精益生產之線平衡模式-Line-Balance-ModelsGabriel

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過程改善流程分析控制改進定義選定題目列出客戶從顧客之聲中列出關建需求定出項目焦點和重要指標完成PDF測量繪制業(yè)務流程圖繪制價值流程圖制定數(shù)據(jù)收集計劃測量系統(tǒng)分析收集數(shù)據(jù)過程能力分析分析提出關鍵因子區(qū)分關鍵因子驗證關鍵因子評枯每個關鍵因子對結果的影響量化機會根本原因排序尋找根本原因針對關鍵因子改進關鍵因子確認發(fā)掘潛在的解決方法選擇方案優(yōu)化方案實行方案控制過程變革和控制制定控制計劃計算最終財務過程指標項目過渡給未來項目管理者項目鑒別轉化機會測量定義項目編號工具項目定義表凈現(xiàn)值分析內部回報率分析折算現(xiàn)金流分析？（按現(xiàn)值計算的現(xiàn)金流量分析）PIP管理過程RACIQuad表過程圖價值分析腦力風暴投票歸類法柏拉圖因果圖/魚骨圖FMEA查檢表運行圖控制圖量具R&RCp&Cpk供應鏈加速器分析多變動圖i盒狀圖交互作用圖回歸分析ANOVAC&E矩陣圖FMEA腦力風暴拉系統(tǒng)減少設置TPM流程圖標桿管理親和圖DOE假設檢驗力場分析圖樹狀圖甘特圖查檢表運行圖柱狀圖散布圖控制圖柏拉圖互動回顧愚巧法Revised1-12-025LearningObjectivesHowtodesignandimplementaprocesssupportedbyalinebalancingmodelthatensuresoptimaluseof:PeopleFloorspaceCapitalAssetsMaterialKnowhowtomaximizeproductivity6學習目標如何設計和實施由“線平衡模型”支持的一個流程以確保優(yōu)化配置：人地方固定資產材料知道如何使生產率最大化7What’sinItforMe?AbletodesignandimplementabalancedprocesslineUnderstandtheissuesinatypicalprocessenvironmentandhowtoimpactthoseissues8益處能夠設計和實施一個線平衡的生產線了解典型流程環(huán)境中的問題及如何影響那些問題9LineBalanceModelALineBalancingModelallowstheusertoviewtasktimesacrossaprocesstoidentifybottlenecksandthuscalculateoutputrates(throughput)andTaktTimes.Inaddition,theuserwillbeabletovisuallyseeunbalancedareasandwheretaskscanbeshiftedtobalancetheprocess.TheLineBalancetechniquesareapplicableintransactionalaswellasmanufacturing,e.g.,orderentryoperations.10線平衡模型線平衡模型允許用戶在一個流程中確定瓶頸問題，并計算產出比率（產能）和TaktTimes。除此，用戶將能直觀地看到不平衡的區(qū)域和使流程平衡所做的任務。

線平衡方法與生產互動一樣是可行的，如訂單進入生產。11PrimaryIssuesinTypicalProcessEnvironmentsLargeorerraticbatchesExcessiveWIPPoorfloorspaceutilizationLowemployeeefficiencyLong/erraticcycletimesPoorbalanceofoperationsandlaboracrossprocessstepsConveyance,standbyandmotionwasteDisorganizedworkspaceandcomponent/supplystorageHighvariabilityofdemandonmultipleprocessingcenters,e.g.,callcenters/flowlines12典型的流程環(huán)環(huán)境

中的主主要問題大批量或反復無常的批批量過多的WIP地方利用的差差較低的員工效效率長的/反復無無常的周期時時間流程步驟中差差的生產平衡衡和勞動力傳送、備用和和啟動浪費無規(guī)則的工作作地點和元件件/供應存儲儲對于多重的流流程中心，需需求變化差異異大2，如電電話中心/流流出線13LineBalance–DesignPrinciplesMinimizeBatchSize/TransferQuantity/WorkInProcessMinimize/StabilizeCycleTimeMaximizeLaborEfficiencyOptimizenumberofworkstations/processstepsBalancetasks/laboracrossworkstationsMaximizespaceutilizationMinimizetaktvarianceMinimizeNVA(conveyance,standby,andmotionwastes)Minimizetheneedtore-balanceasdemandrequirementschangeMinimizevolumevariability(combineproductcategorydemand)Maximizeflexibilitytoallowforproductintroductionsanddiscontinuations14線平衡–設設計原則使批量規(guī)模/轉移質量/在制品最小化化將周期時間最最小化/穩(wěn)定定化使勞動效率最最大化優(yōu)化配置工作作站/流程步步驟平衡任務/工工作站里的勞勞動最大限度利用用空間使takt的變化最小化化最小化NVA(運送、備用和和啟動浪費)根據(jù)需求的變變化使再平衡衡的需求最小小化使批量差異最最小化(綜合產品種類類需求)使柔性最大化化以允許產品品引入和非持持續(xù)性15ValueDefinitionsValueAdd:Addingform,fit,orfunctiontotheproduct.Ataskoractivityforwhichthecustomerwouldbewillingtopay.Example–AssemblerscrewingaboltintoapieceofaluminumrequiredtoholdthewindowtogetherExample–FinancialServicesemployeeaddingcredithistorytoacreditapplicationBusinessValueAdd:AtaskthatisrequiredtobuildawindowbutforwhichthecustomerisnotwillingtopayExample–Thetimeittakesforanassemblertograbapartthatisatpoint-of-useandreadyitforassemblyExample–ThetimeittakesforaFinancialServicesemployeetosecureacreditapplicationandreadyitforprocessingNon-ValueAdd:AtaskthatisnotrequiredandshouldbeeliminatedbecauseitiswastefulExample–AssemblerhavingtosearcharoundtheirareatoretrieveapartforassemblyExample–FinancialServicesemployeehavingtolookformissinginformationneededtoaddcredithistoryinformation16價值定義增值:增加加產品的形式式、或功能。。客戶愿意付付費的任務或活動。。如–在鋁鋁合金中裝配配螺釘以把窗窗子固定在一一起如–給員員工在應用用信用方面面提供信信用歷史的的財務服務務業(yè)務增值:所需的一項項任務是一扇窗子，，但是客戶戶不愿付費費如–裝配配商花時間間抓住一個個零件在使使用點上進進行裝配如–為為員工提供供財務服務務是花時間間確保信用用的應用17LineBalanceApproachesTwoDifferentApproaches:Approach#1––LongTermPlanner:Giventheinputsofaverageproductivity,assembly/processingtime,andforecastedoutput(demand),andhourspershift,calculatethenumberofassemblers/processorsandaveragetakttimeitwilltaketosatisfythedemand.Approach#2––Day-to-DayScheduler:Giventheinputsofaverageproductivity,assembly/processingtime,numberofassemblers/processors,anddesiredoutput(demand),calculatethehourspershiftandtaktrateitwilltaketosatisfythedemand.What’’sthedifference?LongTermPlannerallowsmanagementtounderstandstaffingincrementsbaseduponsomeforecasteddemandonalinebylinebasis.Day-to-Dayschedulerallowslinesupervisiontocalculateprocessparameters(taktrate,hourstowork)basedonthenumberofunitstoprocessandthenumberofpeoplewhoshowuptoworkthatday.18線平衡步驟驟兩種不同的的方法:方法#1–長長期計劃員員:作出平均投投入生產率率、裝配/加工時間間、及預計計的產量（（需求），，每班的時時間，計算算裝配工/操作工的的數(shù)量，及及滿足需求求所花的平平均時間。。方法#2–日日常安排員員:作出平均投投入生產率率,裝配/加工工時間，裝裝配工/操操作工的數(shù)數(shù)量，理想想的產量（（需求），，計算每班班所用的時時間和滿足足需求的takt比率。區(qū)別是什么么?長期計劃員員允許管理理來了解在在以生產線線為基礎上上的需求預預測而增加加員工。日常安排員員允許生產產的監(jiān)督來來計算流程程參數(shù)（takt比率，工時時），這個個參數(shù)是基基于加工工單元數(shù)量量和人員數(shù)數(shù)量。Approach#1LongTermPlanner途徑#1長期計劃員員21Input1.Demandrequirements2.Laborefficiency3.Assemble/processtasksandtimes4. Hourspershiftornumberofassembler/stationsOutput1.Taktrate2.NumberofAssemblers/ProcessorsORNumberofhourspershift3.StaffinglevelsatvaryingdemandProcessBalanceModel(spreadsheet)ProcessBalanceModel:DesignprocessOr22投入1.需求需要要2.勞動效率率3.裝配/加加工任務務和時間間4.每班時間間或裝配配工/工工作站數(shù)數(shù)量產出1.Takt比率2.裝配工/操作工工數(shù)量或或每班時時間3.在變化基基礎上的的員工水水平過程平衡衡模型(spreadsheet)ProcessBalanceModel:設計流程程Or23ProcessBalanceModel:StepsStep1:Understandpresentstateprocessoperation(gatheranddocumentdata)Step2:Determinetotaltimerequiredtoprocessunit(valueaddandbusinessvalueadd)Step3:DeterminemaximumoperatingparametersandplugparametersintoyellowcellsStep4:Determinetargetunit/dayoutputrequirementandplotontabletodeterminenumberofshifthourstoworktoachieverequirementStep5:PlotcurrentoperatingrangetodeterminelaborreductionrequiredtomeetoperatinggoalsStep6:Grouptasksinlogicalandefficientmannerthatdoesnotviolatedesignprinciples24過程平衡衡模型步驟Step1:了解目前前的生產產流程狀狀況(收集數(shù)據(jù)據(jù)并文件件化)Step2:確定處理理單元所所需的全全部時間間（增值值和業(yè)務務增值））Step3:確定最大大的運行行參數(shù)并并將參數(shù)數(shù)插入黃黃格中Step4:將目標單單元/天所需的的產量在在桌面上上標出以以確定達達到需要要的每班班工作時時間Step5:標出目前前的運行行變化以以確定滿滿足生產產目標所所需減少少的勞動動力Step6:在不影響響設計原原則的情情況下，，按邏輯輯和效率率態(tài)度將將任務分分解25Step1Understandpresentstateprocessoperation(gatheranddocumentactivitytimeactuals)Note:Timeshouldincludecustomervalueadd,businessvalueadd,andnon-valueaddtimesforeachstep/operation/taskStep2Determinetotal(current)timerequiredtoprocessunit.Note:Modelshouldautomaticallycalculatetotaltimeenteredinseconds,minutes,andhoursProcessBalanceModel:Steps1and226步驟1了解現(xiàn)在在過程狀狀況(收集、記記錄活動動時間)注意:時間應該該包括CVA、、BVA、與每一步步驟、作作業(yè)、與與任務的的時間步驟2決定全部部（目前前）需要要完成任任務的時時間。注注意：：模型應應該可以以自動計計算時間間。過程平衡衡模型步驟1和227Step3Determinemaximumoperatingparametersandplugparametersintohighlightedcells-Allothercellsarecalculatedautomatically(Examplecalculationsarelocatedattheendofthissection.)ProcessBalanceModel:Step328步驟3決定最大大的作業(yè)業(yè)參數(shù)與與加乘參參數(shù)到設設定的格格位中。。其他的的格位可可自動計計算。(計算案例例在本節(jié)節(jié)最后。。)過程平衡衡模型步驟329Step4Determinetargetunit/dayoutputrequirementandplotontabletodetermine#ofshifthourstoworktoachieverequirementProcessBalanceModel:Step4ThislinesaysthatIneedtoworkan8hourshiftwith12processorstoachievea400unit/dayoutputrequirement30步驟4決定需要要的目標標單位/日表，，并圖示示需要完完成任務務需要的的工作時時間。過程平衡衡模型:步驟4這行說明明我需要要使用12人，，8小時時班來完完成每天天400單單位的需需要31Modelwillbuildthefollowinggraphwhichshowshowweshouldplanto:Staffinequalincrements(tolimithavingtore-balanceline)VaryhoursworkedtogetcompletecoverageofdemandrequirementsProcessBalanceModel:Step4(Cont.)32模型可建建立如下下圖說明明:每一階段段需要的的人力完成任務務需要的的工作時時間過程平衡衡模型:步驟4(續(xù).)33Step5PlotcurrentoperatingrangetodeterminelaborreductionrequiredtomeetoperatinggoalsProcessBalanceModel:Step5Themodelhascalculatedthatatarateof150units/day,theareashouldbeworkinga6hourshiftwith7processors.Thisis2fewerprocessorsthantheircurrentenvironment.34步驟5繪制目前的作作業(yè)范圍來決決定完成目標標可節(jié)約的人人力過程平衡模型型:步驟5在150單單位/天的需求下,需要每班班6小時時，7位作業(yè)員.比目前人力少少兩人35Step6Groupprocesstasksinlogicalandefficientmannerthatdoesnotviolatedesignprinciples(eg-(tasktime<taktratetime)ProcessBalanceModel:Step636步驟6合乎邏輯與共共效率的團隊隊工作不違反反設計原則(例-(tasktime<taktratetime)過程平衡模型型:步驟637Thisworksheetprovidesasummaryofinputsusedandoutputsgeneratedforeachwindowcategorythatisrunthroughthemodel.Thisworksheetisautomaticallycreatedandupdatedbythemodel.ModelSummary38這個工作表提提供了在本模模式運行下的的按窗口分類類的投入和產產出的總結。。這份表格是是自動生成的的并能通過該該模式更新。。模型總結39Approach#1:CalculationNotes(Step3)MaxLaborEfficiencyBestinclassis65%AssumptionisthatlaborefficiencydeclinesthemoretaskseachprocessorisaskedtoperformMaxhrspershiftShouldbesetto11hourstoobtainoptimalcoverageofrequirementsMaxDemand(units/hour)=MaxDemandRequirement/MaxhrspershiftMaxDemand(units/minute)=MaxDemand(units/hour)/60TaktTime(seconds/unit)=60/MaxDemand(units/minute)Thisistheamountoftimebetweenproductsexiting-ThisisalsothemaximumamountofprocesstimethatanyoneworkstationshouldperformwithoutcompromisingthelineflowTotalAssemblers/Processors=((TotalProcessTime(hrs)*MaxDmdReq(units/shift))/

Maxhrspershift)/MaxLaborEfficiencyTheresultisroundeduptothenextwholeassemblerThisisthenumberofassemblers/processorsIshouldhavetoprocessthemaximumdemandrequirementatthemaximumlaborefficiencyWorkstationTime(secs/workstation)=TotalProcessTime(hrs)*60*60/TotalProcessors1processor=1workstationThisistheoptimalamountoftimethattasksshouldbegroupedbytobalancethelineLaborProductivity(Units/LaborHour)=MaxDemand(units/hour)/TotalProcessors40途徑#1:計算說明(步驟3)最高勞動效率率最好是65%假設勞動效率率下降，需要要每個操作工工做更多的工工作每班最多工時時應該設為11個小時以最最好地滿足需需要最大需求(units/hour)=最大需求需要要/每班最多多工時最大需求(units/minute)=最大需求(units/hour)/60Takt時間(seconds/unit)=60/最大需求(units/minute)這是現(xiàn)有產品品之間的時間間量-這這也是每每個工作站的的最多的流程程時間全部裝配工/操作工=((TotalProcessTime(hrs)*最大需求需要要(units/shift))/Maxhrspershift)/最高勞動效率率這個結果接近近下次的全部部操作工這是在最高勞勞動效率下的的滿足了最高高需求下的操操作工人數(shù)工作站時間(secs/workstation)=TotalProcessTimehrs)*60*60/TotalProcessors1操作工=1工作作站這是將任務分分組的最佳時時間勞動生產率(Units/LaborHour)=最大需求(units/hour)/全部操作工41Approach#1:TeamExercise1.GototheVirtualCoachExerciseTabandopenthefiletitled:WindowsRUsLineBalancingExercise.doc2. Readthescenarioandcompletesteps1through4usingthespreadsheettitled:WindowsRUsLineBalancingData.xls3.Preparea5minutepresentationwithyourteamanswers.Youhave45minutestobuildthispartofalinebalancemodel.Detailedinstructionsareonthenextslide.42Approach#1:小組組練練習習1.看看虛虛擬擬輔輔導導練練習習并并打打開開以以下下抬抬頭頭的的文文件件:WindowsRUsLineBalancingExercise.doc2.讀情情節(jié)節(jié)并并完完成成第第1到到第第4步步，，使使用用有有以以下下抬抬頭頭的的工工作作表表格格:WindowsRUsLineBalancingData.xls準備備5分分鐘鐘的的展展示示你有有45分鐘鐘的的時時間間來來建建這這個個線線平平衡衡模模型型部部分分具體體的的指指導導顯顯示示在在下下一一個個幻幻燈燈片片上上.43ExerciseObjectivesTeachthestudenthowtobalancealinemathematicallyTeachthestudentthemethodtore-layoutthelinetorealizethemathematicalbalanceTheexercisewilldevelop:TaktTimechartSkillMatrixProposedtimecalculation44練習的的目標標教學生生怎樣樣用數(shù)數(shù)學方方法來來平衡衡一條條線教學生生對線線進行行再布布局的的方法法以實實現(xiàn)數(shù)數(shù)學上上的平平衡這個練練習將將制作作出:Takt時間圖圖表技能距距陣擬定時時間的的計算算45ExerciseInstructions1.UsingtheExcelspreadsheet,lookatthe““Currenttimes”tabtocompletethe““CurrentTaktTimeChart.””2.Lookatthe““CurrentStaffing””tabtocompletethe““SkillMatrix”tab.3.Usethethreetabsandre-dividethetaskstohaveabalancednumberoftaskswiththesamenumberofpeopleandsamesequenceastheoriginalline.Note:Aproposedlayoutisnottobemade.Currentextrusiondataisnottobedeveloped.Improvementstabisnottobecompleted.46練習指指南1.使使用用Excel工作表表格,看“目前的的時間間”以完成成“CurrentTaktTimeChart.”2.看““CurrentStaffing””完成“SkillMatrix”3.使用這這三個個表重重新分分配任任務，，用同同樣的的認輸輸和程程序在在原來來的生生產線線上平平衡任任務數(shù)數(shù)量。。Note:不必做做出一一個擬擬定的的布局局不用做做出目目前的的數(shù)據(jù)據(jù)不必完完成改改進表表47AssemblyBalanceModel:Day-to-DaySchedulerStep1:Understandcurrentstateoperation(gatheranddocumentdataaroundlayout,processflow,etc.).Step2:Determinetotaltimerequiredtoprocessunit(customervalueadd,businessvalueadd,currentnon-valueadd).Step3:Determinemaximumoperatingparametersandplugparametersintotaktratecalculator.Step4:Reviewoutputs:taktrateandnumberofhourstoworktoachieverequirement.Usethisoutputtofilloutlinetaktboard.48組裝平衡衡模型日常安排排員Step1:了解目前前的生產產狀況(在布局和和流程周周圍收集集數(shù)據(jù)并并使之文文件化).Step2:確定單元元流程所所需的全全部時間間(客戶增值值、業(yè)務務增值、、目前非非增值））Step3:確定最大大的生產產參數(shù)并并將參數(shù)數(shù)插入taktratecalculatorStep4:回顧產能能:takt比率和滿滿足需要要所需的的工時。。用這個個產能來來填linetaktboard.Approach#2Day-to-DayScheduler途徑#2每天作業(yè)業(yè)的計劃劃51Step1Understandcurrentstateoperation(gatheranddocumentactivitytime).Note:Timeshouldincludecustomervalueadd,businessvalueadd,andnon-valueaddtimesforeachstep/operation/task.Step2Determinetotal(current)timerequiredtoprocessunit.Note:Modelshouldautomaticallycalculatetotaltimeenteredinseconds,minutes,andhours.Day-To-DayScheduler:Steps1and252步驟1了解目前前作業(yè)狀狀況(收集、記記錄作業(yè)業(yè)與作業(yè)業(yè)時間)。注意:時時間應應包括每每一步驟驟、作業(yè)業(yè)、任務務的CVA、、BVA與NV時間。步驟2決定目前前總時間間。注意意：模型型要能夠夠自動運運算時間間日計劃:步驟1與253Step3DetermineoperatingparametersandplugparametersintoTaktRateCalculator-Allothercellsareca