精益生产工具.ppt
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精益生产工具.ppt
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TenantsofSinglePieceFlow,DoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectsZeroDefects=0DefectsNot3.4ppm,Quality,Quality,QualityDefectsaretheWorstKindofWaste,7TypesofWasteDefectivePartsOverProductionInventoryMotionTransportationWaitingManualTouches,Batch,SinglePieceFlow,From:
TheToyotaProductionSystem,BuildingQualityintotheProcessSinglePieceFlow,Thenextprocessisthecustomerneversenddefects!
SampleInspectcatchesDefecttooLateWhenyouFinallyFindaDefectHowmanymoredoyouhave?
Wherearetheyintheprocess?
WhatistherootCause?
SinglePieceFlowcatchesDefectsimmediatelyWhenyoufindaDefectYouonlyhaveoneYouknowwhereitoccurredYouCanfind/ResolvetheRootCauseimmediately,Check,Do,Verify,Check-Thepreviousoperatorswork.Do-Yourwork.Verify-Thatyoudidyourworkcorrectly.,Process,Inspect,Transport,Transportationisintegratedintotheproductionprocessviaautomatione.g.,movingline,Process,Inspect,Process,Inspect,Transport,Process,Inspect,Transportationisintegratedintotheproductionprocessviahumanconveyancee.g.,Chaku-Chaku,BuildingQualityintotheProcess2waystoperformSPF,Thenextprocessisthecustomerneversenddefects!
Check,Do,Verify,GetsyouintoPartsPerMillionquality-Whenyouverifyyourwork,youcatch1flawin100parts.Thenextpersonchecksyourworkandcancatch1/100sothats1/10,000.ThenthatpersonVerifiestheirworkandcancatch1/100.Thats1/1,000,000errorsthatcangetthrough.,Check,Do,Verify,EveryCustomerinaProcesshas:
-arighttoexpectperfectmaterial-anobligationtoinspectthematerialbeforeuse.-anobligationtoinformthepreviousstepintheprocessofanyproblem.-anobligationtostoptheprocessuntilanyproblemhasbeenresolved.,SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess.ThisisachievedbyestablishingataktTime,developingstdwork,andswip.ThepremiseisthatanOperatorcanonlyworkononepieceatatime,andperformsaQuickqualitycheckontheCTQsoftheprocessbeforemovingTheparttothefollowingprocess.Ifadefectisdetected,JidokaIsenactedthelineisstopped,andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurence,TakttimeStdwork,Flow:
work(process)thatisdoneinconjunctionwithorsimultaneoustotransportation,OnePieceFlow,Theproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis/hersupplierandcustomerinthechain.Asonepersonfinishestheirelement,sodoall.Workisthenmoveddownthelinesynchronously.Everypersonisempoweredtostoptheproductionprocessifarejectisspotted.,Organization,Area,Supervisor,New/Rev,Page,of,Date,ProductionLine,PartNumber,PartName,Operator,StandardWorkSheet,To:
Turns,DPUs,EndFinish,Weld,EndFinish,Weld,OrbitalWeld,HydroTest,Mark,Mech.Clean,TorchBraze,Tubing,CFMCell,FernBissonnette,Cell6AllPartsAllTubes,11,Mech.Clean,Rawmaterial,Weld,100/Day,FPIX-RayEDM,2ndQtr.01,EndFinish,OutsideCell,27-avglot=6,Flex,FinishedGoods,ACTIONWORKOUT,g,GEMSGlobalProductionSystem,Thenextprocessisthecustomerneversenddefects!
Check,Do,Verify,OnePieceFlow,Yourcustomeristhenextstepintheprocess.Givetoyourcustomer,exactlywhattheyneed(1item),exactlywhentheyneedit,doneperfecteverytime.,Tenantsof1pcsFlow,DoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefect,Quality,Quality,QualityDefectsaretheWorstKindofWaste,Systemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals,intheexactstandardizedamountneeded.,PullProductionMethodology&Sequence,Definition,RefMaterialPresentationtrainingforexplanationonSupermarketdefinitionanduse,1,3,4,5,6,7,8,9,10,2,AssemblyLine,CellorChaku-Chakuline,Supplier,PullProductionMethodology&Sequence,JIT,Jidoka,eGPSforGPC,Heijunka,LevelLoading,Sequencing,FindingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacityAdjustingaproductionscheduletomeetunexpectedchangesincustomerdemand,OrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitems,takenfrommemoryJogger,Leveledproductionmeansloweringthepeaksamongthedailyproductionvolumesasmuchaspossibleandmakingtheproductionflowsmoothandunflucuating.Ingeneral,themorefluctuationsyouintheproductionflow,themoremudayouenduphaving.Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand.Iftheproductionlineproducesonlyasingleproduct,youmaybeabletoreducemudasimplybyadjustingtheproductionscheduleandstaffinglevel.Butifyouwanttoproduceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline,youhavetodotheaveragingnotjustinvolumebutinkindsaswell.ThiswayofaveragingbothvolumeandinkindsiscalledproductionlevelingorheijunkainJapanese.,LeveledProduction,LeveledLoadProduction,BuildtoforecastBuildtoFGinv,BuildafterorderisreceivedALLcomponentsneedtobestockedinRMAnorderfromtheseproductstakesprecedenceover1-2-3productsbuildthisfirst!
%,F1,F1,F1,F1,F1,F1,F2,F2,F2,F2,F2,F2,TAKTTimeDeterminedbyPSI,2Q,3Q,4Q,OktoBuildtoFG,RepeatableProducts,Non-RepeatableProducts,NeedtoDetermine.,HowMuch20bulbsperdayWhatKind15/60Watts5/100WattsWhen5-60W,2100W,560W,2200W,560W,1100W,TAKTLevelLoadMixLevelLoadSequence,Ifweweremakinglightbulbs.,QuarterlyWeeklyWeekly,Frequency,60,60,60,60,60,100,100,60,60,60,60,60,100,100,60,60,60,60,60,100,TaktTime=,Operatingtimeperday,Productionrequirementperday,Assumptions:
MachineBreakdown=0hourSetupChange=0hourDefectRate=0%,TaktTimeEquation,FormoreinformationonTAKTRefertoJITSection,QuickExample,SettingtheproductionsequenceofmultipleTRAMRACTypes(MedSystemsProduct),Thisisdatafor3products,Model1,Model2,andModel3,areproducedatGEMS.Thechartdisplaysthemonthlyproductionlevel,thedailyproductionlevel(monthlydividedby30),andtheTakttimeforeachproducttype.THEYAREALLPRODUCEDONTHESAMELINE.Howcantheseunitsbebuiltinalevelproductionmodeusingthisexample?
Model1,Model2,Model3,DetailedExample,Sincethesethreeproductsareonthesameline,youwillneedtofollowthesequencepatternof1-2-1-3inyourproductionmix.Bydoingitthiswayyouareabletolevel-loadyourproductionbothintermsofquantityandtypes.,#1Prod1,#4Prod3,#2Prod2,#3Prod1,REPEAT,MixedAssemblyLine,ProductionSequencebyType,Ifproducedinbatches,onlytheModel1swillmeetTakttimes,Ifproducedtoasequence,2unitswillbeproducedin2Takttimes,Letsshowhowwevalidatethis,Model,LineTakt,Takt/CycleGraph,Part-Quantity,PartRouter,1,3,2,7.5,7.5,7.5,SeeStdWorkComboSheetforexample.Onesheetiscreatedforeachoperator,SCT=25,SCT=40,SCT=30,7,6,6,6,7,6,13,8,12,7.5,9,7.5,TaktBuildTime,=#ofOperations*Takt,ActualBuildTime,=SCT,Model,TBT,Model,ABT,Model,Objectives:
ProducetoTaktTime(understandingno2productswillhavetheexactsameABT),ThesumoftheDTotiszeroEveryproductisproduceatleastonceNoproductisproducedtwiceinarow,Createaproductsequencewhere:
Dtot=S(#ofUnitsinsequence*D)Dtot=-5(#of1s)+10(#of2s)+0(#of3s)0=-5
(2)+10
(1)+0
(1),IneachsequencewillcontainoneModel1,twoModel2s,and1Model3),Accordingtotherulesthesequencemustrun:
Model1Model2Model1Model3,GuidingPrinciples:
GPSLevel-loading,Purpose:
Toprovideguidelinesfordevelopingthemethodandtoolstolevel-scheduletheshopfloor.KeyElementsofLevel-schedulingProductionunitsarestratifiedaccordingtoplannedsalesvolumeTheproductionsequencecombinesbothordersandforecastSequenceisdesignedtoachievethecombinedTAKTtimeforallitemsEliminatingproductionratevarianceisrequiredtoachieveTAKTtimeOnlybuildhighvolumeproducts(top80%)toFGinventory,ifordersarenotavailableFGinventorylevelsareNOTtargeted,butaresultofTAKTtime&ordersflowLower-levelgroupitemsareNOTsequencedwithoutfirmordersHoldRMcomponentsinventoryonlyforlowvolumeitems.TheseareitemsthatyoucantbuilduntilyouhaveanorderFillordersfirstfromFG,secondWIP,&thirdsequencethem(attachtheordertotheproductionplan),
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