優(yōu)化生產(chǎn)中的物流活動(dòng)S

MaterialMovementinaLeanManufacturingOperation

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

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

那么,什么是準(zhǔn)時(shí)準(zhǔn)量生產(chǎn)?Theconceptofproducingthenecessaryunitsinthenecessaryquantitiesatthenecessarytimeisdescribedbytheshort-phrase“Just-In-Time”.JIT生產(chǎn)是:在必需時(shí)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(shuō)明:在生產(chǎn)成品鞋的時(shí)候:制鞋所必需的部件(鞋幫和鞋底)要準(zhǔn)時(shí),準(zhǔn)量,準(zhǔn)型號(hào)地到達(dá)制造車(chē)間.IfweachieveJIT:

如果我們做到準(zhǔn)時(shí),準(zhǔn)量生產(chǎn):Unnecessaryinventorieswillbeeliminated.不必要的庫(kù)存就會(huì)消除Storesandwarehouseswillnotbeneeded.儲(chǔ)存區(qū)和倉(cāng)庫(kù)也可以取消Materialcarryingcostswillbediminished.資材搬運(yùn)成本降低However….TorelysolelyonacentralplanningapproachthatinstructstheproductionschedulestoallprocessessimultaneouslyisnotlikelytoresultinaJITprocessforalloperations.但是：?jiǎn)渭兊匾蕾?lài)計(jì)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(shí)，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(jì)劃Typically,onecontroloperationreceivesthecustomers’ordersanddisseminatesschedules.

通常，生產(chǎn)控制部門(mén)接受客戶(hù)定單，然后制訂并傳達(dá)計(jì)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(jì)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(wèn)題的時(shí)候，就會(huì)發(fā)生一些問(wèn)題：庫(kù)存庫(kù)存庫(kù)存庫(kù)存Theresultisexcessinventory…

結(jié)果是導(dǎo)致過(guò)多的庫(kù)存……withintheplantasWork-In-Process…在本車(chē)間工序內(nèi)積壓過(guò)多的庫(kù)存…supplierssendinginpartsthatarenotneeded…上一道工序發(fā)來(lái)的并不需要的部件Additionally另外,Weneedextrafloorspacetostorethematerial.我們需要額外的空間來(lái)堆放材料Needexpeditorstosatisfythechangesinschedule.需要人力和時(shí)間投入來(lái)改變生產(chǎn)計(jì)劃Runovertimetomakeuppartsthatwenowneed.用加班時(shí)間來(lái)生產(chǎn)現(xiàn)在所需部件Toyotarethoughthowtocommunicateschedules.豐田公司對(duì)對(duì)調(diào)整生產(chǎn)產(chǎn)計(jì)劃做了了改進(jìn):Toyotadiscoveredadifferentwaytomanagetheirschedule,豐田使用不不同的方法法來(lái)制訂調(diào)調(diào)整生產(chǎn)計(jì)計(jì)劃Theystoppedtryingtoguesswhatthecustomerwillwant.他們并不去去猜想客戶(hù)戶(hù)的需求Instead相反..Eachdepartmenthadinstalledasmallinventoryofeachproduct.每個(gè)車(chē)間都都保持少量量的庫(kù)存Downstreamprocessescometothesupplyingdepartmentsandtakewhatitneeds.下一道工序序到上一道道工序去取取他們所需需部件Thisallowstheprocessesupstreamtosimplyreplacewhatwastaken.這樣,上一一工序只要要補(bǔ)充被取取走的部件件即可.TheToyotaProductionSystemTPS豐田體系…….Islikelytobethemoststudiedanddiscussedoperationsprogramintheworld.是極可能被被全世界研研究和討論論的體系NumerousbooksandpapershavebeenwrittenaboutTPS.出版了很多多關(guān)于TPS的書(shū)籍和其其它資料ManyhavecometocharacterizeTPSas“l(fā)eanproduction”orNOS.許多人認(rèn)為為豐田體系系(TPS)實(shí)際上就代代表優(yōu)化生生產(chǎn)或NOSLeanManufacturing(NOS)NOS優(yōu)化生產(chǎn)Regardlessofanyauthor’’sopinionorrational,allagreethatthefoundationofleanmanufacturing(NOS)isthecontinualpursuittoeliminatewaste.盡管大家的的觀點(diǎn)有些些不一樣,但所有人人都認(rèn)為NOS的基礎(chǔ)是持持續(xù)不斷地地減少浪費(fèi)費(fèi)Wasteisdefinedasanythingthatconsumesresourcesortime,butdoesnotaddvaluetotheproduct.浪費(fèi)是任何何耗費(fèi)資源源或時(shí)間,但不增加加產(chǎn)品價(jià)值值的活動(dòng)ExcessInventoryisWaste多余的庫(kù)存存是一種浪浪費(fèi)Excessinventoryhidesproblems多余的庫(kù)存存會(huì)隱藏一一些問(wèn)題SeaofInventory大量庫(kù)存RawMaterial

原資材FinishedGoods

成品LongTransportation過(guò)長(zhǎng)運(yùn)輸時(shí)間VendorDelivery

供應(yīng)商運(yùn)送Absenteeism缺勤Commun-icationProblemPoorScheduling計(jì)劃不力MachineBreakdown設(shè)備停機(jī)QualityProblems質(zhì)量問(wèn)題LineImbalance線(xiàn)內(nèi)不平衡衡LongSet-UpTime過(guò)長(zhǎng)調(diào)整時(shí)時(shí)間LackofHouse-Keeping倉(cāng)儲(chǔ)管理問(wèn)問(wèn)題溝通問(wèn)題OurgoalformaterialsmanagementinNOSNOS資材管理的的目標(biāo)Theidealstateisasmoothflowofmaterialsthroughoutourownfactory理想的狀態(tài)態(tài)是物料在在整個(gè)工廠(chǎng)廠(chǎng)內(nèi)順暢的的流動(dòng).Wewanttotietogetherprocessesthatareseparatedbylargephysicaldistances.使那些有一一定距離而而相對(duì)分離離的生產(chǎn)流流程緊密結(jié)結(jié)合起來(lái)Weneedtoimprovecommunicationinregardstomaterialmovement.在物流方面面要加強(qiáng)各各工序間的的溝通ThePushSystem”推動(dòng)“生產(chǎn)產(chǎn)體系Intraditionalmanufacturing,variousproductionschedulesarereleasedtoallprocesses;componentmakingandassembly.在傳統(tǒng)的生生產(chǎn)中,各各種生產(chǎn)計(jì)計(jì)劃被傳達(dá)達(dá)到各個(gè)工工序,部件件生產(chǎn)和組組裝部門(mén).ThePushSystem(cont.)”推動(dòng)“Thesepart-makingprocessesproducethepartsinaccordancetotheirschedulesandtransportthepartstothenextprocess.部件生產(chǎn)產(chǎn)部門(mén)按按照收到到的計(jì)劃劃生產(chǎn)并并把成品品部件運(yùn)運(yùn)送到下下一道工工序.ThePushSystem(cont.)”推動(dòng)“Thismethodmakesitdifficulttopromptlyadapttochanges.這種方法法使生產(chǎn)產(chǎn)很難迅迅速對(duì)變變化作出出反應(yīng)Eachproductionschedulemustbechangedateachprocesssimultaneously.每個(gè)工序序的生產(chǎn)產(chǎn)計(jì)劃都都必需同同時(shí)變化化以適應(yīng)應(yīng)同步生生產(chǎn)ThePushSystem(cont.)”推動(dòng)”TheResult導(dǎo)致:Thecompanymustholdextrainventoryamongallprocesses.公司不得得不在各各個(gè)工序序保持額額外的庫(kù)庫(kù)存Thiscreatesanimbalanceofstockbetweenprocesses.各工序間間的庫(kù)存存達(dá)不到到平衡ThePullSystem“拉動(dòng)”生生產(chǎn)體系系Incontrast,inaPULLSYSTEM,eachprocesswillwithdrawthepartsitneedsfromtheproceedingprocess.相反,““拉動(dòng)動(dòng)”生產(chǎn)產(chǎn)體系要要求各個(gè)個(gè)工序僅僅需從上上一道工工序提取取自己所所需要的的部件.BA“production”kanban“withdrawal”kanbanProduct部件Product部件Market供應(yīng)超市SupplyingProcess供應(yīng)工序序CustomerProcess客戶(hù)工序序“生產(chǎn)””指示板板“拒收””指示板板ThePullSystem(cont.)”拉動(dòng)”體體系Sinceonlythefinal-assemblyprocesscanaccuratelyknowthenecessarytimingandquantityofpartsrequired,theyaretheonlyonestoreceiveaschedule.因?yàn)橹挥杏兄圃鞙?zhǔn)準(zhǔn)確地了了解所需需時(shí)間和和部件數(shù)數(shù)量,以以只要制制造收到到生產(chǎn)計(jì)計(jì)劃即可可.AssemblyStock-fit準(zhǔn)備Stitching縫紉Assembly制造Shipping裝船WeeklySchedule每周生產(chǎn)產(chǎn)計(jì)劃FinalAssemblyreceivesascheduleandpullsfromtheMarketPlace.StitchingandStock-fitreplenishestheMarketPlace.制造接受受生產(chǎn)計(jì)計(jì)劃,并并借助““供應(yīng)超超市”拉拉動(dòng)生產(chǎn)產(chǎn).縫紉紉和準(zhǔn)備備向“供供應(yīng)超市市”補(bǔ)充充部件.ProductionControl生產(chǎn)控制制ThePullSystem(cont.)”拉動(dòng)”體體系Withtheschedule,thefinal-assemblygoestothesupplyingdepartmentsandwithdrawswhatpartsareneeded.根據(jù)生產(chǎn)計(jì)劃劃,制造到供供應(yīng)車(chē)間去提提取所需部件件.ThePullSystem(cont.)”拉動(dòng)“生產(chǎn)Theprecedingoperationthenproducesthereplacementsofthepartswithdrawnbythesubsequentprocess.這樣,前一道道工序開(kāi)始生生產(chǎn)被下一道道工序提走的的部件以補(bǔ)充充所需.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)”指示示板“拒收”指示示板Markets“供應(yīng)超市”Marketsarethestoragelocationsforallthepartspriortogoingtothenextoperation.“供應(yīng)超市”是是為下一道工工序儲(chǔ)存所需需各種部件的的區(qū)域.Marketssimplyareorganizedcollectionsofpurchasedpartsandwork-in-process.組建“供應(yīng)超超市”只是為為了搜集購(gòu)買(mǎi)買(mǎi)的部件和線(xiàn)線(xiàn)上的庫(kù)存.Ifpartsarealreadystoredinyourplant,thenyoucanconstructmarkets.如果工廠(chǎng)內(nèi)有有儲(chǔ)存部件,那就可以設(shè)設(shè)置此體系.CautionsaboutMarkets關(guān)于“超市體體系”的警告告:Don’tgetcaughtupinotherpeople’’sphilosophy.不要受別的觀觀點(diǎn)的影響:Marketsdonothavetobelocatednexttothereceivingdocks.超市不一定要要靠近部件接接受區(qū)Marketsdonothavetobelargeinsize.規(guī)模不一定很很大Youcanhaveseveralmini-marketsifspaceisdifficulttoget.若空間不夠,可設(shè)多個(gè)分分散的小超市市.Useyourowncommonsense運(yùn)用自己的常常識(shí)來(lái)解決問(wèn)問(wèn)題!RulesfordevelopingMarkets設(shè)立“超市””的規(guī)則:Haveastoragelocationforeverypart.為每一部件設(shè)設(shè)立儲(chǔ)存區(qū)Determinethemaximumofanyonepartthatwillbestored.為任一需儲(chǔ)存存部件設(shè)立最最大庫(kù)存標(biāo)準(zhǔn)準(zhǔn)Provideadequatestoragespace.提供合適的儲(chǔ)儲(chǔ)存區(qū)域Safetyisapriority.要優(yōu)先考慮安安全因素.LessonsLearnedaboutMarkets設(shè)立超市需注注意的幾點(diǎn):Haveanoverflowspotandameanstomonitor.設(shè)立庫(kù)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(chǔ)存空空間Preferably,donotstorethesamepartinmorethanonelocation.同一部件最好好儲(chǔ)存在一個(gè)個(gè)區(qū)域Makesureaislewayscanaccommodateforklifts.保證過(guò)道可容容納或通行搬搬運(yùn)工具.Determinecustomerdemand確定客戶(hù)需求求Takttimeisareferencenumberthatgivesyouasenseforthepaceatwhicheachprocessneedstobeproducing.TAKT節(jié)拍時(shí)間為了了解并調(diào)整各各個(gè)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(shí)間除以以客戶(hù)需求量量，即為節(jié)拍時(shí)間間.Forourplant對(duì)我們公司來(lái)來(lái)說(shuō):Oneshiftisninehoursthereisone60-minutelunch9小時(shí)一個(gè)班次次,其中有1個(gè)小時(shí)的就就餐休息時(shí)間間Work-time工作時(shí)間8Hrs.X60min/hr=480minutes8小時(shí)X60=480分鐘480minutespershiftThereis28,800secondspershift480分鐘每個(gè)班次次,即28,800秒每每個(gè)班次Customerdemand客戶(hù)需求Thecustomerneeds2,000pairseachday.客戶(hù)每天需要要2,000足鞋WeworkoneshifteachdayinAssembly,6daysperweek.制造車(chē)間每天天一個(gè)班次,每周工作6天Customerdemandis客戶(hù)的需求是是:2,000Pairs/28,800sec2,000足/28,800秒秒or1PAIRevery14.4seconds或每14.4秒需要產(chǎn)一一足鞋Marketsetupsandlocations供應(yīng)超市準(zhǔn)備備和位置選定定Locatespacewithintheplantthatcanbeusedasamarket(s).選定公司可作作為超市的位位置Minimizethenumberofmarkets.Ifmaybenecessarytostartwithseveralsmallones,latertocombineintoone.盡量減少超市市的數(shù)量,若若有必要可先先設(shè)立幾個(gè)小小的超市,以以后再合并成成大的超市.Manpowerandequipmentneeded人員和設(shè)備要要求PartsaredeliveredtothelinebyMaterialHandlersusinghand-carts.搬運(yùn)人員用手手推車(chē)將部件件運(yùn)到生產(chǎn)線(xiàn)線(xiàn)TheMaterialHandlerhasadesignatedroutethatcoversallthestationshe(orshe)isresponsiblefor.搬運(yùn)人員按照照指定的運(yùn)輸輸路線(xiàn)負(fù)責(zé)自自己的工作區(qū)區(qū)域Hedeliversallpartsneededonthatdeliverycycle,retrievesallemptycontainers搬運(yùn)人員必須須循環(huán)搬運(yùn)所所需部件,并并取回空的部部件箱Training培訓(xùn)Thepeoplewhoareaffectedbythenewsystemneedtounderstandwhythecompanyhasimplementedtheprogram.新體系所涉及及到的人員需需要懂得為什什么公司實(shí)施施此體系Thosewhoaretosupportitmustunderstandhowitworks.支持新體系的的人員需懂得得體系是怎樣樣運(yùn)作的Allpeoplemustreceiveadequatetraininginorderforthesystemtobebothrobustandsuccessful.所有相關(guān)人員員需接受培訓(xùn)訓(xùn)以保證新體體系的運(yùn)作效效率和成功。。超市Training(continued)培訓(xùn)Rememberwhotheaudienceis:Productionworkershavelittleregardforhowmanyturnstheinventorymakes……Materialhandlerswillnotseeinventoryreductionasabenefit….記住誰(shuí)誰(shuí)是培培訓(xùn)對(duì)對(duì)象：：那些對(duì)對(duì)庫(kù)存存的影影響不不太關(guān)關(guān)心的的生產(chǎn)產(chǎn)者……看不到到減少少庫(kù)存存會(huì)帶帶來(lái)收收益的的資材材管理理者……Training(continued)培訓(xùn)Designyourtrainingprogram(s)usingtheknowledgeyouwillgaininthesystem’sdevelopment.運(yùn)用你你在實(shí)實(shí)施NOS的過(guò)程程中得得到的的經(jīng)驗(yàn)驗(yàn)來(lái)設(shè)設(shè)計(jì)培培訓(xùn)內(nèi)內(nèi)容，，Keepitsimple.使培訓(xùn)訓(xùn)內(nèi)容容簡(jiǎn)潔潔易懂懂，Giveyourselfenoughtimetohandlethetoughquestions.Respectthepeople’’sconcerns.用足夠夠的時(shí)時(shí)間來(lái)來(lái)解決決比較較棘手手的問(wèn)問(wèn)題，，尊重重別人人的意意見(jiàn)。。ResultsofaPullSystem生產(chǎn)拉拉動(dòng)體體系的的結(jié)果果Inoperationswheretheimplementationhasbeensuccessful,boththemanagementandworkforcebelievetheworkenvironmenttobe““enhanced””在拉動(dòng)動(dòng)體系系取得得成功功的那那些環(huán)環(huán)節(jié),無(wú)論論是管管理層層還是是工人人都會(huì)會(huì)認(rèn)為為他們們的工工作環(huán)環(huán)境正正在改改善。。ResultsofaPullSystem生產(chǎn)拉拉動(dòng)體體系的的結(jié)果果Wheretherehasbeenlittleefforttomakethesystemwork,theplanttypicallyhasshortagesandmissesdeliverywindows.若工廠(chǎng)廠(chǎng)沒(méi)有有努力力去實(shí)實(shí)現(xiàn)拉拉動(dòng)生生產(chǎn)，，就會(huì)會(huì)出現(xiàn)現(xiàn)部件件投入入不足足和不不能按按照生生產(chǎn)需需要來(lái)來(lái)搬運(yùn)運(yùn)部件件。9、靜夜四無(wú)鄰鄰，荒居舊業(yè)業(yè)貧。。1月-231月-23Saturday,January7,202310、雨中黃葉葉樹(shù)，燈下下白頭人。。。17:58:4717:58:4717:581/7/20235:58:47PM11、以我獨(dú)獨(dú)沈久，，愧君相相見(jiàn)頻。。。1月-2317:58:4717:58Jan-2307-Jan-2312、故人江海海別，幾度度隔山川。。。17:58:4717:58:4717:58Saturday,January7,202313、乍見(jiàn)翻翻疑夢(mèng)，，相悲各各問(wèn)年。。。1月-231月-2317:58:4817:58:48January7,202314、他鄉(xiāng)鄉(xiāng)生白白發(fā)，，舊國(guó)國(guó)見(jiàn)青青山。。。07一一月月20235:58:48下下午17:58:481月-2315、比不了得得就不比，，得不到的的就不要。。。。一月235:58下下午1月-2317:58January7,202316、行動(dòng)出成果果，工作出財(cái)財(cái)富。。2023/1/717:58:4817:58:4807January202317、做前，能能夠環(huán)視四四周；做時(shí)時(shí)，你只能能或者最好好沿著以腳腳為起點(diǎn)的的射線(xiàn)向前前。。5:58:48下下午5:58下下午17:58:481月-239、沒(méi)沒(méi)有有失失敗敗，，只只有有暫暫時(shí)時(shí)停停止止成成功功?。?。。1月月-231月月-23Saturday,January7,202310、很多多事情情努力力了未未必有有結(jié)果果，但但是不不努力力卻什什么改改變也也沒(méi)有有。。。17:58:4817:58:4817:581/7/20235:58:48PM11、成功功就是是日復(fù)復(fù)一日日那一一點(diǎn)點(diǎn)點(diǎn)小小小努力力的積積累。。。1月-2317:58:4817:58Jan-2307-Jan-2312、世間成事，，不求其絕對(duì)對(duì)圓滿(mǎn)，留一一份不足，可可得無(wú)限完美美。。17:58:4817:58:4817:58Saturday,January7,202313、不知知香積積寺，，數(shù)里里入云云峰。。。1月-231月-2317:58:4817:58:48January7,2