優(yōu)化生產(chǎn)中的物流活動二

MaterialMovementinaLeanManufacturingOperation

優(yōu)化生產(chǎn)中的物流活動TotalSystemsDevelopment

全體系生產(chǎn)提高JIT生產(chǎn)(準(zhǔn)時,準(zhǔn)量生產(chǎn)):Whatismeantbytheterm,“Just-In-Time”?JIT生產(chǎn)意味著什么?DoesitmeanJITSupply?準(zhǔn)時,準(zhǔn)量供應(yīng)?DoesitmeanJITProduction?準(zhǔn)時,準(zhǔn)量生產(chǎn)?So,whatisJust-In-Time?

那么,什么是準(zhǔn)時準(zhǔn)量生產(chǎn)?Theconceptofproducingthenecessaryunitsinthenecessaryquantitiesatthenecessarytimeisdescribedbytheshort-phrase“Just-In-Time”.JIT生產(chǎn)是:在必需時間內(nèi)生產(chǎn)必需數(shù)量的必需部品的概念.Forexample….Inbuildingshoes:Thenecessarysubassembliesoftheproceedingprocess(uppersandbottoms)shouldarriveattheassemblylineatthetimeneededintheamountsneeded.舉例說明:在生產(chǎn)成品鞋的時候:制鞋所必需的部件(鞋幫和鞋底)要準(zhǔn)時,準(zhǔn)量,準(zhǔn)型號地到達(dá)制造車間.IfweachieveJIT:

如果我們做到準(zhǔn)時,準(zhǔn)量生產(chǎn):Unnecessaryinventorieswillbeeliminated.不必要的庫存就會消除Storesandwarehouseswillnotbeneeded.儲存區(qū)和倉庫也可以取消Materialcarryingcostswillbediminished.資材搬運(yùn)成本降低However….TorelysolelyonacentralplanningapproachthatinstructstheproductionschedulestoallprocessessimultaneouslyisnotlikelytoresultinaJITprocessforalloperations.但是：單純地依賴計劃生產(chǎn)的方法,使所有工序同步生產(chǎn)，并不能完全實(shí)現(xiàn)所有環(huán)節(jié)的準(zhǔn)時，準(zhǔn)量生產(chǎn).TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每周生產(chǎn)計劃Typically,onecontroloperationreceivesthecustomers’ordersanddisseminatesschedules.

通常，生產(chǎn)控制部門接受客戶定單，然后制訂并傳達(dá)計劃.

ProductionControl生產(chǎn)控制TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每周生產(chǎn)計劃ProductionControl生產(chǎn)控制IIIIIITheproblemcomeswhenachangeismadeeitherbecausetheorderchangesorequipmentbreaksdown.

但是當(dāng)定單有變化或設(shè)備出現(xiàn)問題的時候，就會發(fā)生一些問題：庫存庫存庫存庫存Theresultisexcessinventory…

結(jié)果是導(dǎo)致過多的庫存……withintheplantasWork-In-Process…在本車間工序內(nèi)積壓過多的庫存…supplierssendinginpartsthatarenotneeded…上一道工序發(fā)來的并不需要的部件Additionally另外,Weneedextrafloorspacetostorethematerial.我們需要額外的空間來堆放材料Needexpeditorstosatisfythechangesinschedule.需要人力和時間投入來改變生產(chǎn)計劃Runovertimetomakeuppartsthatwenowneed.用加班時間來生產(chǎn)現(xiàn)在所需部件Toyotarethoughthowtocommunicateschedules.豐田田公公司司對對調(diào)調(diào)整整生生產(chǎn)產(chǎn)計計劃劃做做了了改改進(jìn)進(jìn):Toyotadiscoveredadifferentwaytomanagetheirschedule,豐田使使用不不同的的方法法來制制訂調(diào)調(diào)整生生產(chǎn)計計劃Theystoppedtryingtoguesswhatthecustomerwillwant.他們并并不去去猜想想客戶戶的需需求Instead相反..Eachdepartmenthadinstalledasmallinventoryofeachproduct.每個車車間都都保持持少量量的庫庫存Downstreamprocessescometothesupplyingdepartmentsandtakewhatitneeds.下一道道工序序到上上一道道工序序去取取他們們所需需部件件Thisallowstheprocessesupstreamtosimplyreplacewhatwastaken.這樣,上一一工序序只要要補(bǔ)充充被取取走的的部件件即可可.TheToyotaProductionSystemTPS豐田體體系…….Islikelytobethemoststudiedanddiscussedoperationsprogramintheworld.是極可可能被被全世世界研研究和和討論論的體體系NumerousbooksandpapershavebeenwrittenaboutTPS.出版了了很多多關(guān)于于TPS的書籍籍和其其它資資料ManyhavecometocharacterizeTPSas““l(fā)eanproduction””orNOS.許多人人認(rèn)為為豐田田體系系(TPS)實(shí)際上上就代代表優(yōu)優(yōu)化生生產(chǎn)或或NOSLeanManufacturing(NOS)NOS優(yōu)化生生產(chǎn)Regardlessofanyauthor’’sopinionorrational,allagreethatthefoundationofleanmanufacturing(NOS)isthecontinualpursuittoeliminatewaste.盡管大大家的的觀點(diǎn)點(diǎn)有些些不一一樣,但所所有人人都認(rèn)認(rèn)為NOS的基礎(chǔ)礎(chǔ)是持持續(xù)不不斷地地減少少浪費(fèi)費(fèi)Wasteisdefinedasanythingthatconsumesresourcesortime,butdoesnotaddvaluetotheproduct.浪費(fèi)是是任何何耗費(fèi)費(fèi)資源源或時時間,但不不增加加產(chǎn)品品價值值的活活動ExcessInventoryisWaste多余的的庫存存是一一種浪浪費(fèi)Excessinventoryhidesproblems多余的的庫存存會隱隱藏一一些問問題SeaofInventory大量庫存RawMaterial

原資材FinishedGoods

成品LongTransportation過長運(yùn)輸時間VendorDelivery

供應(yīng)商運(yùn)送Absenteeism缺勤Commun-icationProblemPoorScheduling計劃不不力MachineBreakdown設(shè)備停停機(jī)QualityProblems質(zhì)量問問題LineImbalance線內(nèi)不不平衡衡LongSet-UpTime過長調(diào)調(diào)整時時間LackofHouse-Keeping倉儲管管理問問題溝通問問題OurgoalformaterialsmanagementinNOSNOS資材管管理的的目標(biāo)標(biāo)Theidealstateisasmoothflowofmaterialsthroughoutourownfactory理想的的狀態(tài)態(tài)是物物料在在整個個工廠廠內(nèi)順順暢的的流動動.Wewanttotietogetherprocessesthatareseparatedbylargephysicaldistances.使那些些有一一定距距離而而相對對分離離的生生產(chǎn)流流程緊緊密結(jié)結(jié)合起起來Weneedtoimprovecommunicationinregardstomaterialmovement.在物流流方面面要加加強(qiáng)各各工序序間的的溝通通ThePushSystem”推動““生產(chǎn)產(chǎn)體系系Intraditionalmanufacturing,variousproductionschedulesarereleasedtoallprocesses;componentmakingandassembly.在傳統(tǒng)統(tǒng)的生生產(chǎn)中中,各各種生生產(chǎn)計計劃被被傳達(dá)達(dá)到各各個工工序,部件件生產(chǎn)產(chǎn)和組組裝部部門.ThePushSystem(cont.)”推動““Thesepart-makingprocessesproducethepartsinaccordancetotheirschedulesandtransportthepartstothenextprocess.部件生生產(chǎn)部部門按按照收收到的的計劃劃生產(chǎn)產(chǎn)并把把成品品部件件運(yùn)送送到下下一道道工序序.ThePushSystem(cont.)”推動““Thismethodmakesitdifficulttopromptlyadapttochanges.這種方方法使使生產(chǎn)產(chǎn)很難難迅速速對變變化作作出反反應(yīng)Eachproductionschedulemustbechangedateachprocesssimultaneously.每個工工序的的生產(chǎn)產(chǎn)計劃劃都必必需同同時變變化以以適應(yīng)應(yīng)同步步生產(chǎn)產(chǎn)ThePushSystem(cont.)”推動””TheResult導(dǎo)致:Thecompanymustholdextrainventoryamongallprocesses.公司不不得不不在各各個工工序保保持額額外的的庫存存Thiscreatesanimbalanceofstockbetweenprocesses.各工序序間的的庫存存達(dá)不不到平平衡ThePullSystem“拉動””生產(chǎn)產(chǎn)體系系Incontrast,inaPULLSYSTEM,eachprocesswillwithdrawthepartsitneedsfromtheproceedingprocess.相反,““拉動動”生生產(chǎn)體體系要要求各各個工工序僅僅需從從上一一道工工序提提取自自己所所需要要的部部件.BA“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市SupplyingProcess供應(yīng)工序CustomerProcess客戶工序“生產(chǎn)”指指示板“拒收”指指示板ThePullSystem(cont.)”拉動”體系系Sinceonlythefinal-assemblyprocesscanaccuratelyknowthenecessarytimingandquantityofpartsrequired,theyaretheonlyonestoreceiveaschedule.因?yàn)橹挥兄浦圃鞙?zhǔn)確地地了解所需需時間和部部件數(shù)量,以只要制制造收到生生產(chǎn)計劃即即可.AssemblyStock-fit準(zhǔn)備Stitching縫紉Assembly制造Shipping裝船WeeklySchedule每周生產(chǎn)計計劃FinalAssemblyreceivesascheduleandpullsfromtheMarketPlace.StitchingandStock-fitreplenishestheMarketPlace.制造接受生生產(chǎn)計劃,并借助““供應(yīng)超市市”拉動生生產(chǎn).縫紉紉和準(zhǔn)備向向“供應(yīng)超超市”補(bǔ)充充部件.ProductionControl生產(chǎn)控制ThePullSystem(cont.)”拉動”體系系Withtheschedule,thefinal-assemblygoestothesupplyingdepartmentsandwithdrawswhatpartsareneeded.根據(jù)生產(chǎn)計計劃,制造造到供應(yīng)車車間去提取取所需部件件.ThePullSystem(cont.)”拉動“生產(chǎn)產(chǎn)Theprecedingoperationthenproducesthereplacementsofthepartswithdrawnbythesubsequentprocess.這樣,前一一道工序開開始生產(chǎn)被被下一道工工序提走的的部件以補(bǔ)補(bǔ)充所需.BAssembly制造Stitching縫紉A“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市“生產(chǎn)”指指示板“拒收”指指示板Markets“供應(yīng)超市””Marketsarethestoragelocationsforallthepartspriortogoingtothenextoperation.“供應(yīng)超市””是為下一一道工序儲儲存所需各各種部件的的區(qū)域.Marketssimplyareorganizedcollectionsofpurchasedpartsandwork-in-process.組建“供應(yīng)應(yīng)超市”只只是為了搜搜集購買的的部件和線線上的庫存存.Ifpartsarealreadystoredinyourplant,thenyoucanconstructmarkets.如果工廠內(nèi)內(nèi)有儲存部部件,那就就可以設(shè)置置此體系.CautionsaboutMarkets關(guān)于“超市市體系”的的警告:Don’tgetcaughtupinotherpeople’sphilosophy.不要受別的的觀點(diǎn)的影影響:Marketsdonothavetobelocatednexttothereceivingdocks.超市不一定定要靠近部部件接受區(qū)區(qū)Marketsdonothavetobelargeinsize.規(guī)模不一定定很大Youcanhaveseveralmini-marketsifspaceisdifficulttoget.若空間不夠夠,可設(shè)多多個分散的的小超市.Useyourowncommonsense運(yùn)用自己的的常識來解解決問題!RulesfordevelopingMarkets設(shè)立“超市市”的規(guī)則則:Haveastoragelocationforeverypart.為每一部件件設(shè)立儲存存區(qū)Determinethemaximumofanyonepartthatwillbestored.為任一需儲儲存部件設(shè)設(shè)立最大庫庫存標(biāo)準(zhǔn)Provideadequatestoragespace.提供合適的的儲存區(qū)域域Safetyisapriority.要優(yōu)先考慮慮安全因素素.LessonsLearnedaboutMarkets設(shè)立超市需需注意的幾幾點(diǎn):Haveanoverflowspotandameanstomonitor.設(shè)立庫存限制制和監(jiān)控方法法Trytoreservespacesforfutureparts.提前考慮，為為以后的部件件留出儲存空空間Preferably,donotstorethesamepartinmorethanonelocation.同一部件最好好儲存在一個個區(qū)域Makesureaislewayscanaccommodateforklifts.保證過道可容容納或通行搬搬運(yùn)工具.Determinecustomerdemand確定客戶需求求Takttimeisareferencenumberthatgivesyouasenseforthepaceatwhicheachprocessneedstobeproducing.TAKT節(jié)拍時間為了了解并調(diào)整各各個工序的生生產(chǎn)速度提供供參考依據(jù)Tocalculatetakttime,dividetheavailabletimebythecustomerdemand.用可利用的生生產(chǎn)時間除以以客戶需求量量，即為節(jié)拍時間間.Forourplant對我們公司來來說:Oneshiftisninehoursthereisone60-minutelunch9小時一個班次次,其中有1個小時的就就餐休息時間間Work-time工作時間8Hrs.X60min/hr=480minutes8小時X60=480分鐘480minutespershiftThereis28,800secondspershift480分鐘每個班次次,即28,800秒每每個班次Customerdemand客戶需求Thecustomerneeds2,000pairseachday.客戶每天需需要2,000足鞋鞋WeworkoneshifteachdayinAssembly,6daysperweek.制造車間每每天一個班班次,每周周工作6天天Customerdemandis客戶的需求求是:2,000Pairs/28,800sec2,000足/28,800秒or1PAIRevery14.4seconds或每14.4秒需要要產(chǎn)一足鞋鞋Marketsetupsandlocations供應(yīng)超市準(zhǔn)準(zhǔn)備和位置置選定Locatespacewithintheplantthatcanbeusedasamarket(s).選定公司可可作為超市市的位置Minimizethenumberofmarkets.Ifmaybenecessarytostartwithseveralsmallones,latertocombineintoone.盡量減少超超市的數(shù)量量,若有必必要可先設(shè)設(shè)立幾個小小的超市,以后再合合并成大的的超市.Manpowerandequipmentneeded人員和設(shè)備備要求PartsaredeliveredtothelinebyMaterialHandlersusinghand-carts.搬運(yùn)人員用用手推車將將部件運(yùn)到到生產(chǎn)線TheMaterialHandlerhasadesignatedroutethatcoversallthestationshe(orshe)isresponsiblefor.搬運(yùn)人員按按照指定的的運(yùn)輸路線線負(fù)責(zé)自己己的工作區(qū)區(qū)域Hedeliversallpartsneededonthatdeliverycycle,retrievesallemptycontainers搬運(yùn)人員必必須循環(huán)搬搬運(yùn)所需部部件,并取取回空的部部件箱Training培訓(xùn)Thepeoplewhoareaffectedbythenewsystemneedtounderstandwhythecompanyhasimplementedtheprogram.新體系所涉涉及到的人人員需要懂懂得為什么么公司實(shí)施施此體系Thosewhoaretosupportitmustunderstandhowitworks.支持新體系系的人員需需懂得體系系是怎樣運(yùn)運(yùn)作的Allpeoplemustreceiveadequatetraininginorderforthesystemtobebothrobustandsuccessful.所有相關(guān)人人員需接受受培訓(xùn)以保保證新體系系的運(yùn)作效效率和成功功。超市Training(continued)培訓(xùn)Rememberwhotheaudienceis:Productionworkershavelittleregardforhowmanyturnstheinventorymakes……Materialhandlerswillnotseeinventoryreductionasabenefit….記住誰是培培訓(xùn)對象：：那些對庫存存的影響不不太關(guān)心的的生產(chǎn)者……看不到減少少庫存會帶帶來收益的的資材管理理者…Training(continued)培訓(xùn)Designyourtrainingprogram(s)usingtheknowledgeyouwillgaininthesystem’sdevelopment.運(yùn)用你在實(shí)實(shí)施NOS的過程中得得到的經(jīng)驗(yàn)驗(yàn)來設(shè)計培培訓(xùn)內(nèi)容，，Keepitsimple.使培訓(xùn)內(nèi)容容簡潔易懂懂，Giveyourselfenoughtimetohandlethetoughquestions.Respectthepeople’sconcerns.用足夠的時時間來解決決比較棘手手的問題，，尊重別人人的意見。。ResultsofaPullSystem生產(chǎn)拉動體體系的結(jié)果果Inoperationswheretheimplementationhasbeensuccessful,boththemanagementandworkforcebelievetheworkenvironmenttobe““enhanced”在拉動體系系取得成功功的那些環(huán)環(huán)節(jié),無論論是管理層層還是工人人都會認(rèn)為為他們的工工作環(huán)境正正在改善。。ResultsofaPullSystem生產(chǎn)拉動體體系的結(jié)果果Wheretherehasbeenlittleefforttomakethesystemwork,theplanttypicallyhasshortagesandmissesdeliverywindows.若工廠沒有有努力去實(shí)實(shí)現(xiàn)拉動生生產(chǎn)，就會會出現(xiàn)部件件投入不足足和不能按按照生產(chǎn)需需要來搬運(yùn)運(yùn)部件。9、靜靜夜夜四四無無鄰鄰，，荒荒居居舊舊業(yè)業(yè)貧貧。。。。1月月-231月月-23Saturday,January7,202310、雨中中黃葉葉樹，，燈下下白頭頭人。。。17:58:5317:58:5317:581/7/20235:58:53PM11、以以我我獨(dú)獨(dú)沈沈久久，，愧愧君君相相見見頻頻。。。。1月月-2317:58:5317:58Jan-2307-Jan-2312、故人江海海別，幾度度隔山川。。。17:58:5317:58:5317:58Saturday,January7,202313、乍見翻疑夢夢，相悲各問問年。。1月-231月-2317:58:5317:58:53January7,202314、他鄉(xiāng)生生白發(fā)，，舊國見見青山。。。07一一月20235:58:54下午午17:58:541月-2315、比不了得就就不比，得不不到的就不要要。。。一月235:58下下午1月-2317:58January7,202316、行動出出成果，，工作出出財富。。。2023/1/717:58:5417:58:5407January202317、做前，能夠夠環(huán)視四周；；做時，你只只能或者最好好沿著以腳為為起點(diǎn)的射線線向前。。5:58:54下午5:58下下午17:58:541月-239、沒有失敗敗，只有暫暫時停止成成功！。1月-231月-23Saturday,January7,202310、很很多多事事情情努努力力了了未未必必有有結(jié)結(jié)果果，，但但是是不不努努力力卻卻什什么么改改變變也也沒沒有有。。。。17:58:5417:58:5417:581/7/20235:58:54PM11、成功就是是日復(fù)一日日那一點(diǎn)點(diǎn)點(diǎn)小小努力力的積累。。。1月-2317:58:5417:58Jan-2307-Jan-2312、世間成事，，不求其絕對對圓滿，留一一份不足，可可得無限完美美。。17:58:5417:58:5417:58Saturday,January7,202313、不知知香積積寺，，數(shù)里里入云云峰。。。1月-231月-2317:58:5417:58:54January7,202314、意志堅強(qiáng)強(qiáng)的