精益生产工具（英文PPT22

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1、Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,,,*,Tenants ofSingle Piece Flow,,Do NotMake,Defects,Do NotPassAlong,Defects,Do NotAccept,Defects,,ZeroDefects =0 DefectsNot 3.4ppm,Quality, Quality, Quality,…,…Defects are the Worst Ki

2、nd ofWaste,7 Types ofWaste,DefectiveParts,OverProduction,Inventory,Motion,Transportation,Waiting,Manual Touches,,,,Batch,Single Piece Flow,From:,The ToyotaProduction System,Building Quality into theProcess,Single Piece Flow,The next process isthe customer …neversenddefects !,Sample Inspectcatches De

3、fecttoo Late,Whenyou Finally Find a Defect,How many more do youhave?,Wherearetheyin the process?,Whatis the root Cause?,Single Piece Flow catchesDefects immediately,Whenyou find aDefect,You only have one,You know whereit occurred,You Can find/ResolvetheRootCauseimmediately,,,Check, Do,Verify,,Check-

4、 Thepreviousoperatorswork.,Do- Your work.,Verify- That youdidyourworkcorrectly.,,,Process,Inspect,Transport,Transportationis integrated into the production process,via automatione.g.,moving line,Process,Inspect,Process,Inspect,Transport,Process,Inspect,Transportationis integrated into the production

5、 process,via humanconveyancee.g., Chaku-Chaku,Building Quality into theProcess,2 ways toperform SPF,The next process isthe customer …neversenddefects !,,,Check, Do,Verify,Getsyou into PartsPer Million quality-,Whenyou verifyyourwork, youcatch 1 flaw in 100parts. The next personchecks your work andc

6、ancatch1/100 sothat’s 1/10,000. Then that personVerifies theirworkand can catch 1/100.That’s 1/1,000,000errors that can getthrough.,,,Check, Do,Verify,EveryCustomerin aProcess has:,- a rightto expectperfect material,- anobligationto inspect the materialbefore use.,- anobligationto inform the previo

7、us stepin the process of any problem.,- anobligationto stoptheprocessuntil any problem has been resolved.,,,Single pieceoronepiece flow is ameans toprimarily build,Qualityintotheprocess. This is achieved by establishing atakt,Time, developingstdwork, and swip.Thepremiseisthatan,Operatorcanonly work

8、on one pieceat atime, and performsa,Quickquality check on theCTQs of theprocess beforemoving,Theparttothefollowing process. If adefect is detected,Jidoka,Isenacted…theline is stopped, andimmediateaction is taken,Toremediatethe situationandtakecountermeasurestoprevent,reoccurence,Takt time,Stdwork,,F

9、low:,work (process)that is doneinconjunctionwithor,simultaneoustotransportation,,,OnePieceFlow,Theproductionisorganizedintoa synchronous chain where eachperson hasa,balanced,amountofworkrelativetohis/her supplier andcustomerinthechain.,Asoneperson finishes their element, so do all.Workisthen moved d

10、ownthe linesynchronously.,Everypersonisempowered to stopthe productionprocessifa rejectisspotted.,,,Organization,Area,Supervisor,New/Rev,Page,of,Date,Production Line,Part Number,Part Name,Operator,StandardWork Sheet,To:,Turns,DPU's,Scope of Operations,From:,Quality,Check,Safety,Precaution,Standard,W

11、ork-in-Process,# Lots of,Standard,Work-in-Process,Takt/Rate,Time,Total Manual & Travel Time,Man/Travel Time,Operator,End Finish,Weld,End Finish,Weld,Orbital,Weld,HydroTest,Mark,Mech.,Clean,Torch,Braze,,,,,Tubing,CFM Cell,FernBissonnette,Cell6,All Parts,All Tubes,11,Mech.,Clean,Raw material,Weld,100/

12、Day,FPI,X-Ray,EDM,2nd Qtr. ‘01,End,Finish,,,,Outside Cell,27 -avg lot =6,Flex,Finished Goods,ACTION WORKOUT,g,GEMSGlobal Production System,The next process isthe customer …neversenddefects !,Check, Do,Verify,,,One PieceFlow,Yourcustomer is thenextstepin the process. Give toyourcustomer,exactly what

13、they need (1 item), exactly when they need it,doneperfect everytime.,,,,,Tenants of1 pcs Flow,,Do Not Make Defects,Do Not Pass Along Defects,Do Not Accept Defect,Quality, Quality, Quality,…,…Defects are the Worst Kind ofWaste,,,System ofmanufacturing in which the final process,withdrawsthe partsit n

14、eeds from the preceding,process atexact timing intervals,in the exact,standardizedamountneeded.,PullProductionMethodology&Sequence,Definition,Ref,MaterialPresentation,trainingforexplanationonSupermarketdefinitionanduse,,,Parts,1,3,4,5,6,7,8,9,10,2,AssemblyLine,CellorChaku-Chakuline,Supplier,Material

15、,Information,Supermarket,Empty container,Full container,Legend,1,Sequence / Timing,PullProductionMethodology&Sequence,,,,,,JIT,Jidoka,,e,GPS,for,GPC,,,Heijunka,LevelLoading,Sequencing,Findingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacity,Adjustingaproductionscheduletomeet

16、unexpectedchangesincustomerdemand,OrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitems,takenfrommemoryJogger,,,Leveledproductionmeansloweringthepeaksamongthedailyproductionvolumesasmuchaspossibleandmakingtheproductionflowsmoothandunflucuating.Ingeneral,themorefluctuationsyouinthepro

17、ductionflow,themoremudayouenduphaving.Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand.Iftheproductionlineproducesonlyasingleproduct,youmaybeabletoreducemudasimplybyadjustingtheproductionscheduleandstaffinglevel.Butifyouwantto

18、produceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline,,youhavetodotheaveragingnotjustinvolumebutinkindsaswell,.Thiswayofaveragingbothvolumeandinkindsiscalledproduction,leveling,or,heijunka,inJapanese.,LeveledProduction,Amount of products that can be sold,H

19、EIJUNKA,Average by total volume,Average by model,,,LeveledLoadProduction,Buildtoforecast,BuildtoFGinv,Buildafterorderisreceived,ALLcomponentsneed to,bestocked in RM,Anorderfrom these,products,takesprecedence over1-2-3,products,…,… build thisfirst!,Use Stocks,Build Stocks,TAKT,%,,,,,,F1,F1,F1,F

20、1,F1,F1,F2,F2,F2,F2,F2,F2,,,,,,,,,,,TAKT Time,Determined by PSI,2Q,3Q,4Q,OktoBuildtoFG,Repeatable Products,Non-RepeatableProducts,,,Need to Determine. ..,HowMuch,20bulbsperday,,,What Kind,15/60Watts,5/100Watts,,When,5 -60W, 2,–,–100W, 5,–,–60W,,2 –200W,5 –60W, 1,–,–100W,TAKT,,,LevelLoad Mi

21、x,,,LevelLoad Sequence,Ifwewere makinglightbulbs...,Quarterly,,,Weekly,,,Weekly,Frequency,60,60,60,60,60,100,100,60,60,60,60,60,100,100,60,60,60,60,60,100,Takt Time,=,Operatingtimeperday,Production requirement perday,Assumptions:,MachineBreakdown=0hour,Se,tupChange=0hour,DefectRate=0%,,TaktTimeEquat

22、ion,FormoreinformationonTAKT,–,–RefertoJITSection,QuickExample,,,SettingtheproductionsequenceofmultipleTRAM,–,–RACTypes(MedSystemsProduct),Product,MonthlyRequirement,DailyRequirement,TAKT Time,Model 1,720 units,24 units,5 min,Model 2,360 units,12 units,10 min,Model 3,360 units,12 units,10 min,Tota

23、l,1440 units,48 units,7.5 min,Thisisdatafor3products,Model1,Model2,andModel3,areproducedatGEMS.Thechartdisplaysthemonthlyproductionlevel,thedailyproductionlevel(monthlydividedby30),andtheTakttimeforeachproducttype.,THEYARE ALL PRODUCED ONTHE SAME LINE.,How can these unitsbe built in a levelproductio

24、nmodeusing this example?,Model1,Model2,Model3,Detailed Example,,,,Sincethese three products areon the same line, you will need tofollow the sequencepattern of 1-2-1-3in your production mix. By doing itthiswayyou are able tolevel-load your production both interms ofquantity and types.,# 1 –Prod1,# 4

25、–Prod3,# 2 –Prod2,# 3 –Prod1,REPEAT,MixedAssemblyLine,ProductionSequenceby Type,If produced inbatches, only the Model 1,’,’s will meet Takt times,If produced toa sequence, 2 unitswillbe produced in2 Takt times,Let’sshowhowwe validate this…,,,Model,Line,Takt,Takt/Cycle,Graph,Part- Quantity,PartRouter

26、,1,3,2,7.5,7.5,7.5,See Std Work Combo Sheetfor example. One sheet is createdfor each operator,S,CT,=25,S,CT,=40,S,CT,=30,7,6,6,6,7,6,13,8,12,7.5,9,7.5,,,TaktBuildTime,= # of Operations *Takt,Actual Build Time,=S,CT,1,30,2,30,3,30,1,25,2,40,3,30,Model,TBT,Model,ABT,,1,-5,2,+10,3,0,Model,Objectives:

27、,Produce toTaktTime,(understandingno 2products will have the exact same ABT),The sum ofthe,D,Tot,is zero,Everyproduct is produceat least once,No productis produced twice in a row,Create a product sequencewhere:,D,tot,=,S,(# ofUnits insequence*,D,),D,tot,= -5(# of1’s)+10(#of 2’s)+0(# of3’s),0 = -5(2)

28、+10(1)+0(1),In each sequence will containone Model1, two Model 2s, and1 Model 3),Accordingto the rules the sequencemustrun:,Model1 –Model2 –Model1 –Model3,,,Guiding Principles:GPS Level-loading,Purpose:,To provideguidelines fordeveloping themethod and tools tolevel-scheduletheshopfloor.,,Key Element

29、s ofLevel-scheduling,Productionunits are,stratifiedaccordingto planned sales volume,The productionsequence combines,bothorders andforecast,Sequence is designedto achieve,the combined TAKT time for allitems,Eliminating production rate variance isrequired to achieveTAKTtime,Onlybuildhighvolume product

30、s,(top80%)to FGinventory, iforders arenotavailable,FG inventory levelsare,NOT targeted,, buta resultof TAKT time &orders flow,Lower-level group items are NOT sequenced withoutfirmorders,HoldRM components inventory only for low volume items.These are items that you can,’,’t build untilyou have an ord

31、er,Fillorders,first,fromFG,,second,WIP,&,third,sequence them (attach theorder tothe productionplan),,,9,、静夜四无,邻,邻，荒居旧,业,业贫。。11月-2211月-22,Saturday,November 5, 2022,10,、雨中黄叶,树,树，灯下白,头,头人。。11:30:4011:30:4011:30,11/5/202211:30:40 AM,11,、以我独,沈,沈久，愧,君,君相见频,。,。。11月-2211:30:4011:30,Nov-2205-Nov-22,12,、故人江,海

32、,海别，几,度,度隔山川,。,。。11:30:4011:30:4011:30,Saturday, November 5, 2022,13,、,乍,乍,见,见,翻,翻,疑,疑,梦,梦,，,，,相,相,悲,悲,各,各,问,问,年,年,。,。,。,。11,月,月-2211,月,月-2211:30:4011:30:40,November5,2022,14,、,他,他,乡,乡,生,生,白,白,发,发,，,，,旧,旧,国,国,见,见,青,青,山,山,。,。,。,。05,十,十,一,一,月,月202211:30:40,上,上,午,午11:30:4011,月,月-22,15,、比不了得,就,就不比，得,不,不

33、到的就不,要,要。。。十一月 2211:30,上,上午11月-2211:30,November 5, 2022,16,、行动出成,果,果，工作出,财,财富。。2022/11/511:30:4011:30:40,05 November 2022,17,、做前，能,够,够环视四周,；,；做时，你,只,只能或者最,好,好沿着以脚,为,为起点的射,线,线向前。。11:30:40 上,午,午11:30,上,上午11:30:4011月-22,9,、没,有,有失,败,败，,只,只有,暂,暂时,停,停止,成,成功,！,！。11,月,月-2211,月,月-22,Saturday,November5,2022,1

34、0,、很多,事,事情努,力,力了未,必,必有结,果,果，但,是,是不努,力,力却什,么,么改变,也,也没有,。,。。11:30:4011:30:4011:30,11/5/202211:30:40AM,11,、成功就,是,是日复一,日,日那一点,点,点小小努,力,力的积累,。,。。11月-2211:30:4011:30,Nov-2205-Nov-22,12,、世间成,事,事，不求,其,其绝对圆,满,满，留一,份,份不足，,可,可得无限,完,完美。。11:30:4011:30:4011:30,Saturday, November 5, 2022,13,、不知香积,寺,寺，数里入,云,云峰。。11月

35、-2211月-2211:30:4011:30:40,November 5, 2022,14,、意志坚强,的,的人能把世,界,界放在手中,像,像泥块一样,任,任意揉捏。05 十一,月,月 202211:30:40 上,午,午11:30:4011月-22,15,、,楚,楚,塞,塞,三,三,湘,湘,接,接,，,，,荆,荆,门,门,九,九,派,派,通,通,。,。,。,。。十,一,一,月,月2211:30,上,上,午,午11,月,月-2211:30,November5,2022,16,、,少,少,年,年,十,十,五,五,二,二,十,十,时,时,，,，,步,步,行,行,夺,夺,得,得,胡,胡,马,马,骑,

36、骑,。,。,。,。2022/11/511:30:4011:30:40,05November2022,17,、空山新雨,后,后，天气晚,来,来秋。。11:30:40 上,午,午11:30,上,上午11:30:4011月-22,9,、杨柳散和,风,风，青山澹,吾,吾虑。。11月-2211月-22,Saturday,November 5, 2022,10,、阅读一切,好,好书如同和,过,过去最杰出,的,的人谈话。11:30:4011:30:4011:30,11/5/202211:30:40 AM,11,、越是没,有,有本领的,就,就越加自,命,命不凡。11月-2211:30:4011:30,Nov-

37、2205-Nov-22,12,、越是无,能,能的人，,越,越喜欢挑,剔,剔别人的,错,错儿。11:30:4011:30:4011:30,Saturday, November 5, 2022,13,、知人,者,者智，,自,自知者,明,明。胜,人,人者有,力,力，自,胜,胜者强,。,。11月-2211月-2211:30:4011:30:40,November5,2022,14,、,意,意,志,志,坚,坚,强,强,的,的,人,人,能,能,把,把,世,世,界,界,放,放,在,在,手,手,中,中,像,像,泥,泥,块,块,一,一,样,样,任,任,意,意,揉,揉,捏,捏,。,。05,十,十一月202211:

38、30:41,上,上午11:30:4111月-22,15,、最,具,具挑,战,战性,的,的挑,战,战莫,过,过于,提,提升,自,自我,。,。。十一,月,月2211:30,上,上午11,月,月-2211:30,November5,2022,16,、业余生,活,活要有意,义,义，不要,越,越轨。2022/11/5 11:30:4111:30:41,05 November2022,17,、一个人,即,即使已登,上,上顶峰，,也,也仍要自,强,强不息。11:30:41,上,上午11:30 上午11:30:4111月-22,,MOMODA POWERPOINT,Lorem ipsum dolor sit amet, consectetur adipiscing elit. Fusce id urna blandit, eleifend nulla ac, fringilla purus. Nulla iaculis tempor felis ut cursus.,感谢您的,下,下载观看,专家告诉,