3缩短制造周期解读课件.ppt

1、StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-Q

2、ualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS缩短制造周期缩短制造周期定义：定义：Short Lead Time Definition:The desired reduction in time from the placement of an order by the final customer to the delivery of the product and receipt of payment. There are four types of lead time which contribute to th

3、e short lead time concept: 1.Total Lead Time 2.Product Development Lead Time 3.Process Lead Time 4.From factory to customer.从最终用户订货至交货收款之间期望能减少的时间，它包含四从最终用户订货至交货收款之间期望能减少的时间，它包含四种类型：种类型：1、总的制造周期（收到订单至收到货款）、总的制造周期（收到订单至收到货款）2、产品开、产品开发周期（从概念设计至发周期（从概念设计至SORP）3、工艺制造周期工艺制造周期（从原材（从原材料至料至SORP）4、装配厂至用户。、装配

4、厂至用户。StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS9.供应链的管理供应链的管理 Supply Chain Management (3)7.内部拉动内部拉动/交货交货Internal Pull/Delivery (7)5.有计划的发运有计划的发运 /收货收货Schedule Shi

5、pping/Receiving (7)3.固定周期订货系统固定周期订货系统Fixed Period Ordering System (5)1.简易的工艺流程简易的工艺流程Simple Process Flow (8)2.少量包装少量包装 Small Lot Packaging (19)4.受控的外部运输受控的外部运输 Controlled External Transportation (18)6.临时物料储存临时物料储存 Temporary Material Storage CMA (9)8.均衡定购车辆的生均衡定购车辆的生产计划产计划 Level Vehicle Orders (4)Sta

6、ndardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS1-1、简易的工艺流程简易的工艺流程 Simple Process Flow (8)定义：以获得一个简易的物料与信息流为目的的流程定义：以获得一个简易的物料与信息流为目的的流程Definition: A process which incorpo

7、rates a constant drive to attain a simple sequential process flow of material and information.目的：设计和实施这样一种工艺目的：设计和实施这样一种工艺,这种工艺在这种工艺在优化成本优化成本,降低工序内库存和易发现问题的同降低工序内库存和易发现问题的同时坚持先进先出这一原则并且具有可跟踪性时坚持先进先出这一原则并且具有可跟踪性,可视性可视性,能缩短制造周期能缩短制造周期. Purpose: To design and implement processes that maintain FIFO, all

8、ow trace ability, are visual, reduce lead time, easily detects problems while optimizing cost, and reduces inventory and work in process.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvem

9、entSGM-GMSSGM-GMS2、必须控制和优化所有缓冲区和工序内的工作、必须控制和优化所有缓冲区和工序内的工作-缓冲区管理缓冲区管理Line side and work-in-process (vehicles, parts) are controlled and optimized - buffer management.1、先进先出这一原则体现在所有物料存储操作中、先进先出这一原则体现在所有物料存储操作中First In First Out is practiced in ALL Material Storage operations.1-2、简易的工艺流程简易的工艺流程 Simpl

10、e Process Flow (8)3、当从经济角度出发需要进行批量或小规模、当从经济角度出发需要进行批量或小规模生产时生产时,必须始终考虑减少这种生产的可能性必须始终考虑减少这种生产的可能性. When batch or small lot production is economically necessary, batch or lot size must always be challenged for reduction.4、有一个简单、直接、连续的物料操作流程、有一个简单、直接、连续的物料操作流程来实现合理的规划布置和操作来实现合理的规划布置和操作Layouts and proce

11、sses facilitate a direct, continuous and simple material flow.要求要求 Requirements:StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS1-3、简易的工艺流程简易的工艺流程 Simple Process Flow (

12、8)5、操作工的工作区域的设置必须考虑安全、操作工的工作区域的设置必须考虑安全有效的零部件摆放有效的零部件摆放Operator envelopes are set to allow safe, efficient parts presentation. 6、必须有均衡的生产计划以实现实现简、必须有均衡的生产计划以实现实现简易的流程（看板、周期时间、重新定购点易的流程（看板、周期时间、重新定购点等）等）Leveled production schedules are in place to allow simple flow (kanban, cycle time, reorder points

13、, etc,). 7、生产指导、生产指导(材料清单、目视板、拉动单等材料清单、目视板、拉动单等)必须以清晰的格式张贴在车间上部所对应必须以清晰的格式张贴在车间上部所对应的位置的位置Production instructions (manifest, screens, pull card, etc.) are visually present on the shop floor in a simple format. 8、对所有移动设备和生产设备有简、对所有移动设备和生产设备有简单的操作、维护流程以便使用及维单的操作、维护流程以便使用及维护护Mobile equipment and produc

14、tion equipment facilitate simple flow. StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS2-1、少量包装少量包装 Small Lot Packaging (19)定义：定义： 确定确定,分配或设计合适的标准数量和料箱分配或设计合适的标准数量和料箱De

15、finition: Determining, assigning or designing the appropriate standard quantity and container.目的目的: 以易于操作的包装方式为操作工提供零部件以易于操作的包装方式为操作工提供零部件,这种包装这种包装使部件在船运使部件在船运,储存和发货过程中不易受损储存和发货过程中不易受损,且易操纵且易操纵.Purpose: To provide parts to the operator in a user-friendly package that facilitates damage-free and econ

16、omical handling during shipment, storage and delivery.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS2-2、少量包装少量包装 Small Lot Packaging (19)4、对于每一个零件的包装尺寸都应、对于每一个零件的包装尺寸

17、都应标准化标准化Container dimensions are standardized per part number. 5、每种料箱都应张贴与其物料对应、每种料箱都应张贴与其物料对应的认可的物料标签（零件号、零件名的认可的物料标签（零件号、零件名称、数量等）以进行辨识。称、数量等）以进行辨识。Container contents are identified on an approved label (part number, description, quantity, etc.)3、每种零件都应有唯一的标准包装数、每种零件都应有唯一的标准包装数量（包括备用的量（包括备用的/紧急的包装

18、）紧急的包装） One standard pack quantity per part number exists (including alternate / emergency packaging).2、料箱设计：、料箱设计： (a)减少从第一个部件到最后一个部件因取料造成的人体减少从第一个部件到最后一个部件因取料造成的人体疲劳和时间疲劳和时间; (b) 在保持产品质量的前提下，尽量减少在保持产品质量的前提下，尽量减少间隔衬垫的使用和处理间隔衬垫的使用和处理; (c)减少准备时间减少准备时间(例如包装材料例如包装材料和和 箱盖的拆除等箱盖的拆除等) 和额外整理和额外整理的相关活动的相关活动

19、(如收集、分类、处理如收集、分类、处理)。Container design (a) minimizes ergonomic stress and time to access parts from first to last (b) maintains part quality while minimizing dunnage and dunnage handling (c) minimizes preparation time (removing banding, wrapping, etc.) and disposal activity (collecting, sorting, proc

20、essing). 1、根据有效的操作空间优化料箱尺寸（零件操作适合工、根据有效的操作空间优化料箱尺寸（零件操作适合工作区域），工作区域的料箱应能易于操作者操作。作区域），工作区域的料箱应能易于操作者操作。Container size is optimized for available operator space (parts fit within the work envelope) and containers are presented in the workstation layout within easy reach supporting the operators needs.

21、 要求要求 Requirements:StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS2-3 、少量包装少量包装 Small Lot Packaging (19)7、人工搬运的料箱包装量应不大于、人工搬运的料箱包装量应不大于2小时的用量小时的用量（不包括坚硬的零件如罗栓、螺母、卡扣等）（

22、不包括坚硬的零件如罗栓、螺母、卡扣等） Manually handled containers hold a maximum of 2 hours worth of material (excluding hardware parts such as nuts, bolts, fasteners, etc) 8、料箱设计及选择过程中，应充分考虑人工搬运料、料箱设计及选择过程中，应充分考虑人工搬运料箱及交换箱及交换DOLLY的使用，尽量减少叉车的使用的使用，尽量减少叉车的使用The container design and selection process increases the use

23、of manually handled containers and dolly exchange, promoting the elimination of fork trucks.9、非手工操作的大件料箱，其包装量应不、非手工操作的大件料箱，其包装量应不大于大于4小时的用量。小时的用量。Non-manually handled (bulk) containers hold a maximum of 4 hours worth of material.10、不能因为减少每小时的不能因为减少每小时的库存目标而减少包装数量（库存目标而减少包装数量（料箱装载空气是不合理的）料箱装载空气是不合理的）

24、Point of use hourly inventory targets should not compromise filling the container (no air).11、尽量使用通用型可回收周转箱、尽量使用通用型可回收周转箱Use of common returnable containers is maximized. 6、料箱尺寸应实现模数化，、料箱尺寸应实现模数化，以提高卡车及拖车的容积率以提高卡车及拖车的容积率并保证装载的稳定性。并保证装载的稳定性。Container sizes should be modular to truck or rail car for b

25、est cube utilization and load stability.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS2-4 、少量包装少量包装 Small Lot Packaging (19)15、空料箱返回区域：、空料箱返回区域： (a) 用于收集、整用于收集、整理、发运料

26、箱理、发运料箱; (b)对操作区域做明确的标对操作区域做明确的标识和可视化的控制，使其清晰可辨（如整识和可视化的控制，使其清晰可辨（如整理区、发运区、供应商区、周转区、待处理区、发运区、供应商区、周转区、待处理区等）理区等）; (c)按计划的数量发运按计划的数量发运; (d)指定指定由供应商自己负责或集装箱整合运输由供应商自己负责或集装箱整合运输; (e)所在位置应满足最小的综合运送距离并有所在位置应满足最小的综合运送距离并有标准化的操作流程标准化的操作流程 。Empty container return areas: (a) are designated for collecting, so

27、rting and staging (b) are clearly identified with appropriate addresses and visual controls (e.g. Type of area Sort, Stage; supplier, return schedule, preparation instructions, etc.) (c) accommodate planned quantities of containers (d) are designated for every supplier and/or container combination (

28、e) are located to minimize travel distance and standardize the work flow. 14、尽可能减少重新包装、尽可能减少重新包装(重复操作重复操作)Container re-packaging is minimized (double handling).13、按照供应商零件包装的要求，、按照供应商零件包装的要求，物料应使用指定的料箱（或备用料物料应使用指定的料箱（或备用料箱）进行运输。箱）进行运输。Material is shipped in the designated container (or backup) for al

29、l plant build requirements.12、人工搬运的料箱和部件间隔衬垫应满足人机工程、人工搬运的料箱和部件间隔衬垫应满足人机工程提升准则提升准则(如重量、尺寸、把手等如重量、尺寸、把手等) Manually handled containers / dunnage are ergonomic to assist operator handling (weight, dimension, grip points & etc.).StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuo

30、usImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS2-5 、少量包装少量包装 Small Lot Packaging (19)18、外运的卡车和拖车：、外运的卡车和拖车： (a)根据运输计划根据运输计划装载准备好的空料箱装载准备好的空料箱; (b)通过文件跟踪外通过文件跟踪外运的集装箱和空料箱。运的集装箱和空料箱。Outbound trucks and rail cars : (a) are loaded with all prepare

31、d empty containers per the shipping schedule (b) have all required paperwork processed to document outbound shipment of containers for container tracking. 17、货箱应准备完好和确保返回、货箱应准备完好和确保返回(例如：加盖、分类和堆栈等例如：加盖、分类和堆栈等)Containers are properly prepared and secured for return (capped, sorted, stacked, etc.).19、

32、有效的新包装确认流程、包装更改及、有效的新包装确认流程、包装更改及现有的包装评估流程现有的包装评估流程Process in place to validate new packaging, changes to existing packaging and evaluate current packaging.16、空料箱操作、空料箱操作: (a) 确保一旦最后的零件确保一旦最后的零件用完后，操作工即刻把空的料箱放置在合适用完后，操作工即刻把空的料箱放置在合适的返回装置中的返回装置中; (b)遵循有书面形式的内部衬遵循有书面形式的内部衬隔处理流程隔处理流程; (c)遵循有书面形式的正确遵循有书

33、面形式的正确 的分的分类、转运、装卸等的工作程序类、转运、装卸等的工作程序; (d)避免包装避免包装箱挪为他用箱挪为他用; (e)确保返回供应商的空箱内没确保返回供应商的空箱内没有杂物有杂物; (f)对需要维修和处理的料箱进行标对需要维修和处理的料箱进行标示和发运。示和发运。Empty container handling practices: (a) assure operator places empty container on appropriate return device as soon as last part is used (b) conform to a written

34、process for handling internal dunnage (c) conform to a written process for proper sorting, staging, loading, and unloading (d) prevent misuse of containers (e) assure empty containers are free of debris before returning them to suppliers (f) identify and route damaged containers for repair/disposal.

35、 StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS3 -1 、固定周期订货系统固定周期订货系统 Fixed Period Ordering System (5)定义：在均衡的基础上根据物料的有效供应机制，定义：在均衡的基础上根据物料的有效供应机制，建立预定的、固定的零件订货周期建立预定的

36、、固定的零件订货周期 Definition: Pre-determined, fixed period for parts ordering allowing for the effective supply of material on a leveled basis目的：确保物流供应既可以预知又可靠目的：确保物流供应既可以预知又可靠 Purpose: To ensure predictable, reliable flow of materials through the pipelineStandardizationStandardizationShort LeadShort LeadT

37、imeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS3 -2 、固定周期订货系统固定周期订货系统 Fixed Period Ordering System (5)2、确保每次在约定时间节点之前向、确保每次在约定时间节点之前向供应商和承运商发布订货计划供应商和承运商发布订货计划Material schedules are communicated to the supplier and the

38、 transportation contact per agreed upon time horizon.1、建立零部件订货和发运的固定周期、建立零部件订货和发运的固定周期A fixed period is established for parts ordering and delivery.3、按标准包装数量订货、按标准包装数量订货Material schedules are stated in standard pack quantities.4、备有例外的流程处理突发、备有例外的流程处理突发事件事件An exception process exists to cover emergen

39、cies. 5、内部管理零件订货流程、内部管理零件订货流程Parts Ordering Process is managed locally.要求要求 Requirements:StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS4-1 、受控的外部运输受控的外部运输 Controlled

40、External Transportation (18)定义定义:由物流供应商按确立的方式管理运作既定的物流途径由物流供应商按确立的方式管理运作既定的物流途径Definition: Scheduled logistics pipeline with established controls managed by a lead logistics provider.目的目的: 提供一个可预见的方法以应付频繁的提供一个可预见的方法以应付频繁的物料移动并达到各种资源的最优化物料移动并达到各种资源的最优化 purpose: To provide a predictable method for fre

41、quent material movement that maximizes use of resources.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS4-2 、受控的外部运输受控的外部运输 Controlled External Transportation (18)3、物流供

42、应商提供并维持战、物流供应商提供并维持战略路线规划略路线规划The single Lead Logistics Provider (LLP) or single point of contact for logistics provides strategic route planning and maintains the route board.4、供应商提供其以往操作数据。、供应商提供其以往操作数据。The single Lead Logistics Provider (LLP) or single point of contact for logistics provides a hi

43、storical database.5、供应商提供不断降低成本的、供应商提供不断降低成本的步骤措施步骤措施The single Lead Logistics Provider (LLP) or single point of contact for logistics provides a process for further cost reduction. 6、供应商为实际运输商单位和、供应商为实际运输商单位和/或运输分承或运输分承包商提供培训包商提供培训The single Lead Logistics Provider (LLP) or single point of contact

44、for logistics provides training for carrier and/or transportation providers.1、物流供应商提供一个主要的执行检验标准，、物流供应商提供一个主要的执行检验标准，并定期进行评估考核。并定期进行评估考核。The single Lead Logistics Provider (LLP) or single point of contact for logistics provides a process to measure key performance criteria and has regular performanc

45、e reviews with LLP and plant.2、供应商配备专人驻厂提供操作服务、供应商配备专人驻厂提供操作服务The single Lead Logistics Provider (LLP) or single point of contact for logistics provides a resident in the plant for transportation modeling and operation.要求要求 Requirements:StandardizationStandardizationShort LeadShort LeadTimeTimeConti

46、nuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS4-3、受控的外部运输受控的外部运输 Controlled External Transportation (18)10、到工厂的运输是按照小时、天、周的水平、到工厂的运输是按照小时、天、周的水平来操作的，以平衡生产和设备，同时将库存降来操作的，以平衡生产和设备，同时将库存降到最小到最小Deliveries to the Plant are level hour-

47、to-hour, day to day, week to week to balance workload and equipment as well as minimize inventory.9、所有的零件都送到工厂或物流再分配中、所有的零件都送到工厂或物流再分配中心的指定接收地点。心的指定接收地点。All parts are delivered to the plant and/or distribution center to scheduled windows. 11、提供一个能不断提高货物配载率的适当、提供一个能不断提高货物配载率的适当流程。流程。 A process is in

48、place to continuously improve cube efficiency of trailers and railcars. 12、在经济和运输可靠的基础上、在经济和运输可靠的基础上，固定每条运输线路的装卸及挂，固定每条运输线路的装卸及挂靠港口靠港口Live unloading vs drop and swap is determined for each route based on economics and transportation reliability. 8、企业的安全规章制度得到严格执行、企业的安全规章制度得到严格执行Plant safety rules ar

49、e communicated and followed (e.g. tire chocking, jack stands, etc.).7、物流商保证将其目标汇总融入企业的商、物流商保证将其目标汇总融入企业的商业规划中业规划中The single Lead Logistics Provider (LLP) or single point of contact for logistics provides that the LLP objectives are integrated into the plants business plan (Business Plan Deployment).

50、StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMS4-4 、受控的外部运输受控的外部运输 Controlled External Transportation (18)17、需要流程规范物料因供应商延误、需要流程规范物料因供应商延误时的紧急应急方案时的紧急应急方案 A process is