manageme1-1、簡易的工藝流程 Simple Process Flow (8)定義：以獲得一個簡易的物料與信息流為目的的流程Definition: A process which incorporates a constant drive to attain a simple sequential process flow of material and information.目的：設計和實施這樣一種工藝,這種工藝在優(yōu)化成本,降低工序內庫存和易發(fā)現(xiàn)問題的同時堅持先進先出這一原則并且具有可跟蹤性,可視性,能縮

5、短制造周期. Purpose: To design and implement processes that maintain FIFO, allow trace ability, are visual, reduce lead time, easily detects problems while optimizing cost, and reduces inventory and work in process.1-1、簡易的工藝流程 Simple Process Flo2、必須控制和優(yōu)化所有緩沖區(qū)和工序內的工作-緩沖區(qū)管理Line side and work-in-process (ve

6、hicles, parts) are controlled and optimized - buffer management.1、先進先出這一原則體現(xiàn)在所有物料存儲操作中First In First Out is practiced in ALL Material Storage operations.1-2、簡易的工藝流程 Simple Process Flow (8)3、當從經(jīng)濟角度出發(fā)需要進行批量或小規(guī)模生產(chǎn)時,必須始終考慮減少這種生產(chǎn)的可能性. When batch or small lot production is economically necessary, batch or

7、 lot size must always be challenged for reduction.4、有一個簡單、直接、連續(xù)的物料操作流程來實現(xiàn)合理的規(guī)劃布置和操作Layouts and processes facilitate a direct, continuous and simple material flow.要求 Requirements:2、必須控制和優(yōu)化所有緩沖區(qū)和工序內的工作-緩沖區(qū)管理1、1-3、簡易的工藝流程 Simple Process Flow (8)5、操作工的工作區(qū)域的設置必須考慮安全有效的零部件擺放Operator envelopes are set to a

8、llow safe, efficient parts presentation. 6、必須有均衡的生產(chǎn)計劃以實現(xiàn)實現(xiàn)簡易的流程（看板、周期時間、重新定購點等）Leveled production schedules are in place to allow simple flow (kanban, cycle time, reorder points, etc,). 7、生產(chǎn)指導(材料清單、目視板、拉動單等)必須以清晰的格式張貼在車間上部所對應的位置Production instructions (manifest, screens, pull card, etc.) are visuall

9、y present on the shop floor in a simple format. 8、對所有移動設備和生產(chǎn)設備有簡單的操作、維護流程以便使用及維護Mobile equipment and production equipment facilitate simple flow. 1-3、簡易的工藝流程 Simple Process Flo2-1、少量包裝 Small Lot Packaging (19)定義： 確定,分配或設計合適的標準數(shù)量和料箱Definition: Determining, assigning or designing the appropriate stand

10、ard quantity and container.目的: 以易于操作的包裝方式為操作工提供零部件,這種包裝使部件在船運,儲存和發(fā)貨過程中不易受損,且易操縱.Purpose: To provide parts to the operator in a user-friendly package that facilitates damage-free and economical handling during shipment, storage and delivery.2-1、少量包裝 Small Lot Packaging 2-2、少量包裝 Small Lot Packaging (1

11、9)4、對于每一個零件的包裝尺寸都應標準化Container dimensions are standardized per part number. 5、每種料箱都應張貼與其物料對應的認可的物料標簽（零件號、零件名稱、數(shù)量等）以進行辨識。Container contents are identified on an approved label (part number, description, quantity, etc.)3、每種零件都應有唯一的標準包裝數(shù)量（包括備用的/緊急的包裝） One standard pack quantity per part number exists (

12、including alternate / emergency packaging).2、料箱設計： (a)減少從第一個部件到最后一個部件因取料造成的人體疲勞和時間; (b) 在保持產(chǎn)品質量的前提下，盡量減少間隔襯墊的使用和處理; (c)減少準備時間(例如包裝材料和 箱蓋的拆除等) 和額外整理的相關活動(如收集、分類、處理)。Container design (a) minimizes ergonomic stress and time to access parts from first to last (b) maintains part quality while minimizing

13、dunnage and dunnage handling (c) minimizes preparation time (removing banding, wrapping, etc.) and disposal activity (collecting, sorting, processing). 1、根據(jù)有效的操作空間優(yōu)化料箱尺寸（零件操作適合工作區(qū)域），工作區(qū)域的料箱應能易于操作者操作。Container size is optimized for available operator space (parts fit within the work envelope) and con

14、tainers are presented in the workstation layout within easy reach supporting the operators needs. 要求 Requirements:2-2、少量包裝 Small Lot Packaging 2-3 、少量包裝 Small Lot Packaging (19)7、人工搬運的料箱包裝量應不大于2小時的用量（不包括堅硬的零件如羅栓、螺母、卡扣等） Manually handled containers hold a maximum of 2 hours worth of material (excludi

15、ng hardware parts such as nuts, bolts, fasteners, etc) 8、料箱設計及選擇過程中，應充分考慮人工搬運料箱及交換DOLLY的使用，盡量減少叉車的使用The container design and selection process increases the use of manually handled containers and dolly exchange, promoting the elimination of fork trucks.9、非手工操作的大件料箱，其包裝量應不大于4小時的用量。Non-manually handle

16、d (bulk) containers hold a maximum of 4 hours worth of material.10、不能因為減少每小時的庫存目標而減少包裝數(shù)量（料箱裝載空氣是不合理的）Point of use hourly inventory targets should not compromise filling the container (no air).11、盡量使用通用型可回收周轉箱Use of common returnable containers is maximized. 6、料箱尺寸應實現(xiàn)模數(shù)化，以提高卡車及拖車的容積率并保證裝載的穩(wěn)定性。Contain

17、er sizes should be modular to truck or rail car for best cube utilization and load stability.2-3 、少量包裝 Small Lot Packaging2-4 、少量包裝 Small Lot Packaging (19)15、空料箱返回區(qū)域： (a) 用于收集、整理、發(fā)運料箱; (b)對操作區(qū)域做明確的標識和可視化的控制，使其清晰可辨（如整理區(qū)、發(fā)運區(qū)、供應商區(qū)、周轉區(qū)、待處理區(qū)等）; (c)按計劃的數(shù)量發(fā)運; (d)指定由供應商自己負責或集裝箱整合運輸; (e)所在位置應滿足最小的綜合運送距離并有標準

18、化的操作流程 。Empty container return areas: (a) are designated for collecting, sorting and staging (b) are clearly identified with appropriate addresses and visual controls (e.g. Type of area Sort, Stage; supplier, return schedule, preparation instructions, etc.) (c) accommodate planned quantities of cont

19、ainers (d) are designated for every supplier and/or container combination (e) are located to minimize travel distance and standardize the work flow. 14、盡可能減少重新包裝(重復操作)Container re-packaging is minimized (double handling).13、按照供應商零件包裝的要求，物料應使用指定的料箱（或備用料箱）進行運輸。Material is shipped in the designated con

20、tainer (or backup) for all plant build requirements.12、人工搬運的料箱和部件間隔襯墊應滿足人機工程提升準則(如重量、尺寸、把手等) Manually handled containers / dunnage are ergonomic to assist operator handling (weight, dimension, grip points & etc.).2-4 、少量包裝 Small Lot Packaging2-5 、少量包裝 Small Lot Packaging (19)18、外運的卡車和拖車： (a)根據(jù)運輸計劃裝載

21、準備好的空料箱; (b)通過文件跟蹤外運的集裝箱和空料箱。Outbound trucks and rail cars : (a) are loaded with all prepared empty containers per the shipping schedule (b) have all required paperwork processed to document outbound shipment of containers for container tracking. 17、貨箱應準備完好和確保返回(例如：加蓋、分類和堆棧等)Containers are properly

22、prepared and secured for return (capped, sorted, stacked, etc.).19、有效的新包裝確認流程、包裝更改及現(xiàn)有的包裝評估流程Process in place to validate new packaging, changes to existing packaging and evaluate current packaging.16、空料箱操作: (a) 確保一旦最后的零件用完后，操作工即刻把空的料箱放置在合適的返回裝置中; (b)遵循有書面形式的內部襯隔處理流程; (c)遵循有書面形式的正確 的分類、轉運、裝卸等的工作程序; (

23、d)避免包裝箱挪為他用; (e)確保返回供應商的空箱內沒有雜物; (f)對需要維修和處理的料箱進行標示和發(fā)運。Empty container handling practices: (a) assure operator places empty container on appropriate return device as soon as last part is used (b) conform to a written process for handling internal dunnage (c) conform to a written process for proper s

24、orting, staging, loading, and unloading (d) prevent misuse of containers (e) assure empty containers are free of debris before returning them to suppliers (f) identify and route damaged containers for repair/disposal. 2-5 、少量包裝 Small Lot Packaging3 -1 、固定周期訂貨系統(tǒng) Fixed Period Ordering System (5)定義：在均衡

25、的基礎上根據(jù)物料的有效供應機制，建立預定的、固定的零件訂貨周期 Definition: Pre-determined, fixed period for parts ordering allowing for the effective supply of material on a leveled basis目的：確保物流供應既可以預知又可靠 Purpose: To ensure predictable, reliable flow of materials through the pipeline3 -1 、固定周期訂貨系統(tǒng) Fixed Period O3 -2 、固定周期訂貨系統(tǒng) Fix

26、ed Period Ordering System (5)2、確保每次在約定時間節(jié)點之前向供應商和承運商發(fā)布訂貨計劃Material schedules are communicated to the supplier and the transportation contact per agreed upon time horizon.1、建立零部件訂貨和發(fā)運的固定周期A fixed period is established for parts ordering and delivery.3、按標準包裝數(shù)量訂貨Material schedules are stated in standar

27、d pack quantities.4、備有例外的流程處理突發(fā)事件An exception process exists to cover emergencies. 5、內部管理零件訂貨流程Parts Ordering Process is managed locally.要求 Requirements:3 -2 、固定周期訂貨系統(tǒng) Fixed Period O4-1 、受控的外部運輸 Controlled External Transportation (18)定義:由物流供應商按確立的方式管理運作既定的物流途徑Definition: Scheduled logistics pipeline

28、 with established controls managed by a lead logistics provider.目的: 提供一個可預見的方法以應付頻繁的物料移動并達到各種資源的最優(yōu)化 purpose: To provide a predictable method for frequent material movement that maximizes use of resources.4-1 、受控的外部運輸 Controlled Extern4-2 、受控的外部運輸 Controlled External Transportation (18)3、物流供應商提供并維持戰(zhàn)略

29、路線規(guī)劃The single Lead Logistics Provider (LLP) or single point of contact for logistics provides strategic route planning and maintains the route board.4、供應商提供其以往操作數(shù)據(jù)。The single Lead Logistics Provider (LLP) or single point of contact for logistics provides a historical database.5、供應商提供不斷降低成本的步驟措施The

30、single Lead Logistics Provider (LLP) or single point of contact for logistics provides a process for further cost reduction. 6、供應商為實際運輸商單位和/或運輸分承包商提供培訓The single Lead Logistics Provider (LLP) or single point of contact for logistics provides training for carrier and/or transportation providers.1、物流供

31、應商提供一個主要的執(zhí)行檢驗標準，并定期進行評估考核。The single Lead Logistics Provider (LLP) or single point of contact for logistics provides a process to measure key performance criteria and has regular performance reviews with LLP and plant.2、供應商配備專人駐廠提供操作服務The single Lead Logistics Provider (LLP) or single point of conta

32、ct for logistics provides a resident in the plant for transportation modeling and operation.要求 Requirements:4-2 、受控的外部運輸 Controlled Extern4-3、受控的外部運輸 Controlled External Transportation (18)10、到工廠的運輸是按照小時、天、周的水平來操作的，以平衡生產(chǎn)和設備，同時將庫存降到最小Deliveries to the Plant are level hour-to-hour, day to day, week to

33、 week to balance workload and equipment as well as minimize inventory.9、所有的零件都送到工廠或物流再分配中心的指定接收地點。All parts are delivered to the plant and/or distribution center to scheduled windows. 11、提供一個能不斷提高貨物配載率的適當流程。 A process is in place to continuously improve cube efficiency of trailers and railcars. 12、在

34、經(jīng)濟和運輸可靠的基礎上，固定每條運輸線路的裝卸及掛靠港口Live unloading vs drop and swap is determined for each route based on economics and transportation reliability. 8、企業(yè)的安全規(guī)章制度得到嚴格執(zhí)行Plant safety rules are communicated and followed (e.g. tire chocking, jack stands, etc.).7、物流商保證將其目標匯總融入企業(yè)的商業(yè)規(guī)劃中The single Lead Logistics Provi

35、der (LLP) or single point of contact for logistics provides that the LLP objectives are integrated into the plants business plan (Business Plan Deployment).4-3、受控的外部運輸 Controlled Externa4-4 、受控的外部運輸 Controlled External Transportation (18)17、需要流程規(guī)范物料因供應商延誤時的緊急應急方案 A process is in place requiring tran

36、sportation carriers to provide corrective actions due to delays in material pick-up at supplier plants. 16、提供一個適當?shù)牧鞒桃源_保承運人能夠迅速將運輸延誤或其它錯誤問題通知工廠。 A process is in place to assure that carriers notify the plant promptly if a delivery is delayed or incorrect. 18、特殊或緊急情況的處理方案A process is in place to coord

37、inate special or emergency shipments.15、需有流程規(guī)定額外運輸費用的承擔方Process is in place and followed to properly classify supplier-responsible premium transportation costs. 14、采取合理方式返空集裝箱。 Empty container return processes are in place.13、采取適當措施保證各段負責人履行預先確定的檢查。（如在從發(fā)貨人處接受貨物時，通過零件號核對包裝數(shù)量）Process is in place to co

38、nfirm that the route driver performs the agreed process checks (such as verifying the standard pack count by part number for the shipment at the time of pick-up at the supplier. 4-4 、受控的外部運輸 Controlled Extern5-1 、有計劃的發(fā)運 /收貨 Schedule Shipping/Receiving (7)定義：貨物運輸根據(jù)指定的時間達到/離開 Definition: Transportatio

39、n carriers arrive / depart at designated time.目的：均衡和標準化發(fā)運/收貨活動以及資源要求 Purpose: To level and standardize shipping / receiving activities and resource requirements.不能早到也不能晚到5-1 、有計劃的發(fā)運 /收貨 Schedule Ship5-2 、有計劃的發(fā)運 /收貨 Schedule Shipping/Receiving (7)2、制定和公布標準作業(yè)單,且在作業(yè)單中描述貨物、供應商和廠方的責任。Standard operating p

40、rocedures are established and displayed, which describe the roles and responsibilities for carrier and plant. 1、貨運在指定的“計劃”時間達到/離開指定的地點Carriers arrive / depart the designated locations at the scheduled window times. 要求 Requirements:3、為使每次運輸?shù)挠媱澓蛯嵤顩r公諸于眾，應設置標準信息欄Standard visuals (e.g. dock boards) are

41、in place to communicate the schedule and actual status of each delivery. 5-2 、有計劃的發(fā)運 /收貨 Schedule Ship5-3 、有計劃的發(fā)運 /收貨 Schedule Shipping/Receiving (7)5、應明顯地標識收貨和發(fā)貨的區(qū)域。Receiving and Shipping material areas are segregated and visual. 6、使用拖車把貨物從收貨泊位運走（該位置經(jīng)濟可行）Tuggers and trailers are used to move materi

42、al from receiving docks (where possible and economical). 7、零部件和料箱在運輸后完好無損。Parts and containers are delivered free from transportation damage.4、應具備處理未按原定“計劃”時間到貨的流程A process is in place to handle shipments that will not arrive within their scheduled window time. 5-3 、有計劃的發(fā)運 /收貨 Schedule Ship6-1、臨時物料儲

43、存 Temporary Material Storage CMA (9)定義：在貨運至使用地之前在指定區(qū)域的固定零部件放置位置Definition: A fixed part location in a designated area before delivery to the point of use.目的：安排和控制庫存以便滿足制造和物流的需求 Purpose: To organize and control inventory to meet manufacturing and material flow needs.6-1、臨時物料儲存 Temporary Material 6-2、

44、臨時物料儲存 Temporary Material Storage CMA (9)2、每個零部件號應有一個固定的儲存位置 Each part number has one fixed storage location.1、優(yōu)化物料存儲區(qū)的數(shù)量及位置Number and location of material storage areas is optimized. 3、 所有零部件位置都有明顯標識(標志,符號等)All part locations are visually identified (signs, labels, etc.). 4、為了保證安全（合理的堆高）、物料流程和庫存控制（

45、min/max、先進先出、溢庫）必須在車間存儲區(qū)的上方懸掛目視化控制板Visual controls are used to ensure that safety ( safe stacking heights ), material flow process, and inventory control (min /max, FIFO, overflow) are managed on the shop floor.6-2、臨時物料儲存 Temporary Material 6-3、臨時物料儲存 Temporary Material Storage CMA (9)8、 溢庫區(qū): (a)盡量小

46、且受控(b)應做明顯標示 (c)遵循維持先進先出的流程Overflow location areas (a) are minimized and controlled, (b) are clearly identified, (c)follow and maintain FIFO flow.9、 工程更改、斷點舊零件、不良品、試生產(chǎn)等物料以及報廢區(qū)應有良好的目視，每種物料應粘附有明顯的標簽Engineering change material, obsolete material, non-conformance, package trials, etc. and garbage areas

47、exist with proper visuals and are adhered to.7、從泊位處運至的物料應直接放置在儲存區(qū) Material delivered from the docks is placed directly into storage area. 6、保持最少/最多的數(shù)量和具備管理異常的流程（如min/max報警流程、缺貨流程、溢庫流程等）Min/max quantities are maintained and a process is in place to manage exceptions (min and max violations, out of st

48、ock conditions, overflow, etc.).思考Think?5、 通道: (a)標清用于儲存或 收發(fā) (b) 為所有使用者提供暢通的交通流向(例如單向通道等) (c) 拖車和鏟車分道而行 (d) 將人行通道和車輛通道作明顯的區(qū)分Aisles: (a) are clearly visually identified for part store / retrieve, (b) provide for smooth traffic flow for all users (one way versus two way traffic) (c) facilitate the sep

49、aration of tugger and forklift traffic (d) clearly identify equipment and pedestrian paths/restrictions .6-3、臨時物料儲存 Temporary Material 7-1、內部拉動/交貨Internal Pull/Delivery (7)定義：由用戶根據(jù)某產(chǎn)品的用量授權在特定時間,地點以一定的數(shù)量制造 和/或 運輸某一產(chǎn)品的補充系統(tǒng) Definition: A replenishment system where the user authorizes the manufacture an

50、d / or delivery of a product at a specific time, place and quantity based on consumption.目的：在使用戶滿意的前提下管理物流和減少庫存 Purpose: To manage the flow of material and minimize inventory while satisfying the user.7-1、內部拉動/交貨Internal Pull/Deliv7-2、內部拉動/交貨Internal Pull/Delivery (7)3、物料工按標準化的流程操作，流程目視化張貼以方便新員工或輪崗員

51、工培訓掌握Standardized work is followed by material team members; instructions are visually displayed and utilized for new/cross functional training. 1、拉動流程必須文件化，同時描述不同種類的物料是如何在物料需求時采用何種適當?shù)男盘?、拉動方式來正確補充物料Pull processes are documented with a description of how each type of pull works and a process is in pl

52、ace to select the appropriate pull signal to be used for each part number to best replenish the material at point of use. 2、物料的配送是以物料的消耗為基礎的，配送的需求是根據(jù)特定的拉動信號產(chǎn)生。Material consumption is the basis for replenishment and the use of a pull signal initiates material replenishment.要求 Requirements:7-2、內部拉動/交貨

53、Internal Pull/Deliv7-3、內部拉動/交貨Internal Pull/Delivery (7)7、采用目視化的方式對流程進行控制（如min/max、拉動時間段、溢庫等）Visual controls are used for process management (min/max, reorder points, overflow, etc.) 6、應有一套有規(guī)則的監(jiān)控,維持和改進每種拉動信號的流程(例如檢測和補充遺失的看板卡，拉動式間段調整等)A process is in place for monitoring, maintaining and improving ea

54、ch signal on a regular basis (e.g. detect and replace missing pull cards, reorder points, etc.). 5、在每一個循環(huán)補充送料到位的同時將空的料箱和內襯、襯墊等物撤離線旁。Empty containers and dunnage are removed from the line side location on each cycle when replenishment parts are delivered. 4、及時準確地將狀態(tài)良好、正確數(shù)量（整包裝）的物料在第一需求時間補充至正確的位置以滿足安裝

55、用料的需求。Material replenishment is timely, to the correct location, in the right (ordered) quantity, free from damage, and in the best presentation with the first part available to the operator.如何操作看流程7-3、內部拉動/交貨Internal Pull/Deliv8-1、均衡定購車輛的生產(chǎn)計劃 Level Vehicle Orders (4)定義：包括預定定購車輛均衡生產(chǎn)標準限制和不變更時間表在內的定單計劃方法 Definition: Order scheduling method incorporating predetermined vehicle order leveling criteria limits and no change schedule time horizon.目的：在全力支持精益物料管理和使客戶滿意的同時提高精益生產(chǎn)的效率 Purpose: To enhance efficient l