2.2NewContinuousFlow單件流第一課時講義

2.2NewContinuousFlow單件流第一課時講義JITProductionCharacteristics(準(zhǔn)時化生產(chǎn)的特性）WorkStatementAnalysis（工作狀況分析）Equipmentinorderofprocesses（設(shè)備按工藝排列）Smallandinexpensiveequipment（用小而經(jīng)濟的設(shè)備）One-pieceflowproduction（單件流生產(chǎn))ProductioninProductCell(orFishbone“Rib”)(再獨立單元內(nèi)生產(chǎn)）Multi-process-handlingworkers（掌握多種技能的工人）Standingoperations,movingwhileworking(站立工作，隨著工作移動）Ergonomically-correctoperations（符合人體工程學(xué)-正確的操作）Productionpacedtotakttime(按照節(jié)拍時間進行生產(chǎn)）BalanceOperationsinthecell,“Standardoperations”definedandimplemented（在獨立單元內(nèi)平衡作業(yè)且“標(biāo)準(zhǔn)作業(yè)方式”被定義和實施）LevelProduction（均衡生產(chǎn)）(UsuallydonebyIndustrialEngineeringwithFactoryManagement)（通常由工業(yè)工程師完成）Category160%ofproduction.（類別160%的生產(chǎn)）Category2next25%ofproduction.（類別2隨后的25%的生產(chǎn)）Category3last15%ofproduction（類別3最后的15%的生產(chǎn)）PartNumberG15G29H15Y17Y18H21Qty25,15016,22912,15511,21411,101150CumulativeQuantity25,15041,37953,53464,74875,84990,120%27.918.013.512.412.30.2Cum%27.945.959.471.884.1100.01XXX2XX3XPQAnalysisPreparedby:D.SmithPeriod:7/1-9/30PartType...............Exle（例如）:Product/Quantity(PQ)Analysis（產(chǎn)品/數(shù)量分析）WorkStatementAnalysis（工作狀況分析）ContinuousFlow(連續(xù)流動）3

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547ProcessRoutingChartPreparedby:D.SmithDate:10/12OperationMachinePartNumber0118,19,2002710416,1705HT2075108521123454ProcessRouteAnalysis(工藝路線分析）Basedonusage:Determinestandardroutings.（決定標(biāo)準(zhǔn)路線）Grouppartnumberswithsimilarroutings.（將相識路線的產(chǎn)品號歸類）Determinepossiblecellsforpartnumbergroupings.（由產(chǎn)品號歸類決定可能的獨立生產(chǎn)單元）Evaluatecapacity,bottlenecks,andequipmentwhichmustbeshared.（評估產(chǎn)能，瓶頸和必須共享的設(shè)備）WorkStatementAnalysis（工作狀況分析）ContinuousFlow(連續(xù)流動）1316,1717__5866658SawDeburrHeatTreatFinishingNibblerPressPressPressMillDrill1LatheLatheLathe345672LatheSawSawSawGrinderGrinderGrinderMillDeburrLatheSawHeatTreatLathePressFinishingLocateEquipmentinOrderofProcesses（按照工藝次序放置設(shè)備）Targetaspecificstatementofworkand選取一個具體的工作內(nèi)容setupaproductorprocesscelltoproducethatstatementofwork.為此項工作建立獨立工作區(qū)Relatecellstopartswithsimilarprocessandroutings.（將有相似工藝和加工路線的獨立工作區(qū)相連）ContinuousFlow(連續(xù)流動）Thingstoconsider:（需考慮的事情）Choosesmall,dedicatedmachines.（選擇小而專用的機器）Installcastersonequipmentforflexibility(abilitytochangelayoutdailyifneeded).（為了靈活，為設(shè)備裝上輪腳）Minimizedistancebetweenoperations.（減少工序間的距離）Avoidlarge,fastequipmentinacell(onlyfastenough).（盡量避免在使用大而快的設(shè)備）Storematerials,supplies,andtoolingatpointofuse.（將材料，供應(yīng)和工裝放在要使用的地方）Small&InexpensiveEquipment（用小而經(jīng)濟的設(shè)備）ContinuousFlow(連續(xù)流動）$100,000Cyclesevery1.2seconds周轉(zhuǎn)時間1.2秒$1,500Cyclesevery60seconds周轉(zhuǎn)時間60秒Takttime=75sec節(jié)拍時間=75秒???RMFGàá3Identifyandeliminatewastesandconstraintswhichlimitone-pieceflow.（識別并消除影響單件流生產(chǎn)的浪費和限制）“One-less-at-a-time”drivesyoutoone-pieceflow.（以每次減少一件的方式來推動單件流）StrivetoProduceandMoveOnePieceataTime（爭取做到單件流生產(chǎn)）ContinuousFlow(連續(xù)流動）Productrequiresthreeprocessesthattakeoneminuteeach（產(chǎn)品需經(jīng)過三個工序，每個工序需用一分鐘）Processingfirstbatchinbatchesof10requires30minutes（如以10個為一批生產(chǎn)用時30分鐘）Processingfirst“batch”one-at-a-timerequiresonly12minutes（如以單件流進行生產(chǎn)僅需12分鐘）TraditionalBatchProcessing（傳統(tǒng)的成批加工）10minutes10minutes10minutesTotalBatchAprocessingtime:30minutes（所有A批次的加工時間為30分鐘）ContinuousFlowProcessing（連續(xù)流動的加工方法）TotalBatchAprocessingtime:12minutes

（所有A批次的加工時間為12分鐘）Only3minutesfor1stpart（僅3分鐘一個）1234567891011123ContinuousFlow(連續(xù)流動）StrivetoProduceandMoveOnePieceataTime（爭取做到單件流生產(chǎn)）Out（出）In（進）One-PieceFlow（單件流）One-PieceFlow（單件流）BatchProcess成批加工(RequiresaLotSizeof120)批量為120BatchConveyance（批量運輸）MaximumTotalInventoryof120atthislocation（此處的最大庫存量為120）ReadyProcessedDealingWithMonuments（針對超大裝備）ContinuousFlow(連續(xù)流動）Enablepeopletoleavemachineandmovetonextprocess.使人能離開機器并移動到下一個工序）Applyautonomation(automationwithahumantouch).（應(yīng)用自動化）Installdevicestostopmachinewhenfinishedorproblemoccurs(Jidoka).（安裝當(dāng)加工完成或出現(xiàn)問題時能停止的裝置）Installmistake-proofingdevices.（安裝防錯裝置）Eliminatewatchingmachinesandwaiting.（消除看管機器和等待的時間)Performanothervalue-addingtaskwhilemachineisworking.(機器工作時做另一項有價值的工作）Before（從前）After（現(xiàn)在）Uh-oh,

there’saproblem.I’dbetterstopandsignalsomeonetocomehere.（有問題，我應(yīng)該找人來看一下。）MoveWhileWorking:SeparatePeoplefromMachines（工作時移動：將人從機器中解放出來）ContinuousFlow(連續(xù)流動）Whatskillsareneededtooperatethecell?（操作獨立工作區(qū)所需的技能？）Whoperformswhattasks?（誰來完成任務(wù)？）Howwillweworktogetherinthecell?（在獨立工作區(qū)，我們?nèi)绾螀f(xié)同工作？）Designformutualassistanceandusedefined“passingzones.”（以互助的方式設(shè)計）Multi-Process-HandlingWorkers（掌握多種技能的工人）ContinuousFlow(連續(xù)流動）JohnMaryFrank333323353363

34333133ProcessSkills（工序所需技能）People（人）1234567PassingZone7333Ask:“Howfastshouldweproduce?”（問：“我們生產(chǎn)需多快？”）Planproductionrateandmaterialflowstomatchrealconsumptionbythecustomer(mayincludesomeplannedstockoffinishedgoods).（生產(chǎn)速率和材料的流動應(yīng)與顧客的實際需求相匹配（可以包含一些計劃內(nèi)的成品庫存））Matchproductionratesandspeedstoconsumptionoffinishedgoods.（使生產(chǎn)速率與成品消耗相一致）RequiredproductionrateistheTakttime.（所需要的生產(chǎn)速率即節(jié)拍）PlanCustomerConsumption（顧客消費）AParts400BParts800CParts600DParts200ProducePacedtoTaktTime(按照節(jié)拍時間進行生產(chǎn)）ContinuousFlow(連續(xù)流動akttime=10ABCDEFGH12345OperatorProblem!Operatorcan’tmakeTakttime.BalanceOperationsContinuousFlow(連續(xù)流動）HGFEDakttime=10BC12345Operator（操作人員）Onesolution:Redistributethework.（一種方案：重新分配工作）WASTEofTime(peoplewaiting)浪費：等待時間LineBalance（平衡生產(chǎn)線）ContinuousFlow(連續(xù)流動）BHFGE1Dakttime=10C12345OperatorE2Anothersolution:IfwecansplitupE,wecanfreeupanoperatorandeliminatealotofwaste.（另一種方案：如可能拆分E,我們可以解放出一個操作人員并消除很多浪費）OPT=operatorcycletime/takttimeLineBalance（平衡生產(chǎn)線）ContinuousFlow(連續(xù)流動）JITProductionCharacteristicsWorkStatementAnalysis（工作狀況分析）Equipmentinorderofprocesses（設(shè)備按工藝排列）Smallandinexpensiveequipment（用小而經(jīng)濟的設(shè)備）One-pieceflowproduction（單件流生產(chǎn))“U”-shapedworkflow,counterclockwise（“U”型逆時針布置工作流）Multi-process-handlingworkers（掌握多種技能的工人）Standingoperations,movingwhileworking(站立工作，隨著工作移動）Ergonomically-correctoperations（符合人體工程學(xué)-正確的操作）Productionpacedtotakttime(按照節(jié)拍時間進行生產(chǎn)）BalanceOperati