推式與拉式系統(tǒng)jit

推式與拉式系統(tǒng)jitJIT目標和建築架構的歸納產品設計流程設計人員因素製造規(guī)劃避免中斷使系統(tǒng)有彈性排除浪費平衡迅速的流程最終目標支援目標建築架構2及時化生產系統(tǒng)常見的資源浪費1超額生產(overproduction)等候時間(waitingtime)不必要的運送(unnecessarytransporting)存貨(inventory)加工浪費(processingwaste)不必要的生產步驟產出瑕疵品3及時化生產系統(tǒng)常見的資源浪費2無效的工作方法(inefficientworkmethod)不佳的佈置和物料搬運模式，增加在製品存貨產品不良再製成本消費者不滿意造成銷售損失4及時化生產系統(tǒng)WasteinOperations5及時化生產系統(tǒng)WasteinOperations6及時化生產系統(tǒng)WasteinOperations7及時化生產系統(tǒng)ThePrinciplesoftheTOYOTAProductionSystem(TPS)1Allworkmustbecompletelyspecifiedastocontent,sequence,timing,andoutcome.Everycustomer-supplierconnectionmustbedirect,unambiguouslyspecifyingthepeopleinvolved,theformandquantityoftheservicesorgoodstobeprovided,thewaytherequestsaremadebyeachcustomer,andtheexpectedtimeinwhichtherequestswillbemet.8及時化生產系統(tǒng)ThePrinciplesoftheTOYOTAProductionSystem(TPS)2Thepathwayforeveryserviceandproductmustbesimpleanddirect.Anyimprovementtothesystemmustbemadeinaccordancewiththescientificmethod,undertheguidanceofateacher,atthelowestpossibleorganizationallevel.9及時化生產系統(tǒng)BasicElementsofJIT1標準的零件(產品設計)模組化設計(產品設計)高產能的系統(tǒng)(產品設計)可同時生產(產品設計)將員工視為資產(人員/組織的要素)訓練員工，使其變成多能工(人員/組織的要素)持續(xù)改善(人員/組織的要素)成本會計(人員/組織的要素)領導與專案管理(人員/組織的要素)10及時化生產系統(tǒng)BasicElementsofJIT2Cellularlayouts(製程設計Pullproductionsystem(製造規(guī)劃與控制)Flexibleresources(製程設計)Kanbanproductioncontrol(製造規(guī)劃與控制)Small-lotproduction(製程設計)Quicksetups(製程設計)Uniformproductionlevels(製造規(guī)劃與控制)Qualityatthesource(製程設計)Totalproductivemaintenance(製造規(guī)劃與控制)Suppliernetworks(製造規(guī)劃與控制)11及時化生產系統(tǒng)FlexibleResourcesMultifunctionalworkers(多能工)PerformmorethanonejobGeneralpurposemachines(通用設備)PerformseveralbasicfunctionsStudyoperators&improveoperations12及時化生產系統(tǒng)CellularLayoutsGroupdissimilarmachinesinmanufacturingcelltoproducefamilyofpartsWorkflowsinonedirectionthroughcellCycletimeadjustedbychangingworkerpaths13及時化生產系統(tǒng)ManufacturingCellwithWorkerRoutesWorker1Worker2Worker3Cell114及時化生產系統(tǒng)WorkerRoutesLengthenedasVolumeDecreasesCell5Worker2Cell2Worker1Cell1Worker3Cell3Cell415及時化生產系統(tǒng)推式與拉式系統(tǒng)推式系統(tǒng)(pushsystem)(例如，MPR)當工作在某工作站完成時，產出就被推往下一站。拉式系統(tǒng)(pullsystem)(例如，JIT)工作移動的控制落於下一站;每一工作站從前一站拉拔所需產出。16及時化生產系統(tǒng)KanbanProductionControlSystem

(看板生產管制系統(tǒng))KanbancardindicatesstandardquantityofproductionDerivedfromtwo-bininventorysystem(雙倉制)KanbanmaintainsdisciplineofpullproductionProductionkanban(生產看板)authorizesproductionWithdrawalkanban(提領看板)authorizesmovementofgoods17及時化生產系統(tǒng)ASampleKanban18及時化生產系統(tǒng)TheOriginofKanbana)Two-bininventorysystem b)KanbaninventorysystemReordercardBin1Bin2Q-RKanbanRRQ=orderquantityR=reorderpoint-demandduringleadtime19及時化生產系統(tǒng)TypesofKanbans—

Dualkanbans20及時化生產系統(tǒng)Single-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2StorageareaEmptycontainersFullcontainersAssemblyline1Assemblyline221及時化生產系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline222及時化生產系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline223及時化生產系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline224及時化生產系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline225及時化生產系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline226及時化生產系統(tǒng)StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline227及時化生產系統(tǒng)看板系統(tǒng)—

singlekanban28及時化生產系統(tǒng)Dualkanbanvs.singlekanbanDualkanbanIsusedwhenmaterialisnotnecessarilymovingbetweentwoconsecutiveprocesses,orwhenthereismorethanoneinputtoaprocessandtheinputsaredispersedthroughoutthefacility.SinglekanbanIsusedwhentheprocessesaretightlylinked.29及時化生產系統(tǒng)TypesofKanbansKanbanSquareMarkedareadesignedtoholditemsSignalKanbanTriangularkanbanusedtosignalproductionatthepreviousworkstationMaterialKanbanUsedtoordermaterialinadvanceofaprocessSupplierKanbansRotatebetweenthefactoryandsuppliers30及時化生產系統(tǒng)TypesofKanbans—

kanbansquareandkanbanracks31及時化生產系統(tǒng)TypesofKanbans—

signalkanbans32及時化生產系統(tǒng)看板管理系統(tǒng)之規(guī)則不要把不良品交給後製程。由後製程到前製程來領取零件。前製程僅生產將被後製程領用去的數量。生產必須平衡?？窗逯蛔鰹槲⒄{整的手段，其張數必須減到最少。製程必須安定化、合理化。33及時化生產系統(tǒng)Single-CardKanbanSystemKANBANPartNumber: 1234567ZLocation: Aisle5 Bin47LotQuantity: 6Supplier: WS83Customer: WS116EachcontainermusthaveacardAssemblyalwayswithdrawsfromfabrication(pullsystem)ContainerscannotbemovedwithoutakanbanContainersshouldcontainthesamenumberofpartsOnlygoodpartsarepassedalongProductionshouldnotexceedauthorization34及時化生產系統(tǒng)看板(容器)數量之決定1K=容器數量。d=工作中心之計劃使用率(預期每日需求)。p=每箱容器零件之平均加工時間。W=在生產過程中之平均等候時間，加上每箱物料的搬運時間。C=標準容器之零件容量。X=政策變數。反應生產系統(tǒng)的效率(10%以內)35及時化生產系統(tǒng)看板(容器)數量之決定2k=在前置時間期間的平均需求+安全庫存每箱內的單位數量=d(w+p)(1+x)c36及時化生產系統(tǒng)看板(容器)數量之決定3where N =numberofkanbansorcontainers d =averagedemandoversometimeperiod L =leadtimetoreplenishanorder S =safetystock C =containersizeNo.ofKanbans=averagedemandduringleadtime+safetystockcontainersizeN=dL+SC37及時化生產系統(tǒng)容器數量決定—範例某汽車零件公司生產4輪傳動車的方向盤及暫停系統(tǒng)中的搖桿手臂組合。一般1箱零件在製造週期中需要0.02天的加工及0.08天的物料處理和等候時間。零件每日的需求為2000個單位。管理部門認為搖桿手臂組合的需求不確定，所以其安全庫存為需求量的10%。若每箱內各有22個零件，則應授權的箱子數量為多少。38及時化生產系統(tǒng)小批量(Small-lotproduction)的效益降低在製品存貨減少因品質發(fā)生問題時所產生的檢驗和重加工成本減少儲存空間問題更容易顯現增加生產彈性易於進行作業(yè)平衡39及時化生產系統(tǒng)InventoryHidesProblems40及時化生產系統(tǒng)LowerLevelsofInventoryExposeProblems41及時化生產系統(tǒng)ComponentsofLeadTime

(前置時間的元素)ProcessingtimeReducenumberofitemsorimproveefficiencyMovetimeReducedistances,simplifymovements,standardize

routingsWaitingtimeBetterscheduling,sufficientcapacitySetuptimeGenerallythebiggestbottleneck42及時化生產系統(tǒng)快速籌置(Quicksetups)Single-digitsetupThegoalofhavingasetuptimeoflessthan10minutes.快速換模又稱一分鐘換模術(single-minuteexchangeofdies,SMED)43及時化生產系統(tǒng)快速籌置的實施步驟1.將換模作業(yè)流程劃分外部整備作業(yè)與內部整備作業(yè)。2.儘可能把內部整備作業(yè)改變成外部整備作業(yè)。3.消除內部整備所需的調整作業(yè)。4.外部整備作業(yè)的標準化。5.推動平行作業(yè)。6.利用機械提高換模效率。7.其他管理部門的充分配合。44及時化生產系統(tǒng)CommonTechniquesforReducingSetupTime145及時化生產系統(tǒng)CommonTechniquesforReducingSetupTime246及時化生產系統(tǒng)CommonTechniquesforReducingSetupTime347及時化生產系統(tǒng)平準化生產(UniformProduction)ResultsfromsmoothingproductionrequirementsKanbansystemscanhandle+/-10%demandchangesThewaytoreducevariabilityinproductionSmoothsdemandacrossplanninghorizonMixed-modelassemblysteadiescomponentproduction48及時化生產系統(tǒng)平準化—範例1TheAPPofTOYOTA:4500vehiclesperweek.Twofullshifts,fivedaysperweek→450pershift(480minutes)Threemodelsareproduced:Camry(C),Avalon(A),andSienna(S).200Camry,150Avalons,and100SiennaspershiftCycletime:480/450=1.067(min)49及時化生產系統(tǒng)平準化—範例2First200C’s→150A’s→100S’sHighaveragecycleinventorylevelLumpyrequirementsSecond4C’s→3A’s→2S’sThecycle=9(1.067)=9.60(50timespershift)50及時化生產系統(tǒng)平準化—範例3ThirdC→S→C→A→C→A→C→S→AThesetuptimesmustbeveryshort.ComponentrequirementsissteadyCapacityrequirementsaresmoothed51及時化生產系統(tǒng)QualityattheSource1Jidoka(自働化)在生產過程中自動偵測缺點Andon(安童)在每個工作站裝置燈號系統(tǒng)，以指示問題及落後狀態(tài)。Undercapacityschedulingallowsforplanning,problemsolving&maintenance52及時化生產系統(tǒng)QualityattheSource2防呆裝置日文發(fā)音為POKAYOKE

，是指在模具，工具，機器設備上設計防止錯誤(不良)發(fā)生的裝置，一旦作業(yè)員做錯或需要作業(yè)上的警示時，防呆裝置可以預防或使機器停下來，確保不產生不良品。目視管理系統(tǒng)(visualcontrol)：係透過顯示板之顯示得以快速且明顯地發(fā)現異常、浪費、故障、斷料等現場不順暢之情形，而達到能速謀對策的一種管理系統(tǒng)。53及時化生產系統(tǒng)VisualControl54及時化生產系統(tǒng)VisualControl55及時化生產系統(tǒng)VisualControl56及時化生產系統(tǒng)Kaizen(改善)ContinuousimprovementRequirestotalemploymentinvolvementEssenceofJITiswillingnessofworkerstoSpotqualityproblemsHaltproductionwhennecessaryGenerateideasforimprovementAnalyzeproblemsPerformdifferentfunctions57及時化生產系統(tǒng)TotalProductiveMaintenance(TPM)BreakdownmaintenanceRepairstomakefailedmachineoperationalPreventivemaintenanceSystemofperiodicinspection&maintenancetokeepmachinesoperatingTPMcombinespreventivemaintenance&totalqualityconcepts58及時化生產系統(tǒng)TPMRequiresManagementto:DesignproductsthatcanbeeasilyproducedonexistingmachinesDesignmachinesforeasieroperation,changeover,maintenanceTrain&retrainworkerstooperatemachinesPurchasemachinesthatmaximizeproductivepotentialDesignpreventivemaintenanceplanspanninglifeofmachine59及時化生產系統(tǒng)導入JIT的基礎—5S運動定義功能整理(seiri,organization)把東西分成必要與不必要，將不必要的東西撤走。排除資源空間的浪費。整頓(seiton,tidiness)需要的東西排放整齊以便取用。排除尋找，縮短作業(yè)或產品線切換、準備時間。清掃(seiso,cleanliness)把工作場所掃除清潔，去除雜物及灰塵。提升效率，排除隱藏的工業(yè)災害與品質不良。清潔(seiketsu,maintenance)保持整理、整頓、清掃所建立之成果。確保作業(yè)安全，延長設備壽命，提升產品品質。修養(yǎng)(shitsuke,discipline)對於規(guī)定的事項確實遵守並養(yǎng)成習慣。加強小團體之自主性活動。60及時化生產系統(tǒng)SupplierPolicies1Locate