同步制造和約束理論課件

2022/12/25FangAihuaWuhanUniversityChapter18

SynchronousManufacturing&

TheoryofConstraints同步制造與約束理論2022/12/19Chapter18

Synchrono2022/12/25FangAihuaWuhanUniversityTheHockeyStickPhenomenon曲棍球球棒現(xiàn)象2022/12/19TheHockeyStickPhe2022/12/25FangAihuaWuhanUniversityTheHockeyStickPhenomenon

曲棍球球棒現(xiàn)象Theend-of-periodrush!Period1234Output($)考前突擊！?。。?022/12/19TheHockeyStickPhe2022/12/25FangAihuaWuhanUniversitySynchronousManufacturing

同步制造Whichrefertotheentireproductionprocessworkingtogetherinharmonytoachievethegoalsofthefirm.為了實(shí)現(xiàn)公司的目標(biāo)，使整個(gè)生產(chǎn)系統(tǒng)協(xié)調(diào)一致地工作2022/12/19SynchronousManufact2022/12/25FangAihuaWuhanUniversity首要特征synchronousmanufacturinglogicattemptstocoordinateallresourcessothattheyworktogetherandareinharmonyoraresynchronized.Insuchasynchronousstate,emphasisisontotalsystemperformance,notonlocalizedperformancemeasuressuchaslaborormachineutilization.

追求企業(yè)的全部資源協(xié)調(diào)、同步運(yùn)轉(zhuǎn)

追求企業(yè)的整體效率，而不是單個(gè)生產(chǎn)要素的利用率（如：勞動、設(shè)備生產(chǎn)率）。2022/12/19首要特征synchronousmanu2022/12/25FangAihuaWuhanUniversityThegoalofthefirm公司的目標(biāo)2022/12/19Thegoalofthefirm2022/12/25FangAihuaWuhanUniversity4GoldrattProclaims

哥德瓦特Thegoalofafirmistomakemoney.2022/12/194GoldrattProclaims

2022/12/25FangAihuaWuhanUniversityPerformanceMeasurements績效評價(jià)2022/12/19PerformanceMeasurem2022/12/25FangAihuaWuhanUniversityPerformanceMeasurement

Financial財(cái)務(wù)評價(jià)Netprofitanabsolutemeasurementindollars

Returnoninvestmentarelativemeasurebasedoninvestment

Cashflowasurvivalmeasurement

凈利潤絕對的賺錢數(shù)量投資收益率現(xiàn)金流量2022/12/19PerformanceMeasurem2022/12/25FangAihuaWuhanUniversity6PerformanceMeasurement

Operational運(yùn)作評價(jià)1.Throughputtherateatwhichmoneyisgeneratedbythesystemthroughsales2.Inventoryallthemoneythatthesystemhasinvestedinpurchasingthingsitintendstosell3.Operatingexpensesallthemoneythatthesystemspendstoturninventoryintothroughput

吞吐量（產(chǎn)銷率）

庫存

運(yùn)作費(fèi)用2022/12/196PerformanceMeasure2022/12/25FangAihuaWuhanUniversityProductivity

生產(chǎn)率DoesnotguaranteeprofitabilityHasthroughputincreased?Hasinventorydecreased?Haveoperationalexpensesdecreased?

不能保證贏利2022/12/19Productivity

生產(chǎn)率Does2022/12/25FangAihuaWuhanUniversityUnbalancedCapacity

不平衡的生產(chǎn)能力2022/12/19UnbalancedCapacity

2022/12/25FangAihuaWuhanUniversity8UnbalancedCapacity

不平衡的生產(chǎn)能力Earlier,wediscussedbalancingassemblylines.ThegoalwasconstantcycletimeacrossallstationsSynchronousmanufacturingviewsconstantworkstationcapacityasabaddecision.

早期觀點(diǎn)：裝配線的生產(chǎn)能力的平衡

同步制造：生產(chǎn)能力的平衡是一種壞觀點(diǎn)2022/12/198UnbalancedCapacity2022/12/25FangAihuaWuhanUniversity9TheStatisticsofDependentEvents

獨(dú)立事件的統(tǒng)計(jì)規(guī)律Ratherthanbalancingcapacities,theflowofproductthroughthesystemshouldbebalancedProcessTime(B)ProcessTime(A)與其平衡能力，不如平衡物流2022/12/199TheStatisticsofD2022/12/25FangAihuaWuhanUniversitySomeCapacityRelatedTerminology術(shù)語2022/12/19SomeCapacityRelate2022/12/25FangAihuaWuhanUniversityCapacity

生產(chǎn)能力Availabletimeforproduction可利用的生產(chǎn)時(shí)間（工時(shí)/臺時(shí)）2022/12/19Capacity

生產(chǎn)能力Availab2022/12/25FangAihuaWuhanUniversityBottleneck

瓶頸Capacityislessthandemandplacedonresource瓶頸是指實(shí)際生產(chǎn)能力小于生產(chǎn)負(fù)荷的一切資源，它是系統(tǒng)內(nèi)部制約產(chǎn)銷率的約束因素，是制造過程中流量最小的地方。實(shí)踐表明大部分工廠只有為數(shù)極少的瓶頸作業(yè)。如果沒有瓶頸，則意味著存在剩余生產(chǎn)能力，這時(shí)應(yīng)該改變系統(tǒng)暴露出系統(tǒng)瓶頸。2022/12/19Bottleneck

瓶頸Capacit2022/12/25FangAihuaWuhanUniversityNonbottleneck

非瓶頸Capacityisgreaterthandemandplacedonresource非瓶頸是指實(shí)際生產(chǎn)能力大于生產(chǎn)負(fù)荷的一切資源。因此，非瓶頸資源不應(yīng)該連續(xù)不斷的工作，因?yàn)樗纳a(chǎn)能力超過需求量，非瓶頸包含空閑時(shí)間。2022/12/19Nonbottleneck

非瓶頸Cap2022/12/25FangAihuaWuhanUniversityCapacity-constrainedresource

次瓶頸資源(CCR)Capacityisclosetodemandplacedonresource次瓶頸資源是指利用率已接近實(shí)際生產(chǎn)能力，并且如果作業(yè)計(jì)劃制定的不太好就可能成為瓶頸資源。例如：一般作業(yè)車間的CCR可能接受好幾個(gè)地方的工作任務(wù)，如果這些工作任務(wù)沒有安排好，就會使工作任務(wù)之間的間歇時(shí)間超過CCR的空閑時(shí)間，從而使CCR成為瓶頸。2022/12/19Capacity-constrained2022/12/25FangAihuaWuhanUniversityBasicManufacturingBuildingBlocks基本制造類型2022/12/19BasicManufacturing2022/12/25FangAihuaWuhanUniversity11Bottleneckfeedingnonbottleneck

瓶頸供給非瓶頸XYMarketCaseA2022/12/1911Bottleneckfeeding2022/12/25FangAihuaWuhanUniversity12Nonbottleneckfeedingbottleneck

非瓶頸供給瓶頸YXMarketCaseB2022/12/1912Nonbottleneckfeed2022/12/25FangAihuaWuhanUniversity13OutputofBottleneckandNonbottleneckassembledintoaProduct組裝XYAssemblyMarketCaseC2022/12/1913OutputofBottlene2022/12/25FangAihuaWuhanUniversity14IndependentMarkets

獨(dú)立市場XYMarketMarketCaseD2022/12/1914IndependentMarket2022/12/25FangAihuaWuhanUniversityMethodsofControl控制方法2022/12/19MethodsofControl控制2022/12/25FangAihuaWuhanUniversity15ComponentsofProductionCycleTime

時(shí)間構(gòu)成SetuptimethetimethatapartspendswaitingforaresourcetobesetuptoworkonthissamepartProcesstimethetimethatthepartisbeingprocessedQueuetimethetimethatapartwaitsforaresourcewhiletheresourceisbusywithsomethingelse

調(diào)整時(shí)間

加工時(shí)間

排隊(duì)時(shí)間2022/12/1915ComponentsofProd2022/12/25FangAihuaWuhanUniversity16ComponentsofProductionCycleTimeWaittimethetimethatapartwaitsnotforaresourcebutforanotherpartsothattheycanbeassembledtogether

等待時(shí)間

空閑時(shí)間Idletimetheunusedtimethecycletimelessthesumofthesetuptime,processingtime,queuetime,andwaittime2022/12/1916ComponentsofProd2022/12/25FangAihuaWuhanUniversityFindingtheBottleneck

尋找瓶頸的方法尋找企業(yè)生產(chǎn)系統(tǒng)中的瓶頸有兩種方法：一種方法是工序負(fù)荷比較表；另一種方法是運(yùn)用有關(guān)工廠的專門知識，考察系統(tǒng)的運(yùn)行，并與管理人員和工人交談。2022/12/19FindingtheBottlene2022/12/25FangAihuaWuhanUniversity17SavingTime

節(jié)約時(shí)間BottleneckNonbottleneckWhataretheconsequencesofsavingtimeateachprocess?2022/12/1917SavingTime

節(jié)約時(shí)間Bo2022/12/25FangAihuaWuhanUniversity18Drum,Buffer,Rope

鼓、緩沖器、繩子ABCDEF鼓(Drum)緩沖器(InventoryBuffer)Communication繩子(rope)Market市場2022/12/1918Drum,Buffer,Rope2022/12/25FangAihuaWuhanUniversity“鼓（Drum）”“鼓”是一個(gè)企業(yè)應(yīng)用TOC的開端，即識別一個(gè)企業(yè)的“約束”所在。“約束”控制著企業(yè)同步生產(chǎn)的節(jié)奏——“鼓點(diǎn)”。要維持企業(yè)內(nèi)部生產(chǎn)的同步、企業(yè)生產(chǎn)和市場需求的同步，存在著一系列的問題。其中一個(gè)主要問題就是企業(yè)的生產(chǎn)如何能滿足市場或顧客的需求而又不產(chǎn)生過多的庫存。2022/12/19“鼓（Drum）”“鼓”是一個(gè)企業(yè)應(yīng)用T2022/12/25FangAihuaWuhanUniversity“緩沖器（Buffer）”“緩沖器”分為“時(shí)間緩沖”和“庫存緩沖”：“庫存緩沖”就是保險(xiǎn)在制品，其位置、數(shù)量的確定原則同“時(shí)間緩沖”?！皶r(shí)間緩沖”則是將所需的物料比計(jì)劃提前一段時(shí)間提交，以防隨機(jī)波動，以約束資源上的加工時(shí)間長度作為計(jì)量單位。2022/12/19“緩沖器（Buffer）”“緩沖器”分為2022/12/25FangAihuaWuhanUniversity“繩子（Rope）”“約束”決定著生產(chǎn)線的產(chǎn)出節(jié)奏，而在其上游的工序?qū)嵭欣瓌邮缴a(chǎn)，等于用一根看不見的“繩子”把“約束”與這些工序串聯(lián)起來，有效地使物料依照產(chǎn)品出產(chǎn)計(jì)劃快速地通過非約束作業(yè)，以保證約束資源的需要。所以，“繩子”起的是傳遞作用，以驅(qū)動系統(tǒng)的所有部分按”鼓”的節(jié)奏進(jìn)行生產(chǎn)。在DBR的實(shí)施中，“繩子”是由一個(gè)涉及原材料投料到各車間的詳細(xì)的作業(yè)計(jì)劃來實(shí)現(xiàn)的。2022/12/19“繩子（Rope）”“約束”決定著生產(chǎn)線2022/12/25FangAihuaWuhanUniversity22InventoryCostMeasurement

DollarDays美元日Ameasurementofthevalueofinventoryandthetimeitstayswithinanarea一定范圍內(nèi)的庫存及其停留時(shí)間的一個(gè)測量指標(biāo)DollarDays=(valueofinventory)(numberofdayswithinadepartment)Example2022/12/1922InventoryCostMea2022/12/25FangAihuaWuhanUniversity23BenefitsfromDollarDayMeasurement

美元日的應(yīng)用MarketingdiscouragesholdinglargeamountsoffinishedgoodsinventoryPurchasingdiscouragesplacinglargepurchaseordersthatonthesurfaceappeartotakeadvantageofquantitydiscountsManufacturingdiscouragelargeworkinprocessandproducingearlierthanneeded市場營銷反對大量成品庫存采購反對大量采購制造反對大量在制品，提前完工2022/12/1923BenefitsfromDoll精品文檔歡迎下載讀書破萬卷，下筆如有神--杜甫精品文檔歡迎下載讀書破萬卷，下筆如有神--杜甫2022/12/25FangAihuaWuhanUniversityChapter18

SynchronousManufacturing&

TheoryofConstraints同步制造與約束理論2022/12/19Chapter18

Synchrono2022/12/25FangAihuaWuhanUniversityTheHockeyStickPhenomenon曲棍球球棒現(xiàn)象2022/12/19TheHockeyStickPhe2022/12/25FangAihuaWuhanUniversityTheHockeyStickPhenomenon

曲棍球球棒現(xiàn)象Theend-of-periodrush!Period1234Output($)考前突擊！?。。?022/12/19TheHockeyStickPhe2022/12/25FangAihuaWuhanUniversitySynchronousManufacturing

同步制造Whichrefertotheentireproductionprocessworkingtogetherinharmonytoachievethegoalsofthefirm.為了實(shí)現(xiàn)公司的目標(biāo)，使整個(gè)生產(chǎn)系統(tǒng)協(xié)調(diào)一致地工作2022/12/19SynchronousManufact2022/12/25FangAihuaWuhanUniversity首要特征synchronousmanufacturinglogicattemptstocoordinateallresourcessothattheyworktogetherandareinharmonyoraresynchronized.Insuchasynchronousstate,emphasisisontotalsystemperformance,notonlocalizedperformancemeasuressuchaslaborormachineutilization.

追求企業(yè)的全部資源協(xié)調(diào)、同步運(yùn)轉(zhuǎn)

追求企業(yè)的整體效率，而不是單個(gè)生產(chǎn)要素的利用率（如：勞動、設(shè)備生產(chǎn)率）。2022/12/19首要特征synchronousmanu2022/12/25FangAihuaWuhanUniversityThegoalofthefirm公司的目標(biāo)2022/12/19Thegoalofthefirm2022/12/25FangAihuaWuhanUniversity4GoldrattProclaims

哥德瓦特Thegoalofafirmistomakemoney.2022/12/194GoldrattProclaims

2022/12/25FangAihuaWuhanUniversityPerformanceMeasurements績效評價(jià)2022/12/19PerformanceMeasurem2022/12/25FangAihuaWuhanUniversityPerformanceMeasurement

Financial財(cái)務(wù)評價(jià)Netprofitanabsolutemeasurementindollars

Returnoninvestmentarelativemeasurebasedoninvestment

Cashflowasurvivalmeasurement

凈利潤絕對的賺錢數(shù)量投資收益率現(xiàn)金流量2022/12/19PerformanceMeasurem2022/12/25FangAihuaWuhanUniversity6PerformanceMeasurement

Operational運(yùn)作評價(jià)1.Throughputtherateatwhichmoneyisgeneratedbythesystemthroughsales2.Inventoryallthemoneythatthesystemhasinvestedinpurchasingthingsitintendstosell3.Operatingexpensesallthemoneythatthesystemspendstoturninventoryintothroughput

吞吐量（產(chǎn)銷率）

庫存

運(yùn)作費(fèi)用2022/12/196PerformanceMeasure2022/12/25FangAihuaWuhanUniversityProductivity

生產(chǎn)率DoesnotguaranteeprofitabilityHasthroughputincreased?Hasinventorydecreased?Haveoperationalexpensesdecreased?

不能保證贏利2022/12/19Productivity

生產(chǎn)率Does2022/12/25FangAihuaWuhanUniversityUnbalancedCapacity

不平衡的生產(chǎn)能力2022/12/19UnbalancedCapacity

2022/12/25FangAihuaWuhanUniversity8UnbalancedCapacity

不平衡的生產(chǎn)能力Earlier,wediscussedbalancingassemblylines.ThegoalwasconstantcycletimeacrossallstationsSynchronousmanufacturingviewsconstantworkstationcapacityasabaddecision.

早期觀點(diǎn)：裝配線的生產(chǎn)能力的平衡

同步制造：生產(chǎn)能力的平衡是一種壞觀點(diǎn)2022/12/198UnbalancedCapacity2022/12/25FangAihuaWuhanUniversity9TheStatisticsofDependentEvents

獨(dú)立事件的統(tǒng)計(jì)規(guī)律Ratherthanbalancingcapacities,theflowofproductthroughthesystemshouldbebalancedProcessTime(B)ProcessTime(A)與其平衡能力，不如平衡物流2022/12/199TheStatisticsofD2022/12/25FangAihuaWuhanUniversitySomeCapacityRelatedTerminology術(shù)語2022/12/19SomeCapacityRelate2022/12/25FangAihuaWuhanUniversityCapacity

生產(chǎn)能力Availabletimeforproduction可利用的生產(chǎn)時(shí)間（工時(shí)/臺時(shí)）2022/12/19Capacity

生產(chǎn)能力Availab2022/12/25FangAihuaWuhanUniversityBottleneck

瓶頸Capacityislessthandemandplacedonresource瓶頸是指實(shí)際生產(chǎn)能力小于生產(chǎn)負(fù)荷的一切資源，它是系統(tǒng)內(nèi)部制約產(chǎn)銷率的約束因素，是制造過程中流量最小的地方。實(shí)踐表明大部分工廠只有為數(shù)極少的瓶頸作業(yè)。如果沒有瓶頸，則意味著存在剩余生產(chǎn)能力，這時(shí)應(yīng)該改變系統(tǒng)暴露出系統(tǒng)瓶頸。2022/12/19Bottleneck

瓶頸Capacit2022/12/25FangAihuaWuhanUniversityNonbottleneck

非瓶頸Capacityisgreaterthandemandplacedonresource非瓶頸是指實(shí)際生產(chǎn)能力大于生產(chǎn)負(fù)荷的一切資源。因此，非瓶頸資源不應(yīng)該連續(xù)不斷的工作，因?yàn)樗纳a(chǎn)能力超過需求量，非瓶頸包含空閑時(shí)間。2022/12/19Nonbottleneck

非瓶頸Cap2022/12/25FangAihuaWuhanUniversityCapacity-constrainedresource

次瓶頸資源(CCR)Capacityisclosetodemandplacedonresource次瓶頸資源是指利用率已接近實(shí)際生產(chǎn)能力，并且如果作業(yè)計(jì)劃制定的不太好就可能成為瓶頸資源。例如：一般作業(yè)車間的CCR可能接受好幾個(gè)地方的工作任務(wù)，如果這些工作任務(wù)沒有安排好，就會使工作任務(wù)之間的間歇時(shí)間超過CCR的空閑時(shí)間，從而使CCR成為瓶頸。2022/12/19Capacity-constrained2022/12/25FangAihuaWuhanUniversityBasicManufacturingBuildingBlocks基本制造類型2022/12/19BasicManufacturing2022/12/25FangAihuaWuhanUniversity11Bottleneckfeedingnonbottleneck

瓶頸供給非瓶頸XYMarketCaseA2022/12/1911Bottleneckfeeding2022/12/25FangAihuaWuhanUniversity12Nonbottleneckfeedingbottleneck

非瓶頸供給瓶頸YXMarketCaseB2022/12/1912Nonbottleneckfeed2022/12/25FangAihuaWuhanUniversity13OutputofBottleneckandNonbottleneckassembledintoaProduct組裝XYAssemblyMarketCaseC2022/12/1913OutputofBottlene2022/12/25FangAihuaWuhanUniversity14IndependentMarkets

獨(dú)立市場XYMarketMarketCaseD2022/12/1914IndependentMarket2022/12/25FangAihuaWuhanUniversityMethodsofControl控制方法2022/12/19MethodsofControl控制2022/12/25FangAihuaWuhanUniversity15ComponentsofProductionCycleTime

時(shí)間構(gòu)成SetuptimethetimethatapartspendswaitingforaresourcetobesetuptoworkonthissamepartProcesstimethetimethatthepartisbeingprocessedQueuetimethetimethatapartwaitsforaresourcewhiletheresourceisbusywithsomethingelse

調(diào)整時(shí)間

加工時(shí)間

排隊(duì)時(shí)間2022/12/1915ComponentsofProd2022/12/25FangAihuaWuhanUniversity16ComponentsofProductionCycleTimeWaittimethetimethatapartwaitsnotforaresourcebutforanotherpartsothattheycanbeassembledtogether

等待時(shí)間

空閑時(shí)間Idletimetheunusedtimethecycletimelessthesumofthesetuptime,processingtime,queuetime,andwaittime2022/12/1916ComponentsofProd2022/12/25FangAihuaWuhanUniversityFindingtheBottleneck

尋找瓶頸的方法尋找企業(yè)生產(chǎn)系統(tǒng)中的瓶頸有兩種方法：一種方法是工序負(fù)荷比較表；另一種方法是運(yùn)用有關(guān)工廠的專門知識，考察系統(tǒng)的運(yùn)行，并與管理人員和工人交談。2022/12/19FindingtheBottlene2022/12/25FangAihuaWuhanUniversity17SavingTime

節(jié)約時(shí)間BottleneckNonbottleneckWhataretheconsequencesofsavingtimeateachprocess?2022/12/1917SavingTime

節(jié)約時(shí)間Bo2022/12/25FangAihuaWuhanUniversity18Drum,Buffer,Rope

鼓、緩沖器、繩子ABCDEF鼓(Drum)緩沖器(InventoryBuffer)Communication繩子(rope)Mark