SupermarketSystem超市系統ActivitySWNo.:4.5.7SupermarketSystemRevision#:004Lastimproved:06-Aug-2013Improvedby:A.MeesterObjectivesofthisModule這個模塊的目標Participantswillbeableto:參與者能夠Identifywheresupermarketsareneededwithinavaluestreamtosupportapullsystem識別出在價值流的哪里需要設置超市來支持拉動系統UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用PFEP數據庫來正確的估算及維護超市Linksupermarketstotheoverallkanbansystemsandconveyanceroutes將超市與整個看板體系及運輸路線鏈接起來Topics主題WhatisaSupermarket?什么是超市？ThreeStepsofSupermarketDesign超市設計的3大步驟SupermarketLocation超市地址SupermarketSizing超市大小PFEP(PlanforEveryPart)DatabasePFEP數據庫DesignDeliveryRoutes設計交付路線RunningtheSupermarket運行超市GroupExercises團隊練習JargonBuster專業術語Supermarket超市PFEP(PlanforEveryPart)單個零件計劃Addresssystem地址系統Kanban看板Routes路線VMI供應商管理庫存JargonBusterPFEP?Supermarket?Addresssystem?WhatisaSupermarket?什么是超市Operation工序20Operation工序10PULL拉動Supermarkets超市Shipping出貨Rawmaterials原材料In-processstock在制品庫存Finishedgoods成品WhatisaSupermarket?什么是超市？Adeliberatelydesignedmaterialstoresareawithcontrolledquantitiesofmaterials故意設定的區域儲存可控數量的材料Thedownstreamprocesstakeswhatisneededandthesupermarketowner(theupstreamprocess)replenishments下游工序拿取需要的材料，超市的所有人（上游工序）進行補料Unliketraditionalstoresarea,noorderforms,paperworktransactions,orstockrequisitionsareneededotherthankanban不同于傳統的儲存區域，沒有除看板以外的訂單格式，紙質的交割或者物料申請HeijunkaBox321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品超市143WhatisaSupermarket?什么是超市RawMaterialsSupermarket原材料超市25761KanbanPost看板架1234CellKanbanPost看板架1234Cell453PartsSupermarket零件超市234453WhatisaSupermarket?什么是超市？Amaterialstoresareawhich:物料儲存區：Putsmaterialclosetopointofuse將物料放置在靠近使用點Eliminatesshortages消除物料短缺現象Setsminimumandmaximumlevelsforinventory設定最大庫存及最小庫存量Usesfloorspaceefficiently更有效的利用空間Simplifiesorderingandmaterialhandling訂購及物料搬運簡單化Removesnonvalueaddedactivities:(receiving,puttingaway,kitting,counting,cycling,requisitions)消除不增值的動作：（收貨，擺料，配料，點數，循環，申請）Improvesmaterialflowintheproductcells改善生產線的物料流程Andmakesthestatusofmaterialsvisible讓物料狀態可視化WhatisaSupermarket?什么是超市？Simplevisualsystemsshowmaterialflow簡單可視化的物料流Location,addressandquantitycontrol位置，地址及數量管理WhatisaSupermarket?什么是超市？Supermarketsandmaterialpresentation超市及物料準備Achieveexcellent6S實現卓越的6SPresentmaterialsandtheirinformationvisibly讓物料及信息更加目視化Eliminatedefects消除不良Usegravityfeeds使用重力送料Reducemotionforloadingandunloading減少上料及退料的動作MaintainFIFO維護先進先出ThreeStepsofSupermarketDesign超市市設設計計的的3大步步驟驟Setsupermarketlocation設置置超超市市的的地地址址Wherewillsupermarketshelpusmost?超市市設設置置在在哪哪里里更更有有幫幫助助Determinesupermarketsizing定義義超超市市大大小小PFEPdatabasetodeterminequantitiesPFEP數據據庫庫來來定定義義數數量量Spacerequired空間間的的要要求求Designdeliveryroutes定義義送送貨貨路路線線Standardworkforwithdrawalanddeliveryofpartsandcontainers補料料及及送送貨貨及及周周轉轉箱箱的的標標準準作作業業Step1:SupermarketsLocation第一一步步：：超超市市選選址址Typicalsupermarketlocations典型型的的超超市市地地址址Attheendoftheproducerprocesswheneverpossible,asarule在有有可可能能的的情情況況下下設設置置在在在在生生產產工工序序的的尾尾部部Atpointofuse(VMI,Citems)在使使用用點點（（供供應應商商管管理理庫庫存存，，C類零零件件））Atreceiving(forexternalsuppliers)在收收貨貨區區（（外外部部供供應應商商））Closetothepointofuseaspossible越靠靠近近使使用用點點越越好好Directdeliverytothesupermarket直接接交交貨貨到到超超市市Minimizerepeatedhandling將重重復復搬搬運運減減少少到到最最少少12Step1:SupermarketsLocation第一一步步：：超超市市選選址址Step1:SupermarketsLocation第一一步步：：超超市市選選址址StandardApproach標準準的的方方法法Locatesupermarketsattheendofthesupplierprocessorproductionline將超超市市設設置置在在供供應應流流程程的的最最尾尾端端或或生生產產線線Makeproblemsimmediatelyvisibletotheproducerprocess將問題立刻可可視化的傳遞遞到生產工序序Donotsacrificevisibilityforthesakeofoptimizingtheworkofmaterialhandlers不為優化物料料搬運工作的的緣故而犧牲牲可視化Step1:SupermarketsLocation第一步：超市市選址Line生產線F1Line生產線F2Line生產線F3Supermarket超市1Supermarket超市2Supermarket超市3Line生產線A1Line生產線A2Line生產線A3234Step1:SupermarketsLocation第一步：超市市選址CentralizedSupermarket集中化的超市市Duetohighvolumeandormix,thefacilitylayout,thesupermarketmaynotalwaysfitattheendoftheline因為大批量或或多品種，工工廠格局的原原因，超市也也許不能總是是設置在生產產線的尾部。。Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstreamanddownstreamprocesstominimizematerialhandling集中化的超市市用于當他們們設置在上游游及下游工序序來減少物料料搬運Supermarketsforincomingpartsforassemblymaybelocatednearthereceivingdock來料零件超市市可以設置在在靠近收貨區區Step1:SupermarketsLocation第一步：超市市選址234Line生產線F1Line生產線F2Line生產線F3ConsolidatedSupermarket統一的超市Line生產線A1Line生產線A2Line生產線A3GroupExercise#1團隊練習#1Goseeactivity去現場看WalkthroughthevaluestreamfromendtoendUsevaluestreammapstoassist通過現場查看看整個價值流流—在價值流程圖圖的幫助下Identifylocationswithinsitevaluestreamswheresupermarketsareneeded在價值流程圖圖中識別出哪哪里需要超市市Documentonfuturestatemapswhereapplicable將適用的地方方在未來價值值流程圖上體體現Wherecanwe…哪里我們可以以Supportkanbansystemefforts?支持看板系統統？Minimizeinventorylevels?最小化庫存水水平？Improvevisibilityandeliminateshortages?提升可視化及及消除物料短短缺？Step2:SupermarketSizing第二步：超市市大小Howmuchofeachpartwillwekeeplineside?每個零件我們們需要多少在在生產線旁Frequencyofconveyance運輸的頻率Quantityofconveyance運輸的數量Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartofanoverallroute通過高頻率小小批量的交付付來最小化生生產線旁的物物料Step2:SupermarketSizing第二步：超市市大小Inordertodeterminesupermarketsize,weneedtoknow……為了定義超市市的大小，我我們需要知道道Usagevolume(quantity)用量的多少（（數量）Whatistheschedulingmethod?什么是計劃的的方法？Hastheusagebeenleveled?用量被均衡化化了嗎？Hasthemixbeensmoothed?生產種類被穩穩定了嗎？Isthereafrozentimewindow?有一個凍結的的時間窗口嗎嗎？Deliveryfrequencyupstream上游工序的交交貨頻率Deliveryquantity交貨數量Containersize周轉箱大小Locationofsignal信號的位置Weight重量Andmore等等ThePlanforEveryPart(PFEP)answers:單個零件計劃劃解答了：Howisthepartpurchased?零件如何進行行采購？Whoproducesthispart?誰生產這個零零件？Howisitpackaged?零件如如何包包裝？？Howisthepartreceived?零件如如何收收貨？？Whereisitstored?在哪里里儲存存？Whereisitspointofuse?在哪里里使用用？Howisitdeliveredtopointofuse?如何交交付到到使用用點?Andmuchmore.等等Step2:SupermarketSizing第二步步：超超市大大小SamplePFEPData數據的的案例例PartNumber物料編號Thenumberusedtoidentifythematerialsatthissite在工廠內物料的識別編號Description描述Commonnameofmaterial物料的通用名稱Dailyusage每天用量Averagequantityofmaterialusedperday物料每天是平均使用量PointofUse使用點Processorareawherethematerialisconsumed物料在哪個工序進行消耗PointofStorage儲存點Addressorlocationwherematerialisstored物料存儲的地址Orderfrequency訂單頻率Howoftenthematerialisorderedfromthesupplier下物料訂單的頻率Suppliername供應商Nameofthesupplierofmaterial零件供應商的名稱Suppliercity供應商城市Citywherethesupplierofthismaterialislocated零件供應商所在城市Supplierregion供應商地區Prefecture,state,district,orprovincewheresupplierislocated零件供應商所在區域Suppliercountry供應商國家Countrywheresupplierislocated供應商所在的國家Containertype包裝箱類型Typeofthecontainerusedforthismaterial物料使用的周轉箱類型Containerweight包裝箱重量Howmuchanemptycontainerweighs空箱的重量Weightperpart零件單重Howmuchoneunitofthismaterialweighs單個零件的重量Totalpkg.weight整箱重量Weightofafullcontainerofthismaterial物料滿箱的總重PFEP(PlanforEveryPart)DatabasePFEP數據庫庫Containerlength周轉箱長度Lengthordepthofcontainer周轉箱的長度或深度Containerwidth周轉箱的寬度Widthofcontainer周轉箱的寬度Containerheight周轉箱高度Heightofcontainer周轉箱的高度Useperassembly每個產品的用量Quantityofmaterialusedforonefinishedproduct零件在單個成品中的用量Hourlyusage每小時的使用量Maximumquantityofmaterialsconsumedperhour每小時最大是使用量Standardcontainerquantity標準的周轉箱數量Quantityofmaterialinonefullcontainer滿箱中的零件數量Hourlycontainerusage每小時的周轉箱用量Maximumquantityofcontainersconsumedperhour每小時周轉箱的最大使用量Shipmentsize送貨的批量大小Standardshipmentsize(inusagedays)標準的出貨大小Carrier貨運公司Nameoftransportationservicecompany運輸服務公司的名稱Timeintransit運輸時間Traveltimefromsuppliertosite(indays)從供應商處到工廠的時間（天數）Kanbanquantity看板數量Quantityofkanbancardsorpullsignalsinsystem拉動信號系統中看板卡的數量Supplierquality供應商質量Performanceratingforquality(percentage)質量的成績（百分比）Supplierdelivery供應商交付Performanceratingfordelivery(percentage)出貨的成績（百分比）SamplePFEPData數據的的案例例PFEP(PlanforEveryPart)PFEP數據庫庫PFEPDatabasePFEP數據庫庫PFEP(PlanforEveryPart)DatabasePFEP數據庫庫Foreachpartnumberinthesupermarket:在超市市中的的每個個零件件編號號：Whatistheaveragedailyusage?平均每每天用用量是是多少少？Whatistheincomingshipmentsize(daysusage)?來料出出貨的的大小小（多多少天天的用用量））？Howmuchbufferisrequired(daysusage)?需要的的緩沖沖庫存存（多多少天天的用用量））？PFEP(PlanforEveryPart)DatabasePFEP數據庫庫PlannedMaximumInventory計劃的的最大大庫存存=Dailyusage每天用用量xShipmentsizeindays’usage出貨的的大小小（多多少天天的用用量））xDays’’usagepurchasedpartssafetystock（采購購件安安全庫庫存使使用的的天數數）Safetystock:安全庫庫存：：Howmanydaysinventorydoweneedtoguardagainst…我們需需要多多少天天的庫庫存來來保障障Supplierissues?供應商商問題題？Transportationissues?運輸問問題Internalissues?內部問問題？？DeterminingBufferSize定義緩緩沖庫庫存的的大小小MaximumContainerQuantity最大周周轉箱箱數量量=PlannedMaximumInventoryLevel計劃的的最大大庫存存水平平/ContainerQuantity包裝箱箱數量量CalculatingContainerQuantity計算周周轉箱箱數量量UpdatingthePFEP更新新PFEPGroupExercise#2團隊隊練練習習#2Supermarketsizing超市市大大小小CreatePFEPDatabase創建建PFEP數據據庫庫Usethisinformationtosizethesupermarket使用用這這些些信信息息來來確確定定超超市市大大小小Designpilotsupermarketbasedonsizeandeaseofstorageandretrieval根據據尺尺寸寸及及儲儲存存的的容容易易程程度度設設計計試試產產的的超超市市的的大大小小Step3:DesignDeliveryRoutes第三三步步：：設設計計送送貨貨路路線線HeijunkaBox均衡衡化化生生產產箱箱321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品品超超市市1234Cell453KanbanPost看板架143RawMaterialsSupermarket原材材料料超超市市251234Cell761KanbanPost看板架PartsSupermarket零件件超超市市234Step3:DesignDeliveryRoutes第三三步步：：設設計計送送貨貨路路線線Setroutedrivetimeatnomorethan33%ofthenon-loadtimeoftheroute設置置路路線線運運輸輸時時間間不不超超過過路路線線空空載載時時間間的的33%Onlymovematerialwhenauthorizedbythepullsignal只有有在在收收到到被被授授權權的的拉拉動動信信號號后后才才移移動動物物料料Ensurekanbansystemrulesarefollowedandworkersremovepullsignalswhenusingthefirstpieceinacontainer確保保員員工工按按照照規規則則操操作作：：在在使使用用周周轉轉箱箱中中第第一一個個物物料料時時員員工工發發出出信信號號Synchronizethelunchandbreaktimesofthematerialhandlerontheroutewiththoseoftheworkersintheareasbeingsupported將物料搬搬運員與與生產線線員工的的午飯時時間及休休息時間間進行同同步Followspecificroutetimesandfrequenciesandinsurethatroutedeliveryisnotinterruptedforanyreason按照特定定的路線線時間及及頻率來來保證運運輸交貨貨不被任任何原因因被打斷斷Standardizeworkonthedeliveryroutetoeliminateallwastedmotionandimprovecontinuously標準化在在交貨路路線上的的作業來來消除所所有的動動作浪費費及持續續進行改改進Step3:DesignDeliveryRoutes第三步：：設計送送貨路線線Designateone-wayandtwo-wayaislesalongnaturalflowpathsinthefacility指定的單單向和雙雙向沿自自然流動動路徑的的通道設設施Designallroutestoflowthroughtheplantandbacktothesupermarket設計所有有的通過過工廠的的路線及及返回到到超市Designstopsanddeliverypointsalongtheroutetominimizethenonvalue-addedworkforthematerialhandler在路線上上設計停停止點及及交貨點點來最小小化物料料員非增增值的工工作Designstopsanddeliverypointsalongtheroutetominimizenonvalue-addedworkfortheoperatorwhoisbeingsupplied在路線上上設計停停止點及及交貨點點來最小小化生產產線員工工非增值值的工作作Startwithone-hourdeliveryroutes,aimingfora95%efficiency(57minutes)從一小時時的送貨貨路線開開始，目目標達到到95%的效率Setloadingtimeatthesupermarketat33%orlessofthecoupleddeliverytime在超市設設置取料料時間是是總交貨貨時間的的33%或更少MaterialHandlerStandardWorkExample物料員標標準作業業的案例例Step步驟StandardWorkElements標準作業步驟ConveyanceCycleTime運輸周期時間1Traveltofirstdeliverypoint到第一個送貨點120seconds秒秒2Pickupwithdrawalkanbanatfirststation(deliverypoint)從第一個工位拿取補料看板卡10seconds秒3Pickupemptycontainersandloadontotrolley拿取空箱放置到物料車上20seconds秒4Delivermaterialtofirststation將物料交付到第一個工位45seconds秒5Traveltonextdeliverypoint移動到下一個送貨點10seconds秒6Traveltoseconddeliverypoint移動到第二個送貨點15seconds秒7Pickupwithdrawalkanbanatfirststation(deliverypoint)從第一個工位拿取補料看板卡10seconds秒8Pickupemptycontainersandloadontotrolley拿取空箱放置到物料車上20seconds秒9Delivermaterialtosecondstation將物料交付到第二個工位45seconds秒10Traveltosupermarket移動到超市120seconds秒11Sortkanbancardsforbestpickingsequence根據取料的順序挑選看板卡10seconds秒12Dropoffemptycontainerspickedupduringroute將空箱放置到相應的位置45seconds秒13Collectcontainersneededforpickingandconveyance收集需要的周轉箱及運輸45seconds秒14Pickpartsandplacethemontrolley(averageof10itemsx10seconds秒perpick)取物料及將物料放置到運輸車上（平均10個零件X每次10秒）100seconds秒15Placewithdrawalkanbancardsinrespectivecontainers將補料看板卡放置到相應的周轉箱10seconds秒Totaltimeforroute總的路線時間625sec秒Step3:DesignDeliveryRoutes第三步：：設計送送貨路線線PUSH-basedMaterialHandlingRoute推動-基于物料料搬運路路線CCBACCBBAASupermarket超市CBABulkdelivery(E.g.4hoursupply)交貨大小小Requiresextraspace需要額外外的空間間AAABBBBACCCCC123PULL-basedMaterialHandlingRoute拉動-基于物料料搬運路路線CBACBACCBBAASupermarket超市CBA1234567Time-fixeddelivery(30minutessupply)固定時間間的交貨貨Mixedloadconveyance多品種的的運輸Line#1Line#28:009:0010:0011:0012:0012:3013:30Shift1345234343345234552552041041761761761119321321311761321234Finishedgoodssupermarket成品超市市CustomerPull客戶拉動???√√???ABProductionLine生產線761Kanbancollected,delivered看板收集及交付LinkSupermarketwithPullSystem將超市與與拉動體體系進行行鏈接Tofinishedgoodssupermarket送至成品品超市Heijunkabox均衡化生生產箱GroupExercise#3團隊連續續#3Designroutes路線設計計Designmaterialhandlingroutesbetweensupermarketsandpointsofuse在設計物物料在超超市及使使用點間間的運輸輸路線Practice,timeanddocumentthework練習，時時間及將將工作文文件化Documentprovisionalstandardwork,practiceandi