精益生產之2箱補充拉系統(tǒng)2BinReplenishmentPull中課件

03十二月2022精益生產之2箱補充拉系統(tǒng)2BinReplenishmentPull(中01十二月2022精益生產之2箱補充拉系統(tǒng)2BinRep12-Bin

補充拉系統(tǒng)2-箱補充拉系統(tǒng)的介紹線旁VS使用點庫存2-箱數(shù)據(jù)的要求和計算庫存部署選擇卡觸發(fā)2-箱流程1-箱系統(tǒng)附錄RD0112022-Bin

補充拉系統(tǒng)2-箱補充拉系統(tǒng)的介紹RD011202LeanSixSigma

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ImprovementPr3LearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentouseabinSystemBeabletosize(calculate)alltheparametersforabinsystem4LearningObjectivesUnderstand4課程目的理解箱補充系統(tǒng)的不同類型知道一個箱系統(tǒng)的好處理解何時使用一個箱系統(tǒng)能夠去計算一個箱系統(tǒng)的所有參數(shù)5課程目的理解箱補充系統(tǒng)的不同類型55What’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystem6What’sinItforMe?Beableto6我學到了什么?能夠在黑帶項目中應用這個工具能夠實施一個箱系統(tǒng)7我學到了什么?能夠在黑帶項目中應用這個工具772-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofastandardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedpartsPurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartreplenishmentis“triggered”basedonconsumption82-BinReplenishmentPullIntro82-箱補充拉系統(tǒng)的介紹2-箱補充拉系統(tǒng)是一個標準的補充拉系統(tǒng)的簡化版本，其好處是：在一個流程中建立戰(zhàn)略性的零件緩沖區(qū)原材料制造的零件采購的零件成品通過緩沖庫存將供應過程和消耗過程聯(lián)系起來零件的補充是基于消耗而觸發(fā)的92-箱補充拉系統(tǒng)的介紹2-箱補充拉系統(tǒng)是一個標準的補充拉系統(tǒng)9WhatIsa2-BinReplenishment?Formanypartsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedperiodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe“1st”isbeingrefilled/replenished.Therearetwoprimaryreplenishmentlocations:Line-SideandPointofUse10WhatIsa2-BinReplenishment?102-箱補充拉系統(tǒng)是什么?對于在流程中的眾多零件而言，一個2-箱系統(tǒng)可以被用來補充零件相對于同步供應:一箱有足夠零件/供應品以滿足在使用點上已計算出的用量周期。當?shù)谝幌溆猛炅撕?，在補充/重新裝料時，第二箱取代第一箱的位置繼續(xù)滿足使用。有兩個主要的補充地點：線旁和使用點112-箱補充拉系統(tǒng)是什么?對于在流程中的眾多零件而言，一個2-11Benefitsof2-BinReplenishmentOrganizedandoverallcleanerappearanceofstoredmaterialsReducedfrequencyoforderssubmittedtothestockroom/vendorReducednumberoftripsforre-supplyBettermanagementofinventoryontheshopfloorMorepredictableinventorycostsImproveemployeeproductivityby:Eliminatingpart/supplyshortagesatthepoint-of-useReducetimewastedbypersonnel/supervisionretrievingsupplies/inventoryfromthestockroomand/orvendorsEliminatelostormisplacedmaterial2-BinReplenishmentcanbeusedforoffice/safetysupplies,productioninventory,productionsupplies–evenathome!12Benefitsof2-BinReplenishmen122-箱補充拉系統(tǒng)的好處存儲的材料外觀非常清潔和有條理提交給庫房/供應商的頻率減少重復供應的差錯數(shù)量減少了現(xiàn)場庫存的管理更好庫存成本更具有預測性提高員工生產率:排除在使用點的零件/供應短缺減少由于人員/管理等，從庫房和/或供應商重新找回供應/庫存的時間浪費排除材料的丟失或放錯地方2-箱補充可以被使用在辦公室，安全供應，生產庫存，生產供應—甚至在家里!132-箱補充拉系統(tǒng)的好處存儲的材料外觀非常清潔和有條理1313WhentoUse2-BinReplenishmentPullRepetitiveproductoffering/processRelativelyconsistentdemand/volume(lowvariability)Part/supplyshortagesareaconsistent/costlyproblemPart/supplyinventorycostsare“outofcontrol”dueto:Lostormisplacedparts/suppliesLackofissue/dispersaldisciplineorcontrol14WhentoUse2-BinReplenishmen14何時使用2-箱補充拉系統(tǒng)重復的產品供應/流程重復穩(wěn)定的需求(底變異)零件/供應短缺是常事，且是一個代價很大的問題零件/供應庫存成本是失控的，由于：零件/供應品丟失或放錯地方缺乏投料/分發(fā)的一致性或控制15何時使用2-箱補充拉系統(tǒng)重復的產品供應/流程1515WhatIsaBin?Doesn’tnecessarilylooklikea“bin”Canbeastandardplasticbin(Acro-bin)Canalsobethebox/containerthepart/supplyisshippedin(alsocalleda“standardpack”–purchasingdefinition)Whenthebox/containermethodisused,a“bin”canbeonestandardpackorseveralstandardpacks.Examples:1boxofscrews2boxesofscrews1drumofoil30bagsofconnectors1rolloflabels4tubesofsealant16WhatIsaBin?Doesn’tnecessar16一箱是什么?這并不是說一定要看上去像個“箱子”它可以是一個標準的塑料箱它也可以是用于零件運輸?shù)囊粋€盒子或容器(也可以用采購的定義被稱為一個“標準包”)當盒子/容器方式使用了后,一個“箱”可以是一個標準的包或幾個標準包。例如：1盒螺釘2盒螺釘1打油30包連接器1卷標貼4管子密封劑17一箱是什么?這并不是說一定要看上去像個“箱子”17172-BinReplenishmentDataParameters/NeedsDemand/Usage(DMD)TypicallyexpressedintermsofAverageDailyUsage(ADU)inunitsLeadTime(LT)ThetimeittakesfromwhenatriggerissenttowhenreplenishmentarrivesInthiscase,canalsobethoughtofas“RestockingTime”O(jiān)rderFrequency(OF)Iforders/triggersaresentatscheduledtimes(i.e.,noteveryday,suchasonceperweek)Typical2-BinsystemsdonotuseanOrderFrequency,asreplenishmentcanoccureveryday/shift(ormore)Box/ContainerQuantityIfstock/supplyroomorvendordoesnotbreakdownshippingquantity,thenthebinquantitymaybesetequaltosomemultipleofthebox/containerquantity(standardpack)thatthepart/supplyisshippedinSafetyStockTypically1/2themax(LT,OF)*DMD,maybesetotherwisedependentonindividualconditions182-BinReplenishmentDataParam182-箱補充系統(tǒng)數(shù)據(jù)

參數(shù)/要求需求/使用(DMD)一般來說用平均每天用量（ADU）來表達交貨期(LT)從補充需求觸發(fā)到補充品到達的時間。在這里，也可以被認為是“再進貨時間”。訂單頻率(OF)如果訂單/觸發(fā)信號的發(fā)放是按預定時間（如：并不是每天，而是每周一次）2-箱系統(tǒng)是不需要用訂單頻率的。補充可以發(fā)生在每天、每班（或更多）盒子/容器數(shù)量如果庫房或供應商沒有列出運輸數(shù)量的明細分類，那么箱數(shù)量可以設定為等于運送零件/供應品的若干盒子/容器數(shù)量安全庫存一般來說的設定為1/2max(LT,OF)*DMD,否則根據(jù)獨立的情況來看192-箱補充系統(tǒng)數(shù)據(jù)

參數(shù)/要求需求/使用(DMD)1919StockRoomorVendor12FullBin/CardMove1to2when2ispulled,Send

TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)2-BinReplenishment

(“Line-Side”Stocking)Reducespart/supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresultinsignificantproductivityimprovementsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF220StockRoomorVendor12FullMove20庫房或供應商12添滿的箱/卡當2被拉動時，移動1到2，發(fā)送觸發(fā)信號使用的部件空的箱/卡使用點位置(POU)或工作庫存(WIP)2-箱補充

(“線旁”庫存)減少零件/供應品庫存，增加生產效率促進WIP的降低將導致在庫房里的顯著的生產力提高降低/消除庫房在批數(shù)量上的影響可以簡單化存貨/周轉的計算流程線旁庫存LTOF2SS/2DMDOF),LTmax(箱數(shù)量

+*=21庫房或12添滿的當2被拉動時，移動1到使用的空的使21FullBin/CardPullfrom1untilempty,sendtriggerandpullfrom2untilempty,sendtrigger,etc.UseComponentsEmptyBin/Card2-BinReplenishment

(“Point-ofUse”Stocking)LTOF12-BinPOUstockingisusedwhenre-stockingisnotanissue.StockRoomorVendorPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)222FullPullfrom1untilempty,U22拉動從1開始直到用完為止,發(fā)送觸發(fā)信號，然后拉動從2開始直到用完為止，發(fā)送觸發(fā)信號,等等.使用部件2-箱補充

(“使用點”庫存)LTOF1SS/2DMDOF),LTmax(箱數(shù)量+*=當重新備庫存不是一個問題時，使用2-箱POU庫存庫房或供應商2添滿的箱/卡空的箱/卡使用點位置(POU)或工作庫存(WIP)23拉動從1開始直到用完為止,發(fā)送觸發(fā)信號，然后拉動從2開始直232-BinReplenishmentCalculationsBinQuantity=Max(LT,OF)+SS/2Ifreplenishinginstandardpacks,BinQuantityisroundeduptotheneareststandardpackmultipleExample:CalculatetheBinQuantityforthefollowing(standardpackreplenishment):PartNumber: 40567Description: RubberGlovesDemand/Usage: 25pairs/dayLeadTime: 2days(trigger-stock/supplyroom-replenishment)OrderFrequency: N/ABoxQuantity: 50pairsBinQuantity=[Max(2days,N/A)*25pairs/day]+.5*[Max(2days,N/A)*25pairs/day]/2=63pairsButwehavetorounduptotheneareststandardpack,so:BinQuantity=100pairs=2boxes242-BinReplenishmentCalculatio242-箱補充的計算箱數(shù)量=Max(LT,OF)+SS/2如果是標準包的補充，箱數(shù)量應該是近似于標準包的倍數(shù)舉例:計算下列數(shù)據(jù)的箱數(shù)量(標準包補充):零件號碼: 40567描述: 橡膠手套需求/用量: 25雙/天交貨時間: 2天(觸發(fā)–庫房–補充)訂單頻率: 不適用箱數(shù)量: 50雙箱數(shù)量=[Max(2天,N/A)*25雙/天]+.5*[Max(2天,N/A)*25雙/天]/2=63雙但是我們要取一個近似標準箱的數(shù)量，所以:箱數(shù)量=100對=2箱252-箱補充的計算箱數(shù)量=Max(LT,OF)+SS25Exercise#1:

2-BinReplenishmentCalculatetheBinQuantityforthefollowingsupplyitemina2-BinLine-SideReplenishmentprocessdirectlylinkedtothesupplier:PartNumber: 80886Description: PrinterPaperDemand/Usage: 22reams/dayLeadTime: 4days(trigger-purchasing-supplier-receiving-replenishment)OrderFrequency: 5daysBoxQuantity: 10reamsBinQuantity=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.Butwehavetorounduptotheneareststandardpack,so:BinQuantity=

=

.26Exercise#1:

2-BinReplenishme26練習#1:

2-箱補充如下供應品的2-箱線旁補充流程直接連接著供應商，計算箱數(shù)量:零件號碼: 80886描述: 打印紙需求/用量: 22令/天交貨時間: 4天(觸發(fā)–采購–運輸–收貨–補充)訂單頻率: 5天箱數(shù)量: 10令箱數(shù)量=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.但是我們要取一個近似標準包的數(shù)量，所以:箱數(shù)量=

=

.27練習#1:

2-箱補充如下供應品的2-箱線旁補充流程直接連27Exercise#2:

2-BinReplenishmentCalculatetheBinQuantityforthefollowingassemblyitemina2-BinLine-SideReplenishmentprocesslinkedtothewarehouse:PartNumber: A44B2Description: 4"Dia.SteelExtrusionDemand/Usage: 225ft/dayLeadTime: 1day(trigger-warehouse-replenishment)OrderFrequency: N/AExtrusionLength: 30ftBinQuantity=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.Butwehavetorounduptotheneareststandardpack,so:BinQuantity=

=

.28Exercise#2:

2-BinReplenishme28練習#2:

2-箱補充如下組裝線2-箱線旁補充流程直接連接著供應商，計算箱數(shù)量:零件號碼: A44B2描述: 直徑4“的鋼鐵拉絲需求/用量: 225英尺/天交貨時間: 1天(觸發(fā)–倉庫–補充)訂單頻率: 不適用拉絲長度: 30英尺箱數(shù)量=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.但是我們要取一個近似標準包的數(shù)量，所以:箱數(shù)量=

=

.29練習#2:

2-箱補充如下組裝線2-箱線旁補充流程直接連接2912-BinReplenishment

BinLabelingandInformationEachBin/StorageLocationshouldhaveabarcodelabelortag.Makesurenottouseapermanentlabelappliedtoarack/bin,becauseyouwilleventuallywanttoresizeandmayhavetomakenewlabels!LabelsforLineSideBins/TagsforResupplyBinsPartNumber,Description,andLocationarePrinted.BinQuantityshouldnotbeprinted(requirestoomanylabelchangeswhenresizing–triggermechanismorsystemwillhaveBinQuantity)EachBinLocationshouldbeuniquetoavoidconfusionwhenrestocking.ExamplesareintheAppendix.LocationPartNumberDescription2LocationPartNumberDescription3012-BinReplenishment

BinLabe3012-箱補充

箱標貼和信息每個箱/庫存地點都應該有一個條碼標貼或標簽確保不要用永久的標簽貼在一個貨架/箱。因為你將會調整大小，且貼上一個新的標貼！在線旁的需要重新補充的箱上的標貼被打印的零件號碼,描述,地點等箱數(shù)量不應該被打印出來(當調整大小時需要太多的標簽變化–觸發(fā)機制或系統(tǒng)將有箱數(shù)量)每個箱地點必須是獨一無二的以避免在重新補充庫存時混淆舉例在附件里.地點零件號碼描述2地點零件號碼描述3112-箱補充

箱標貼和信息每個箱/庫存地點都應該有一個條31Notesona1-BinSystemAonebinsystemisanexceptiontothe2-binforveryslowmovingparts/supplies.1-binpartsarenotstoredin2-binsbecauseof:HighinventorycostSpacerequirementsRacking/storagecost1-binsarereplenisheduponstockoutattheLine-Sidelocation.Stockoutimpactshouldbelowbecause:Parts/suppliesareverylowusers.Parts/suppliesarealsoatpointofusewhenLine-Sidestockoutoccurs.Parts/suppliesarestockedinnearbystock/supplyroom–easytoreplace.32Notesona1-BinSystemAoneb321-箱系統(tǒng)的注意對于流動非常緩慢的零件/供應品來說，一個1-箱系統(tǒng)是2-箱系統(tǒng)的例外.1-箱零件不象2-箱那樣被存儲，因為:高庫存成本空間需要貨架/倉儲成本在線旁的地點庫存短少時，1-箱被補充。庫存短少的影響應該是微弱的，因為:零件/供應品是非常少的使用者。當線旁的存貨短缺發(fā)生時，零件/供應品也同樣在使用點.零件/供應品被存放在庫房附近—容易補充.331-箱系統(tǒng)的注意對于流動非常緩慢的零件/供應品來說，一個1-33StockRoomorVendor11FullBin/CardMove1to2when2ispulled,Send

TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)1-BinReplenishment

(Typicallyfrom“Line-Side”)Reducespart/supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresultinsignificantproductivityimprovementsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF134StockRoomorVendor11FullMove34庫房或供應商111-箱補充

(特別是從“線旁”)LTOF1添滿的箱/卡空的箱/卡當2被拉動時，移動1到2，發(fā)送觸發(fā)信號使用點位置(POU)或工作庫存(WIP)減少零件/供應品庫存，增加生產效率促進WIP的降低將導致在庫房里的顯著的生產力提高降低/消除庫房在批數(shù)量上的影響可以簡單化存貨/周轉的計算流程線旁庫存SS/2OF),LTmax(箱數(shù)量

+*=使用的部件DMD35庫房或111-箱補充

(特別是從“線旁”)LT1添滿的空的當35StockroomorVendor1LinePOU1-BinReplenishmentTransactions1-BinSysteminventorytransactionsmirrorthoseofthe2-BinsystemFrontflushforreducingtransactionsbutreduceoverallinventoryaccuracyBackflushforincreasinginventoryaccuracy(slightly)butincreasenumberofsystemtransactions11-binCardPartXYZTriggerReplenishment1-binCardPartXYZ36Stockroom1LinePOU1-BinReple36庫房或供應商1線POU1-箱補充事務處理1-箱系統(tǒng)庫存交接與2-箱系統(tǒng)相似前端堆積減少交接過程但降低總體庫存量的準確性后端堆積增加了庫存準確性（幅度輕微）但增加了系統(tǒng)處理的事務量11-箱卡零件XYZ觸發(fā)補充1-箱卡零件XYZ37庫房或1線POU1-箱補充事務處理1-箱系統(tǒng)庫存交接與237TakeawaysKnowthethevarioustypesofBinReplenishmentsystemsBeabletodescribethebenefitsofaBinsystemHowtosize(calculate)alltheparametersforaBinsystem38TakeawaysKnowthethevarious38總結知道箱補充系統(tǒng)的不同類型能夠描述一個箱系統(tǒng)的利益能夠去計算一個箱系統(tǒng)的所有參數(shù)39總結知道箱補充系統(tǒng)的不同類型3939APPENDIX

2-BinReplenishmentPullAPPENDIX

2-BinReplenishmentP40附錄

2-箱補充拉系統(tǒng)附錄

2-箱補充拉系統(tǒng)41InstructionsforTypicalCard

Triggered2-BinReplenishmentThisprocessusesgreenandredcardstotriggerreplenishment;“bins”areactuallythebox/containerthepart/supplyisshippedin.1. Employeeremovesabinanddropsitsgreen2-bincardintothemailbox:Pullpartsfrom“bin”withgreencardbeforeusinganywiththeredcard.2. Atsametime(s)eachday,thecardsarepickedupfromthemailboxandreturnedtothestock/supplyroom.3. Thestock/supplyroompullsproperamountofparts/material(notedoncard,setequaltothecalculated“bin”quantity).4. Inventorytransactionsareperformed(dependingonissuemethod),andthematerialsandcardsaredeliveredtothestoragelocation.5. Employeestocksmaterialinstoragelocationandreturnscardtoitsproperplace.Whenstock/supplyroomreplacesthematerial,ensurethattheredcardisplacedonthefullbin.Alwaysleavesyouafullredbinremainingwhengreenbinrunsout.Ifnot,youcouldrundownbothbinsandstockoutbeforeeitherisreplaced;ifaredcardisinthereplenishmentprocess,apartshortageisimminent–actfast!42InstructionsforTypicalCard42典型的卡觸發(fā)2-箱補充的介紹這個流程用綠色和紅色卡來觸發(fā)補充；“箱”是實際用來發(fā)貨零件/供應品的盒子/容器.1. 員工清掉一個箱后，將綠色的2-箱卡放入郵箱:在使用有紅色卡的零件前，先從有綠卡的箱中拉零件2. 每天的同一時候,郵箱卡片被收集并返回到庫房中.3. 庫房拉動零件/材料的適合數(shù)量(在卡上注明，將之設定為計算出的“箱”數(shù)量).4. 庫存處理被執(zhí)行了(根據(jù)發(fā)放的方式),然后材料和卡被傳送到倉儲地點.5. 員工將物料放在倉儲地點然后將卡返回到適合的地方.當庫房補充材料時，確保紅色卡被放在添滿的箱上.當綠箱被放出去使用時，始終保持紅卡箱中的零件已經(jīng)被填滿.如果不是這樣，在任一箱補充前你將用盡每個箱存貨；如果紅卡在補充過程中，零件短缺現(xiàn)象即將出現(xiàn)—盡快采取行動。43典型的卡觸發(fā)2-箱補充的介紹這個流程用綠色和紅色卡來觸發(fā)補充43MaintainingaCardTriggered2-BinProcessCheckperiodicallyforlostcardsandreplace.Besttimeisrightafterreplenishment;anycardsnotreplacedorinthemailboxarelost.Policetheproperuseofcards:Supervisor/Leaddropgreencardswhengreenbinisempty.Supervisor/Leaddropredcardsonstockout–investigate!Supervisor/Leadensurecardsarereplacedwhenpartsarerestocked.Greenbinsarecompletelyusedbeforeredbins.Resizebinswhendemandchanges.Addcardsfornewparts,deletecardsforobsoleteparts.44MaintainingaCardTriggered244保持卡觸發(fā)2-箱系統(tǒng)的過程定期檢查卡片是否丟失并更換.最佳時間是在補充之后，如果卡片未被更換或未在郵箱都視為丟失維持卡片的合理使用:當綠卡箱用完變空時，主管/組長投放綠卡.當存貨用完時，主管/組長投放紅卡–調查!當零件重新補充時，主管/組長確?？ㄆ桓鼡Q.在用紅卡箱前，確保綠卡箱已經(jīng)被用完.當需求改變時需要重新調整箱的數(shù)量.新增的零件要增加不同的卡，過期的死庫存零件要將卡片毀尸滅跡.45保持卡觸發(fā)2-箱系統(tǒng)的過程定期檢查卡片是否丟失并更換.4545Bin1Bin2ExampleCardTriggered

Line-Side2-BinRackBin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-Bin

MailboxOrderCards1. AlwayspullmaterialfrombinwithGREEN

cardifitisthere.2. Store/supplyroomreplacesmaterialandswitchesREDcardtomaterialjustreplaced.3. Thecardsareattachedtomagneticstriplabels(foreaseofmovementforresizing).Bin1Bin1Bin246Bin1Bin2ExampleCardTrigger46Bin1Bin2舉例：

由卡觸發(fā)的線旁2-箱貨架Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-箱郵箱訂單卡片1. 如果這里有綠卡箱，那么必須要從綠卡箱里拉材料.2. 庫房補充材料并將紅卡換到剛補充的材料里.3. 卡片最好是有磁性的(這樣在調整數(shù)量時可以方便移動).Bin1Bin1Bin247Bin1Bin2舉例：

由卡觸發(fā)的線旁2-箱貨架Bin47ExampleCardTriggered

Line-Side2-BinSystem48ExampleCardTriggered

Line-S48舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)49舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)4949ExampleCardTriggered

Line-Side2-BinSystem2-BinCardsareGreenandRed,pertheprocess.Cardsareplacedintoplasticsheathstoprotectthemfromgettingknockedofftheracking.Clearplasticsheathsareattachedtometalrackingviastickymagneticstripmakeresizingeasier.Binlabelsarewhitestickybackedandplacedinsideofplasticsheathforprotection.Aclearplasticsheathoverawhitelabelindicatesthatthebinisbeingreplenished.50ExampleCardTriggered

Line-S50舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)根據(jù)流程的需要，2-箱卡是綠卡和紅卡.卡片可裝入塑料套中以防止摩擦磕碰.透明塑料套通過磁性體吸附到金屬貨架上以便容易的調整數(shù)量.料箱標簽為白色的，貼在塑料套內背面加以保護.塑料套顯示出白色時表明料箱正在補充.51舉例：

由卡觸發(fā)的線旁2-箱系統(tǒng)根據(jù)流程的需要，2-箱卡是綠51Ifaclearplasticsheath/pouchisusedtohousethelabelandthecard,thenaclearpouchovertheracklabelindicatesthatthepartisonorder–aneasywaytoPoka-Yoketheprocess.Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:box UnitsperPack: 6000STOCKOUT4Box(es)HaveBeenOrderedLocation=A25Physical=S-10002-BinR1-L3-S3CommonNamePartNumberPartDescriptionIndicatesPartisonOrderIndicatesQuantityonOrderLine-SideLocationRackandSpaceLocationSampleBin/RackLabel52Ifaclearplasticsheath/pouc52如果一個空塑料套/袋用來收集標貼或卡片時，那么它在貨架上表示該零件已經(jīng)是在途訂單，這是很好的防錯措施擋風膠條40130W/STRIP.270HT.187BKFSW標準包裝:盒 每包件數(shù)： 6000用完4箱已訂貨地點=A25物理位置=S-10002-BinR1-L3-S3名稱零件號碼零件描述指示零件在訂貨中顯示訂貨數(shù)量線旁場所貨架和空間位置箱/貨架標簽實例53如果一個空塑料套/袋用來收集標貼或卡片時，那么它在貨架上表示53Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:box UnitsperPack: 6000Order:4Box(es)WhenNobox(es)AreLeftLocation=A252-BinSpace=S-10002-BinR2-A-4CommonNamePartNumberPartDescriptionIndicatesQuantityonOrderLine-SideLocationRackandBinLocationCardsaretypicallycoloredlightredor

lightgreenandlaminatedforprotection.Sample2-BinCard54WeatherstripCommonNamePartNu54擋風膠條40130W/STRIP.270HT.187BKFSW標準包:盒子 每包數(shù)量: 6000訂貨:當無剩余時，需要4箱訂貨地點=A252-箱空間=S-10002-BinR2-A-4卡片一般是亮紅或亮綠顏色，并有壓膜保護。2-箱卡樣板名稱零件號碼零件描述顯示訂貨數(shù)量線旁場所貨架和空間位置55擋風膠條卡片一般是亮紅或亮綠顏色，2-箱卡樣55SampleRackLayout–FrontRacklayoutsdrawninExcel/othermakeexcellentimplementationandupkeepmapstoguidestocking/restockingefforts.Manytimesitisgoodtohaveparts/suppliesononlyonesideofarack–thatwayyoucan“pullfromoneside”and“replenishfromtheother.”56SampleRackLayout–FrontRack56貨架排布的樣板–前面貨架布置一般可用EXCEL或其他工具來做優(yōu)秀的實施，畫張圖來指導庫存/再次補充庫存的努力，大多數(shù)是一側取用零件/供應品，你可以“從一側拉”并“從另一側補充”。57貨架排布的樣板–前面貨架布置一般可用EXCEL或其他工具57SampleRackLayout–BackIfarackhasafrontandabackside,makesuretolabelboth.Also,ifapart/supplystandardpackcanbeseenfrombothsidesoftherack(largebox/container),labelONLYonesidetoavoidconfusion.58SampleRackLayout–BackIfa58貨架排布的樣板–前面如果貨架是分正反面時，兩面都要有標貼。同樣，如果零件/供應品的包裝箱在貨架兩側都可以看見，標簽只在一側標識，以防止混淆.59貨架排布的樣板–前面如果貨架是分正反面時，兩面都要有標貼59Measurementof2-BinEffectiveness2-BinEffectivenessismeasuredby:Stockoutswhenmaterialwasinthestock/supplyroomNumberofpartsperday/week/month/yearIndicatesthatthebinisnotsizedcorrectly,ORthereplenishmentleadtimeisincorrect,oralackofdisciplineintheprocessArepartsorganized?Yes/NoTypicallyavisualcheckoftheprocesswillsuffice,BUTtheprocessmustbeauditedatperiodicintervals(once/month)Areunscheduledreplenishmentsbeingmade?Howmanyperday/week/month?Consistentunscheduledreplenishmentsmayindicatethatdemandhasincreasedandthebinneedstoberesized.60Measurementof2-BinEffective602-箱效果的量測2-箱效果可以由下列方法量測:當材料在庫房時的物料短缺每天/周/月/年的零件數(shù)量指出箱數(shù)量不正確，或補充交貨時間不正確，或過程缺乏組織性零件是否有組織的?是/否一般可以目視檢查過程的執(zhí)行能力，但應定期對過程進行審核（每月一次）是否有計劃外補充現(xiàn)象?每天/周/月有多少次?持續(xù)的計劃外補充表明需求增加，箱數(shù)量需調整。612-箱效果的量測2-箱效果可以由下列方法量測:6161StockroomorVendor2-BinLine-SideReplenishment

BackflushingInventory1. PartsarepulledfromlinePOUlocation,backflushingrelievesconsumedinventoryfromline-sidelocation.2. Binispulledfromline-sidestoragetore-supplyPOUlocation.3. Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4. Binisrefilledwithappropriatequantity.5. Inventoryistransferredfromstockroomtoline-sidelocation.6. Fullbinwithtriggerreturnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryTransferOccursHere1Line-SideStorage2InventoryBackflush(Charge-Off)OccursHereLinePOU262Stockroom2-BinLine-SideReple62庫房/供應商2-箱線旁補充

后端堆積庫存1. 零件從線使用點（POU）的位置被拉動,后端堆積減輕了從線旁消耗的庫存.2. 箱被拉動著從線旁庫存到使用點（POU）補充位置.3. 觸發(fā)信號(卡,箱,等.)被返回到庫房或供應商.4. 箱被重新添滿到適合的數(shù)量.5. 庫存被轉移從庫房到線旁位置.6. 滿箱將回到線旁.2-箱卡零件XYZ觸發(fā)補充2-箱卡零件XYZ庫存轉移發(fā)生在這里1線旁庫存2庫存后端積壓(Charge-Off)發(fā)生在這里線POU263庫房/供應商2-箱線旁補充

后端堆積庫存1. 零件從線使用點63StockroomorVendor2-BinLine-SideReplenishment

FrontflushingInventory1. PartsarepulledfromlinePOUlocation.2. Binispulledfromline-sidestoragetore-supplyPOUlocation.3. Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4. Binisrefilledwithappropriatequantity.5. Inventoryisfront-flushedoutofstockroomtoWIPorexpenseaccount.6. Fullbinwithtriggerreturnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryFrontflush(Charge-Off)OccursHere1Line-SideStorage2LinePOU264Stockroom2-BinLine-SideReple6403十二月2022精益生產之2箱補充拉系統(tǒng)2BinReplenishmentPull(中01十二月2022精益生產之2箱補充拉系統(tǒng)2BinRep652-Bin

補充拉系統(tǒng)2-箱補充拉系統(tǒng)的介紹線旁VS使用點庫存2-箱數(shù)據(jù)的要求和計算庫存部署選擇卡觸發(fā)2-箱流程1-箱系統(tǒng)附錄RD0112022-Bin

補充拉系統(tǒng)2-箱補充拉系統(tǒng)的介紹RD0112066LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-0267LeanSixSigma

ImprovementPr67LearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentouseabinSystemBeabletosize(calculate)alltheparametersforabinsystem68LearningObjectivesUnderstand68課程目的理解箱補充系統(tǒng)的不同類型知道一個箱系統(tǒng)的好處理解何時使用一個箱系統(tǒng)能夠去計算一個箱系統(tǒng)的所有參數(shù)69課程目的理解箱補充系統(tǒng)的不同類型569What’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystem70What’sinItforMe?Beableto70我學到了什么?能夠在黑帶項目中應用這個工具能夠實施一個箱系統(tǒng)71我學到了什么?能夠在黑帶項目中應用這個工具7712-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofastandardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedpartsPurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartreplenishmentis“triggered”basedonconsumption722-BinReplenishmentPullIntro722-箱補充拉系統(tǒng)的介紹2-箱補充拉系統(tǒng)是一個標準的補充拉系統(tǒng)的簡化版本，其好處是：在一個流程中建立戰(zhàn)略性的零件緩沖區(qū)原材料制造的零件采購的零件成品通過緩沖庫存將供應過程和消耗過程聯(lián)系起來零件的補充是基于消耗而觸發(fā)的732-箱補充拉系統(tǒng)的介紹2-箱補充拉系統(tǒng)是一個標準的補充拉系統(tǒng)73WhatIsa2-BinReplenishment?Formanypartsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedperiodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe“1st”isbeingrefilled/replenished.Therearetwoprimaryreplenishmentlocations:Line-SideandPointofUse74WhatIsa2-BinReplenishment?742-箱補充拉系統(tǒng)是什么?對于在流程中的眾多零件而言，一個2-箱系統(tǒng)可以被用來補充零件相對于同步供