GMS-缩短制造周期课件.ppt

1、StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuil

2、t-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time 缩短制造周期缩短制造周期定义：定义：Short Lead Time Definition:Definition:Reduce the time from the placement of an order by the final customer to the delivery of the product and receipt of payment.There are three types of lead

3、 time that contribute to the short lead time concept.They are:(1)Total Lead Time(receive order to receive payment)(2)Product Development Lead Time(from Document of Strategic Intent DSI to Start of Production-SOP)(3)Process Lead Time(from raw material to final assembly)(4)From factory to customer.定义：

4、缩短从最终客户下订单到交货收款的时间。在缩短制造周期定义：缩短从最终客户下订单到交货收款的时间。在缩短制造周期的概念中有四种类型：的概念中有四种类型：(1)(1)完整的制造周期（从收到定单到收完整的制造周期（从收到定单到收到货款）到货款）(2)(2)产品开发周期（从概念设计到生产开始）产品开发周期（从概念设计到生产开始）(3)(3)工艺工艺制造周期（从原材料到最后装配）制造周期（从原材料到最后装配）(4)(4)从生产基地到客户。从生产基地到客户。StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinu

5、ousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time缩短制造周期缩短制造周期目的：目的：Short Lead Time Purpose:Purpose:To achieve customer enthusiasm by delivering the customer his/her product more quickly,while maintaining good quality.Ultimately,o

6、ur Company benefits through cost reduction and increased customer loyalty.目的：在保证高质量的同时，通过更快地传递产品来获得客户目的：在保证高质量的同时，通过更快地传递产品来获得客户热诚。最终，公司将受益于降低的成本和提升的客户忠诚。热诚。最终，公司将受益于降低的成本和提升的客户忠诚。StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-Qu

7、alityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time9.供应链的管理供应链的管理 Supply Chain Management(4)7.拉动式系统拉动式系统Pull Systems(6)5.有计划的发运有计划的发运/收货收货Schedule Shipping/Receiving(8)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(7)2.少批量包装少批量包装 Small Lo

8、t Packaging(15)4.受控的外部运输受控的外部运输 Controlled External Transportation(14)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 Schedules(3)StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-Qualit

9、yQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead TimeNO.ELEMENTS要素要素#Of Calibration Statements1Simple Process Flow简易的工艺流程简易的工艺流程6（2）2Small Lot Packaging少批量包装少批量包装 7（1）3Fixed Period Ordering固定周期订货系统固定周期订货系统54Controlled External Transportation受控的外部运输受控的外部运输 85Schedule Ship/Receive有计划

10、的发运有计划的发运 /收货收货5（1）6Temporary Material Storage临时物料储存临时物料储存 8（4）7Pull Systems拉动式系统拉动式系统 5（1）8Level Order Scheduling均衡定购车辆的生产计划均衡定购车辆的生产计划 3（1）9Supply Chain Management供应链的管理供应链的管理 410Calibration Statement Totals要素汇总要素汇总512008 GMS SLT要素要素StandardizationStandardizationShort LeadShort LeadTimeTimeContinu

11、ousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time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 incorporates a constant drive to attain a simple sequential process flow of material and informat

12、ion.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时坚持“先进先出先进先出”这一原则并且具有可跟踪这一原则并且具有可跟踪性性,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,allow trace ability,are visual,reduce lead time,easily detects problems while optimizing cost,

13、and reduces inventory and work in process.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time2、在制品及缓冲区受控在制品及缓冲区受控,并被优化及目视化。并被优化及目视化。（例如零件、装配、零部件等）（例如零件、装配、零

14、部件等）Work-in-process and buffers are controlled,optimized and visualized(e.g.parts,assemblies,components,etc.)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.3、目前的布局和流程利于直接目前的布局和流程利于直接,连续及简洁连续及简洁的生产的生产/物料流转物料流转。.Layouts and processes facil

15、itate a direct,continuous and simple product/material flow4、为操作工设置安全、高效的零件摆放环境为操作工设置安全、高效的零件摆放环境。Team member envelopes are set to allow safe and efficient parts presentation要求要求 Requirements:StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-

16、Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Timeu先进先出须在所有的物料存储操作中实施。先进先出须在所有的物料存储操作中实施。u在制品缓冲区物料必须保持先进先出。在制品缓冲区物料必须保持先进先出。u在制品和缓冲区必须正确目视并与最大在制品和缓冲区必须正确目视并与最大/最小控制流程最小控制流程相一致。相一致。u所有按批生产的零件（如工位上预装分总成），其每所有按批生产的零件（如工位上预装分总成），其每次批量应近可能减少。次批量应近可能减少。u在制品必须经常检查以确保其数量上

17、的最小化与最优在制品必须经常检查以确保其数量上的最小化与最优化。化。StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time5、制造制造/仓储目视辅助设施仓储目视辅助设施(清单清单,屏幕屏幕,拉动拉动卡等卡等)要以简洁的格式存放于车间现场要以简洁的格式存放于车间现场

18、Manufacturing/warehousing visual aids(i.e.manifest,build schedules/runsheets,inside rack labels,etc.)are present on the shop floor in a simple format.6、移动设备和生产移动设备和生产/仓储设备支持简洁流程仓储设备支持简洁流程Mobile equipment and production/warehousing equipment facilitate simple flowProduction visual aids(manifest,Stand

19、ardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time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Definition:Determining,assigning or designing the appropriate standar

20、d 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运送使部件在运送,储存和发货过程中不易受损储存和发货过程中不易受损,且易操作且易操作.Purpose:To provide parts to the operator in a user-friendly package that facilitates damage-free and economical handling during shipment,storage and delivery.StandardizationSta

21、ndardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Timec.在搬运时，零件质量得到维护在搬运时，零件质量得到维护，且衬隔操作最小化，且衬隔操作最小化Part quality is maintained while dunnage and dunnage handling are minimizedb.

22、料箱尺寸必须模块化和可堆放，以便支持运输效料箱尺寸必须模块化和可堆放，以便支持运输效率，空间利用率和装载稳定性率，空间利用率和装载稳定性Container sizes should be modular and stackable to support transportation efficiencies,cube utilization and load stability.1.料箱设计料箱设计：Container Design:a.在料箱在料箱/料架订购之前，所有料箱设计提案由物料料架订购之前，所有料箱设计提案由物料、生产、质量、安全和附加小组根据需求进行回顾、生产、质量、安全和附加小组

23、根据需求进行回顾和批准和批准All container design proposals are reviewed and approved by material,production,quality,safety/ergo and additional groups as required before containers/racks are ordered.要求 Requirements:StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovement

24、Built-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time2.料箱内装有的物品须在经核准的标签上明料箱内装有的物品须在经核准的标签上明确显示确显示(零件号，名称，数量等零件号，名称，数量等)Container contents are identified on an approved label(part number,quantity,etc.)3、料箱选择过程文件化且确保选择最高效的料箱。料箱选择过程文件化且确保选择最高效的料箱。Container sele

25、ction process is documented and ensures that the most effective container is selected.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead TimeA,关注于使用手工搬运的料箱。关注于使

26、用手工搬运的料箱。B,频繁运输（例如通常每班数次）决定标准包装数量，且零件必须放满料箱（没有剩余空间）。频繁运输（例如通常每班数次）决定标准包装数量，且零件必须放满料箱（没有剩余空间）。C,要保护完整性的零件需指定使用衬隔。要保护完整性的零件需指定使用衬隔。D,手工搬运手工搬运/移动的料箱的重量必须在本地规范以内。移动的料箱的重量必须在本地规范以内。E,从质量、制造和物料操作提出的需求被收集和反馈。每个班都需要纳入这个过程中。从质量、制造和物料操作提出的需求被收集和反馈。每个班都需要纳入这个过程中。F,分层审核用于检验包装需求和为持续改进寻（即提高料箱装载率、正确尺寸的料箱和标准包装数量）寻找

27、机分层审核用于检验包装需求和为持续改进寻（即提高料箱装载率、正确尺寸的料箱和标准包装数量）寻找机会。会。G,有流程设置定期检查（例如最少每六个月车型年转换）指定的包装是否达到频繁搬运的要求。有流程设置定期检查（例如最少每六个月车型年转换）指定的包装是否达到频繁搬运的要求。H,每个零件都有一个标准包装数量。每个零件都有一个标准包装数量。I,备用料箱备用料箱/一次性使用料箱的尺寸等于或小于可回用料箱。一次性使用料箱的尺寸等于或小于可回用料箱。G,对于提供同一个零件的多加供应商必须使用经过审批的包装。对于提供同一个零件的多加供应商必须使用经过审批的包装。K,对于备用料箱，标准包装数量必须相同。对于备

28、用料箱，标准包装数量必须相同。-Focus on using hand-manageable containers.-Standard pack quantity provides for frequent delivery(e.g.multiple times per shift in most cases)and should fill the container(no air).-Dunnage is assigned where needed to protect the integrity of the part.-Weight of hand-carried/hand-moved

29、containers is within local specification.-Input from quality,manufacturing,and material handling is collected and feedback given.All shifts are involved in the process.-Layered audits are used for verifying packaging requirements and identifying opportunities for continuous improvement(i.e.full cont

30、ainers,right size container and standard pack quantity).-A process is installed to check on a regular basis(at least every 6 months)whether assigned packaging fulfills the guidelines for frequent delivery.-One standard pack quantity per part number exists.-Dimensions for back-up/expendable are the s

31、ame or less than the returnable.-Dual suppliers providing the same part must use the approved packaging.-For the backup container,the standard pack quantity must be the same.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQ

32、ualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time5、尽可能减少或者消除重新包装（翻包尽可能减少或者消除重新包装（翻包装）装）Repacking is minimized/eliminated.4、对于正常生产和所有可销售的生对于正常生产和所有可销售的生产活动，使用指定生产料箱运输物产活动，使用指定生产料箱运输物料。在仓储操作中，对于所有工厂料。在仓储操作中，对于所有工厂而言，最终使用料箱运输物料。要而言，最终使用料箱运输物料。要尽可能使用通用的可回用料箱。尽可能使用通用的可回用料箱。Material is

33、 shipped in the designated production container for regular production and all saleable build events.In warehousing operations,material is shipped in the end-use container for all plant events.Use of common returnable containers is optimized.料箱型号：SCStandardizationStandardizationShort LeadShort LeadT

34、imeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Timec.有清楚的标记便于返回供应商（例如有清楚的标记便于返回供应商（例如料箱型号，供应商名称，料箱对应零件料箱型号，供应商名称，料箱对应零件规格，堆高等）规格，堆高等）clearly marked to facilitate return to suppliers(e.g.container type,suppli

35、er name,part specific containers,stack heights,etc.b.大小合适，且能提供事先的料箱计划大小合适，且能提供事先的料箱计划sized properly and able to accommodate planned quantities of containersd.减少运输距离和标准化作业流程减少运输距离和标准化作业流程located to minimize travel distance and standardize the work flow 6、空箱返回区域：空箱返回区域：Empty container return areas:a.经

36、过目视化清楚的标识（即区域类型经过目视化清楚的标识（即区域类型“筛选筛选”、“存储存储”、供应商、返回计划、准备指示、供应商、返回计划、准备指示等）等）clearly identified with visual controls(i.e.type of area Sort,Stage,supplier,return schedule,preparation instructions,etc.)StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementB

37、uilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Timef.确认损坏的料箱并制定修理确认损坏的料箱并制定修理/处置的方处置的方式式identify and route damaged containers for repair/disposal e.确保在发送供应商之前，空箱中无杂物确保在发送供应商之前，空箱中无杂物assure empty containers are free of debris before shipping them to supplier

38、7、空箱处理准则空箱处理准则Empty container handling practices:a.确保操作工把空箱放置在合适的返确保操作工把空箱放置在合适的返回装置中回装置中assure operator places empty container on appropriate return deviceb.遵循已有的内部衬垫处理流程遵循已有的内部衬垫处理流程conform to a written process for handling internal dunnage c.遵循已有的分类，分级，装卸流程遵循已有的分类，分级，装卸流程conform to a written proc

39、ess for proper sorting,staging,loading,and unloading d.防止料错箱用防止料错箱用prevent misuse of containersStandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time定义：为了能够在均衡

40、基础上有效地提供物料而预定义：为了能够在均衡基础上有效地提供物料而预先确定零部件定购的固定周期先确定零部件定购的固定周期 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 pipelineStand

41、ardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time2、有合适的流程避免零件报废有合适的流程避免零件报废A documented process is in place to avoid obsolete parts1、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

42、的固定周期A fixed period is established for parts ordering and delivery.5、有合适的流程确定系统库存和实际库存一致，以便维有合适的流程确定系统库存和实际库存一致，以便维护零件计划的真实性。护零件计划的真实性。A process is in place to ensure record balance matches physical inventory to maintain part schedule integrity.3、有处理紧急事件的特殊流、有处理紧急事件的特殊流程程An exception process exists

43、to cover emergencies.4、本地管理和维护供应商计本地管理和维护供应商计划和物料的后续跟踪划和物料的后续跟踪Supplier schedules and Material follow-up are managed and maintained locally.要求 Requirements:StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeople

44、InvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time定义定义:精益物流供应商管理有计划的可控的物流流程精益物流供应商管理有计划的可控的物流流程 Definition:Scheduled logistics pipeline with established controls managed by a lead logistics provider.目的目的:为重复性物料的运送提供可预测为重复性物料的运送提供可预测的方法并达到各种资源的最优化的方法并达到各种资源的最优化 purpose:To provide a predictable metho

45、d for frequent material movement that maximizes use of resources.StandardizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Timea.Provides business plan which is integr

46、ated with the Plant Material BPD and includes performance criteria.提供业务计划，应与工厂物提供业务计划，应与工厂物料料BPD结合并包含绩效标准结合并包含绩效标准e.张贴张贴BPD和绩效标准，并定和绩效标准，并定期与工厂回顾（最少每月一次期与工厂回顾（最少每月一次）Posts BPD and performance criteria which is reviewed with the plant(minimum monthly).2.物流联系点负责物流运作物流联系点负责物流运作。Point of contact for Log

47、istics is responsible for operational logistics 1.物流对口部门负责对关键绩效进行考量（物流对口部门负责对关键绩效进行考量（例如：准时配送表现、成本降低、空间利例如：准时配送表现、成本降低、空间利用率等）用率等）Point of contact for Logistics is responsible for and measures key performance criteria(e.g.On time delivery,cost reduction,cube utilization etc.).要求 Requirements:Standar

48、dizationStandardizationShort LeadShort LeadTimeTimeContinuousContinuousImprovementImprovementBuilt-In-Built-In-QualityQualityPeoplePeopleInvolvementInvolvementSGM-GMSSGM-GMSShort Lead Time6.在正确的时间按照正确的数量从供应商处提取在正确的时间按照正确的数量从供应商处提取物料物料Material is picked up from the supplier at the right time and in t

49、he right quantity5.每条路线上是采用即时卸货法还是拖挂车厢每条路线上是采用即时卸货法还是拖挂车厢抛停卸货法是根据经济和交通可靠性来决定的抛停卸货法是根据经济和交通可靠性来决定的Staging trailers in a marshaling area vs.live unloading is determined for each route based on economics and transportation reliability.7.有文件流程并被执行来协调特殊或紧急的有文件流程并被执行来协调特殊或紧急的运输和来正确区分由额外运输费用运输和来正确区分由额外运输费用

50、.A documented process is in place and followed to coordinate special or emergency shipments and to properly classify premium transportation.4.为平衡人员工作量，设备需求及将库存为平衡人员工作量，设备需求及将库存最小化，发运计划应该是均衡的（例如：最小化，发运计划应该是均衡的（例如：每周，每天，每小时每周，每天，每小时Planned delivery windows are level(i.e.hour-to-hour,shift to shift,day