《美鋁公司精益制造》ppt課件

1、AVIC1_ALCOA_1AddCourse IconHereAVIC1 Senior Executive SeminarSharing Strategies for SuccessOur Collective Opportunity inIntegrated Global Supply ChainsAVIC1_ALCOA_2AddCourse IconHere中航一集團高級管理人員研討會共享勝利戰(zhàn)略我們在全球綜合供應(yīng)鏈中我們在全球綜合供應(yīng)鏈中共同的時機共同的時機AVIC1_ALCOA _3Agenda Focusing, Aligning and Integrating to Deliver

2、 Best Value Mary Armstrong, Boeing Commercial Airplanes Vice President and General Manager Fabrication Division Program Management Theory Versus Practice: Practical TipsDon Carlisle, Boeing Commercial Airplanes Managing Director, Wichita Division, Tulsa Business Unit Our Collective Opportunity in In

3、tegrated Global Supply Chains Bob Wetherbee, Alcoa President, Alcoa Mill Products AVIC1_ALCOA _4議程議程 集中、一致以及整合以交付最正確價值集中、一致以及整合以交付最正確價值 瑪麗瑪麗阿姆斯特朗，波音民機集團阿姆斯特朗，波音民機集團 副總裁兼制造部總經(jīng)理副總裁兼制造部總經(jīng)理 工程管理實際與實際工程管理實際與實際: 適用技巧適用技巧 唐唐卡萊爾，波音民機集團卡萊爾，波音民機集團 塔爾薩業(yè)務(wù)部，威奇托部執(zhí)行總監(jiān)塔爾薩業(yè)務(wù)部，威奇托部執(zhí)行總監(jiān) 我們在全球綜合供應(yīng)鏈中共同的商機我們在全球綜合供應(yīng)鏈中共同的商

4、機 鮑勃鮑勃威瑟比，美國鋁業(yè)公司威瑟比，美國鋁業(yè)公司Alcoa 美鋁軋制產(chǎn)品公司總裁美鋁軋制產(chǎn)品公司總裁AVIC1_ALCOA _5Realize Best Value Across the Supply Chain For Customers and Suppliers“We work on our collective systems together to achieve the goal of making Boeing products the most competitively priced in the world.Bob Wetherbee President, Alcoa

5、Mill ProductsAVIC1_ALCOA _6實現(xiàn)供應(yīng)鏈中客戶和供應(yīng)商的最正確價值實現(xiàn)供應(yīng)鏈中客戶和供應(yīng)商的最正確價值“我們共同努力于結(jié)合的體系，以實現(xiàn)波音產(chǎn)品成為世界我們共同努力于結(jié)合的體系，以實現(xiàn)波音產(chǎn)品成為世界上最具價錢競爭力產(chǎn)品這一目的。上最具價錢競爭力產(chǎn)品這一目的。鮑勃鮑勃韋瑟比韋瑟比 美鋁軋制美鋁軋制產(chǎn)品公司總裁產(chǎn)品公司總裁AVIC1_ALCOA _7Alcoa Moved From Vision to Best Value in Four YearsVisionCreated20002004Strategy Developed2001Phase 1Pilot withBo

6、eing fuselage20022003Additional Resources DeployedPhase 4 Extended to new markets, customers and their suppliersContinued waste elimination and system expansionExtending the system to include our suppliers Phase 2Implemented withBoeing wingsPhase 3Extended toBoeing standard plateUnderstanding System

7、 PotentialCapturing System ValueTimeline:Alcoas Integrated Global Supply ChainAVIC1_ALCOA _8美鋁在四年內(nèi)從遠景目的走向最正確價值美鋁在四年內(nèi)從遠景目的走向最正確價值制定遠制定遠景目的景目的20002004制定戰(zhàn)略制定戰(zhàn)略2001第一階段第一階段以波音機身以波音機身為試點為試點20022003部署更多部署更多資源資源第四階段第四階段 擴展到新市場、客擴展到新市場、客戶及其供應(yīng)商戶及其供應(yīng)商繼續(xù)消除浪費繼續(xù)消除浪費并擴展體系并擴展體系延伸體系以延伸體系以包括我們的包括我們的供應(yīng)商供應(yīng)商 第二階段第二階段從波

8、音機翼從波音機翼開場實施開場實施第三階段第三階段擴展到波音規(guī)范板材擴展到波音規(guī)范板材了解體系潛能了解體系潛能獲取體系價值獲取體系價值時間線：時間線：美鋁的全球綜合供應(yīng)鏈美鋁的全球綜合供應(yīng)鏈AVIC1_ALCOA _9A Phased Approach to Change Showed Immediate Results Poor delivery performance Unpredictable flow times High inventory stock levels 50% of orders expedited Problems and waste were hidden withi

9、n the old system On-time and predictable delivery Consistent flow times Reduced inventory stock level Less than 10% of orders expedited High visibility of problems and waste improvement opportunitiesResults of Old SystemResults of Integrated SystemPhase 3: Boeing ExampleAVIC1_ALCOA _10分階段進展變革的方法立刻顯示

10、出效果分階段進展變革的方法立刻顯示出效果 交付績效差 流程時間不可預(yù)知 庫存量高 50% 的訂單加急完成 原有系統(tǒng)中隱藏了問題和浪費 按時、可預(yù)測的交付 流程時間穩(wěn)定 庫存量降低 不到10%的訂單加急完成 問題和浪費的改善時機可視性高原有系統(tǒng)的結(jié)果原有系統(tǒng)的結(jié)果整合后系統(tǒng)的結(jié)果整合后系統(tǒng)的結(jié)果第三階段：第三階段： 波音舉例波音舉例AVIC1_ALCOA _11Dramatic Improvement Seen inOn-time Delivery Delivery Performance DataTarget: 97%System start date40.0%50.0%60.0%70.0%8

11、0.0%90.0%100.0%Feb-03Mar-03Apr-03May-03Jun-03Jul-03Aug-03Sep-03Oct-03Nov-03Dec-03Jan-04Feb-04Mar-04Apr-04Phase 3: Boeing ExampleAVIC1_ALCOA _12在按時交付方面發(fā)生了艱苦改動在按時交付方面發(fā)生了艱苦改動 Delivery Performance DataTarget: 97%System start date40.0%50.0%60.0%70.0%80.0%90.0%100.0%03年2月03年3月03年4月03年5月03年6月03年7月03年8月03年9

12、月03年10月03年11月03年12月04年1月04年2月04年3月04年4月第三階段：第三階段： 波音舉例波音舉例AVIC1_ALCOA _13Begin by Drawing Current System of Material FlowIngot PlantHot Line Finished SawsCustomer Receiving Pre-saw processesShipping123410-12 Week Lead Times Order EntryCustomer Service Customer Usage and OrderingAlcoa Order Fulfillme

13、nt Customer Places Orders 10-16 weeks in advanceRandomOrdersMachining ProcessesHigh Inventory Level=Phase 4 Example28 Sizes28 Plates28 Plates28 Products28 PlatesAVIC1_ALCOA _14從畫出當(dāng)前系統(tǒng)的資料流開場從畫出當(dāng)前系統(tǒng)的資料流開場鋁錠廠鋁錠廠高溫消費線高溫消費線 完工后切割完工后切割客戶接納客戶接納切割前工藝切割前工藝運輸運輸123410-12 周的交貨期周的交貨期 接納訂單接納訂單客戶效力客戶效力 客戶用途和訂貨客戶用途

14、和訂貨美鋁訂單完成情況美鋁訂單完成情況 客戶提早客戶提早10-16周下訂單周下訂單隨意訂單隨意訂單機加工藝機加工藝高庫存量高庫存量 =第四階段舉例第四階段舉例28 種種尺寸尺寸28 種種板材板材28 種種板材板材28 種產(chǎn)品種產(chǎn)品28 種種板材板材AVIC1_ALCOA _15Focus on Customer Usage Versus Customer Orders Customer Usage and Ordering CustomerProductionPlanningUnleveled demand to AlcoaOrders not linked to machine usageP

15、urchase orders arrive unpredictablyHigh Inventory LevelComplex and multiple forecasting processes Frequent change orders1234ReceivingRandomOrdersMachining ProcessesAVIC1_ALCOA _16注重客戶的用途，而不是客戶的訂單注重客戶的用途，而不是客戶的訂單 客戶運用和訂購客戶運用和訂購 客戶消費客戶消費方案方案 對美鋁的需求不分層次對美鋁的需求不分層次 訂單未與機加用途聯(lián)絡(luò)起來訂單未與機加用途聯(lián)絡(luò)起來 無法預(yù)知何時收到購買訂單無法

16、預(yù)知何時收到購買訂單高庫存量高庫存量 復(fù)雜和多重預(yù)測流程復(fù)雜和多重預(yù)測流程 頻繁變卦訂單頻繁變卦訂單1234接納接納隨意隨意訂單訂單機加工藝機加工藝AVIC1_ALCOA _17Old System Provided No Visibility of Actual Customer Usage Alcoa Order Fulfillment Processes not tightly connected Inventories not engineeredIngot PlantHot LineFinish SawsPre-sawPlate MillShippingOrder EntryAVIC

17、1_ALCOA _18原有系統(tǒng)無法提供客戶實踐用途的可原有系統(tǒng)無法提供客戶實踐用途的可視性視性美鋁履行訂單美鋁履行訂單 工藝并未嚴(yán)密聯(lián)絡(luò)起來工藝并未嚴(yán)密聯(lián)絡(luò)起來 未設(shè)計好庫存未設(shè)計好庫存鋁錠廠鋁錠廠高溫消費線高溫消費線完工后切割完工后切割切割前板材銑切切割前板材銑切運輸運輸訂單接納訂單接納AVIC1_ALCOA _19New Pull System Connected Alcoa and Customer ProcessesHot LineReceivingPre-sawProcesses6 sizes3 Day Lead Time Supply Chain Management Innova

18、tions of new system: Built-in tests Help chain for problem solving Kanban boards for store replenishment Ingot PlantFinish SawsShippingDailyOrders6 Plates28 Plates1234Machining ProcessesDaily Use Data Signal28 ProductsAVIC1_ALCOA _20新型拉動式系統(tǒng)將美鋁和客戶工藝聯(lián)新型拉動式系統(tǒng)將美鋁和客戶工藝聯(lián)絡(luò)起來絡(luò)起來高溫消費線高溫消費線接納接納切割前工藝切割前工藝6種種尺寸

19、尺寸三天的交貨期三天的交貨期供應(yīng)鏈管理供應(yīng)鏈管理 新系統(tǒng)的創(chuàng)新性：新系統(tǒng)的創(chuàng)新性： 自測自測 處理供應(yīng)鏈的問題處理供應(yīng)鏈的問題 補充儲存量的看板補充儲存量的看板 鋁錠廠鋁錠廠完工后切割完工后切割運輸運輸每日每日訂單訂單6種板材種板材28種板材種板材1234機加工藝機加工藝每日運用每日運用數(shù)據(jù)信號數(shù)據(jù)信號28 種產(chǎn)品種產(chǎn)品AVIC1_ALCOA _21New System ProvidedImmediate ResultsIncreased on-time delivery from 65% to 97%Reduced customer inventory by 65%Reduced chang

20、e orders from 4500 per year to less than 10 per yearIncrease visibility of problems and waste improvement opportunitiesSmoothing flow of orders for just-in-time deliveryReduced weekly variation in product demand by 67%Results of the New SystemAVIC1_ALCOA _22新系統(tǒng)立刻顯示出效果新系統(tǒng)立刻顯示出效果按時交付率從按時交付率從 65%提高至提高至

21、 97%客戶庫存減少了客戶庫存減少了 65%變卦訂單從每年變卦訂單從每年4500份降低為每年不份降低為每年不到到10份份提高了問題的可視性，添加了改良浪提高了問題的可視性，添加了改良浪費的時機費的時機理順了恰時、恰物、恰量交付的訂貨理順了恰時、恰物、恰量交付的訂貨流程流程產(chǎn)品需求的每周變化降低了產(chǎn)品需求的每周變化降低了67%新系統(tǒng)的效果新系統(tǒng)的效果AVIC1_ALCOA _23New System Resulted in Reduced Costs and Improved ProfitabilityReduced Variation Product Demand New System Sta

22、rt Date Pieces Pulled Each WeekTime in WeeksAVIC1_ALCOA _24新系統(tǒng)使本錢降低、盈利才干添加新系統(tǒng)使本錢降低、盈利才干添加產(chǎn)品需求的變化減少產(chǎn)品需求的變化減少 新系統(tǒng)啟動日新系統(tǒng)啟動日 每周拉動的件數(shù)每周拉動的件數(shù)星期數(shù)星期數(shù)AVIC1_ALCOA _25Success Requires a New Role for the LeaderAVIC1_ALCOA _26勝利需求指點履行新角色勝利需求指點履行新角色AVIC1_ALCOA _27Executive Sponsorship is Critical to Success Creat

23、ing a system vision for integrated global supply chains Changing the traditional procurement philosophy Driving deeper alignment of all supply chain participants Increase communication between all supply chain partners Ongoing dedication to change and continuous improvement of the systemExecutive Sp

24、onsorship RequiresAVIC1_ALCOA _28高級管理人員的支持對勝利至關(guān)重要高級管理人員的支持對勝利至關(guān)重要 制定全球綜合供應(yīng)鏈體系的遠景目的制定全球綜合供應(yīng)鏈體系的遠景目的 改動傳統(tǒng)的采購理念改動傳統(tǒng)的采購理念 驅(qū)使一切供應(yīng)鏈參與者更嚴(yán)密的協(xié)作驅(qū)使一切供應(yīng)鏈參與者更嚴(yán)密的協(xié)作 加強供應(yīng)鏈一切協(xié)作同伴之間的溝通加強供應(yīng)鏈一切協(xié)作同伴之間的溝通 不斷進展變革，不斷改良體系不斷進展變革，不斷改良體系高級管理人員的支持需求高級管理人員的支持需求AVIC1_ALCOA _29Current Supply Chain Offers Opportunities for Improve

25、mentSupply Chain Improvement Opportunities: Delivery Performance Lead times Quality Inventory Communication and information flowsAVIC1_ALCOA _30當(dāng)前的供應(yīng)鏈有改良時機當(dāng)前的供應(yīng)鏈有改良時機供應(yīng)鏈的改良時機：供應(yīng)鏈的改良時機： 交付績效交付績效 交貨期交貨期 質(zhì)量質(zhì)量 庫存庫存 溝通和信息流溝通和信息流AVIC1_ALCOA _31Alcoa Aerospace Center Shanghai : Local presence Evolves into

26、essential point in supply chain Enables more reliable performance Provides direct visibility Offers just-in-time, point-of-use delivery for cut to size servicesShanghai Becomes Key Point in Integrated Global Supply ChainsChinaXianShanghaiChengduAVIC1_ALCOA _32美鋁上海宇航中心：美鋁上海宇航中心： 當(dāng)?shù)貥I(yè)務(wù)當(dāng)?shù)貥I(yè)務(wù) 演化為供應(yīng)鏈的重要點演化為供應(yīng)鏈的重要點 績效更可靠績效更可靠 提供直接可視性提供直接可視性 為切割到用戶所需的適宜尺寸提供適時配送以及配料到運用地點為切割到用戶所需的適宜尺寸