精益生产之普通拉系统GenericPullSysem精选课件.ppt
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1、MeasureAnalyzeControlImproveLean Six SigmaGeneric Pull SystemuDefinition of Generic Pull Best Practiceu Case ExamplesuHow to Determine Generic Pull LevelsuExercise uAntenna SimulationRD010402MeasureAnalyzeControlImproveLean Six Sigma普通拉系统u定义普通拉系统的最佳实践u 案例举例u如何去决定普通拉水准u练习u天线模拟RD010402ImproveGeneric P
2、ull System3Lean Six Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct Mea
3、surementSystem AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potent
4、ial SolutionsSelect SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureDefineProject ID ToolsProject Definition FormNet Pre
5、sent Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp&CpkSupplyChainAccelerator Anal
6、ysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPo
7、ka-YokeRevised 1-12-02ImproveGeneric Pull System4Learning ObjectivesuUnderstand the best practice definitionuHow to apply this best practice in various environmentsuAble to determine the levels of inventory using the five stepsuDemonstrate this best practice through exercises and simulationImproveGe
8、neric Pull System5课程目的u理解最佳实践的定义u如何在多变的环境中应用这个最佳实践u能够去决定库存的水平用5个步骤u通过练习和模拟来示范这一最佳实践ImproveGeneric Pull System6Whats in It for Me?uUnderstand the reason for this tool in different environmentsuHow to use this tool for potential black belt projectsImproveGeneric Pull System7我学到了什么?u理解在不同环境中使用这个工具的原因u对
9、于黑带潜在项目如何去使用这个工具ImproveGeneric Pull System8Generic Pull SystemsuGeneric Pull Systems limit the amount of Work-In-Process inventory in order to control cycle time.ImproveGeneric Pull System9普通拉系统u普通拉系统为了控制周转时间限制了制程库存的数量(Work-In-Process).ImproveGeneric Pull System10WIP CapExitsStartsTriggerGeneric Pul
10、l System DefinedDefinition:uA Generic Pull System establishes a WIP cap on the amount of inventory within a predefined physical work area(set of workstations)or process.uTo maintain the WIP cap,exits from the process trigger starts into the process.Establishing WIP cap is the key to cycle time reduc
11、tion!ImproveGeneric Pull System11WIP CapExitsStartsTrigger普通拉系统的定义定义定义:u一个普通拉系统是在一个预先确定的物理工作区域(工作站)或流程中,在存货金额上建立了一个WIP cap.u来维护 WIP cap,从流程中的“出口”(exits)来触发进入流程的“出发”(Starts).建立WIP cap 是降低周转时间的关键ImproveGeneric Pull System12When to Use Generic PulluAlwaysuGeneric Pull systems can be used in any of the
12、following manufacturing/transactional environments:nRepetitive process/repetitive productlSimilar products/parts run within same process flowuExample:Automotive assembly line,customer order processingnRepetitive process/non-repetitive productlDissimilar products/parts run within same process flowuEx
13、ample:Build to order printed circuit board manufacturer,customer complaint processingnNon-repetitive process/non-repetitive productlDissimilar products/parts run within a dissimilar process flowuExample:Machine model/prototype shop,NPI processesuGeneric Pull systems should always be used when a repl
14、enishment pull system is implemented ImproveGeneric Pull System13何时使用普通拉系统u永远u普通拉系统可以被使用在下列任何制造/事务处理的环境中:n重复的流程/重复的产品l类似的产品/零件在同一个流程中运行u例如:汽车的组装线,客户定单流程n重复的流程/不重复的产品l不同的产品/零件在同一个流程中运行u例如:根据定单定制的电路板制造商,客户投诉流程n不重复的流程/不重复的产品l不重复的产品/零件在不同的流程里运行u例如:机器模型/原型制作车间,NPI流程u当补充拉系统被实施时,普通拉系统将永远被使用ImproveGeneric P
15、ull System14When flying from DFW to OHare,we often wind up waiting on the ground due to“flow control.”Since OHare is overloaded,air traffic control keeps us in Dallas until the congestion over OHare clears,versus getting there and circling Chicago.Either way,we end up late.However,using the“flow con
16、trol”(fixed WIP)method,we use less fuel and reduce the risk of an accident.In addition,we keep our options open(such as re-routing if the weather becomes too bad).In a pull system,maintaining a“fixed WIP”keeps work orders in paper form as long as possible.This provides the greatest flexibility to sc
17、hedule/engineering changes.In addition,low WIP means a faster cycle time,which increases the probability releases are based on actual customer orders versus forecast.“Fixed WIP”Improves FlexibilityImproveGeneric Pull System15当航班从 DFW 到 OHare,我们通常由于“流控制”而在地面上紧张的等待。因为OHare机场超负荷了,空中交通控制要求我们在达拉斯等待,直到OHa
18、re 的堵塞清除掉;与在芝加哥上空盘旋相比,任何一条路都注定会让我们晚点。可是,使用“流控制”(固定WIP)方式,我们用的燃油更少且降低了事故的风险.此外,我们仍然享有我们的选择权(例如重新选择路线如果天气变的更糟的话).在一个拉系统中,维护一个“固定WIP”可以使工作指令尽可能的在计划阶段。这样为制定计划/工艺变更提供了最大的弹性。此外,底WIP意味着更快的周转时间,这样可以增加基于客户的订单而不是根据预测“固定的WIP”改善弹性ImproveGeneric Pull System16The Power of a WIP CapWIP Cap Cycle time is reduced an
19、d stableNo WIP Cap Cycle time fluctuates with amount of WIPImproveGeneric Pull System17WIP Cap的能力WIP Cap 周转时间被降低了且稳定没有WIP Cap 周转时间随WIP的金额而波动ImproveGeneric Pull System18United Technologies:Hose and Fittings Division(PTG)BeforeMetal ware flare running large batches with large amounts of WIPImproveGene
20、ric Pull System19联合技术:Hose and Fittings 分部(PTG)之前之前金属器械运行大批次并伴随大的WIPImproveGeneric Pull System20United Technologies:Hose and Fittings Division(PTG)AfterMetal ware flare area with controls placed on material releases to the departmentImproveGeneric Pull System21联合技术:Hose and Fittings 分部(PTG)之后之后金属器械区
21、域对发料到部门的材料放置进行控制ImproveGeneric Pull System22Teledyne Continental MotorsBeforeNo internal limits existed for the number of cylinders a supplier could push to its customer,resulting in large amounts of WIP in the line.ImproveGeneric Pull System23Teledyne Continental Motors之前之前对于缸体数量没有内部限制,供应商向客户推动供应,导
22、致生产线有大量WIP.ImproveGeneric Pull System24Teledyne Continental MotorsAfterLimits were established workstations and the line was drained of excess WIPImproveGeneric Pull System25Teledyne Continental Motors之后之后建立限制数量,过多的WIP从工位和生产线清除ImproveGeneric Pull System26How to Size a Generic Pull System1.Determine
23、current Manufacturing Cycle Time(MCT)2.Determine current Manufacturing Cycle Efficiency(MCE)3.Identify appropriate target MCE 4.Calculate theoretical best MCT5.Calculate WIP capImproveGeneric Pull System27如何确定普通拉系统的规模1.确定目前的制造周期时间(MCT)2.确定目前的制造周转效率(MCE)3.识别适合的MCE目标4.计算理论上的最佳MCT5.计算 WIP capImproveGen
24、eric Pull System28Manufacturing Cycle TimeuMCT The time from work order release into manufacturing until completion/movement into shipping/finished goods.uIt is measured as:uWIP is the inventory level at a given point in timeuEXITS is the amount of work completed over a given period of time(Weekly,D
25、aily)EXITSWIPMCT ImproveGeneric Pull System29制造周期时间uMCT 从工作单的下发到制造,直到完成/移动到成品的时间.u他被量测如:uWIP 是在给定时间点的存货水平uEXITS 是在一个给定的时间内(每周,每天)工作完成的金额EXITSWIPMCT ImproveGeneric Pull System30MCTExits=20 units/day WIP=Sum of all Inventory within Physical work area=100 unitsMCT=100 units/20 units per dayMCT=5 daysEx
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