如何縮短制造周期二第1頁/共26頁32

GMSContinuousImprovementBuilt-In

QualityShortLead

TimePeople

InvolvementStandardizationShortLeadTime縮短制造周期Healthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessControlled

ExternalTransportationManufacturing

Process

ValidationProduct

Quality

StandardsQuality

System

ManagementScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementValuesVision/MissionShopFloor

ManagementInternalPull/DeliveryAndon

ConceptProblem

SolvingSimple

Process

FlowIn-Process

Control&VerificationStandardized

WorkSmallLot

PackagingTemporary

Material

StorageQuality

Feedback/

Feed-forwardVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

Maintenance

FixedPeriod

Ordering

System/OrderParts第2頁/共26頁ShortLeadTime

縮短制造周期學(xué)完縮短制造周期內(nèi)容，將會：明白縮短制造周期對客戶響應(yīng)及減少成本的重要性了解縮短制造周期的相關(guān)概念了解控制物料進(jìn)入及在工廠內(nèi)流動的精益物料管理系統(tǒng)第3頁/共26頁純粹的精益物流系統(tǒng)是從供應(yīng)商最后的增殖產(chǎn)品到客戶的開始使用期間，沒有等待、儲存量、雙重處理、多余庫存。ShortLeadTimeStrategy縮短制造周期策略Supplier(供應(yīng)商)Plant(工廠)

PointofUse開始使用ReceiveCustomerOrder

接收定單ProduceVehicle生產(chǎn)手機(jī)DeliverVehicle交付產(chǎn)品ReceivePayment收到付款第4頁/共26頁Themovementofmaterialintherightquantity,attherighttime,totherightlocation,withtherightequipment,usingtheshortestleadtimeandlowestpossiblecostforbothsupplierandcustomer.在最短的時間內(nèi)，供應(yīng)商與客戶雙方最少的成本損耗條件下，物料在適當(dāng)?shù)臅r間里把合適的數(shù)量用恰當(dāng)?shù)墓ぞ哌\(yùn)送到一定的地點的流動。LeanMaterialFlowDefinition

精益物流定義第5頁/共26頁1)PartsOrdering

定購零件2)Suppliers

供應(yīng)商3)Packaging

包裝4)Transport

運(yùn)輸5)Receiving

接收6)Temp.Stores臨時倉庫7)MaterialPullSystem物料拉動系統(tǒng)8)AssemblyLine生產(chǎn)線LeanMaterialsManagement

精益物料管理第6頁/共26頁FullFullFullFullEmptyEmptyOperator(操作工)PartPresentation(零件擺設(shè))Conveyance(運(yùn)輸)Staging(分段運(yùn)輸)Receive/Unload(接收/卸貨)Transportation(運(yùn)輸)Suppliers(供應(yīng)商)LOWESTTOTALCOST最低成本REDUCELEADTIMEPLANFOREVERYPARTLeanMaterialFlow:GuidingPrinciples

精益物流：指導(dǎo)原則SAFE(安全)Highvalue

added(高增殖生產(chǎn))Compression（壓）Part

Presentation

（介紹）SmallLotBulkSequenced/Repack（計、序列）Ergonomic

Space(空間)Organization(組織)FIFO(先進(jìn)先出)Method（方式）Frequency(頻率)Communicatin(交流)WindowReceiving(窗口接收)Equipment(裝置)Frequency(頻率)

DirectShip(直接運(yùn)輸）100%Tracked(100%跟蹤)Responsive(響應(yīng))OnTime(及時)Right

Quantity(數(shù)量)To

Specifications(合適規(guī)格)第7頁/共26頁1.VehicleSchedules制造計劃生產(chǎn)計劃應(yīng)均衡各個階段的生產(chǎn)需求。百分百地在交付日期交貨。整個生產(chǎn)部門都應(yīng)該了解制造狀態(tài)。支持減少手機(jī)交付時間和各種生產(chǎn)限制。CustomerOrder客戶定單：WhencanIgetmymobilephone?(什么時候可以交付?)143256ProductionPlan第8頁/共26頁2.PartsOrdering:IndividualParts

訂購：個件Partorderbaseduponaprojectedvehiclebuildschedule零件訂購要以設(shè)定的生產(chǎn)計劃為基礎(chǔ)Order=(PartsNeeded)-(PartsHave)

訂單=(需要零件)-(現(xiàn)有零件)PickUpDocument

訂購文件Deliveryquantityandtiminginstructionspershipment每次運(yùn)輸?shù)臄?shù)量及時限CCIPlantDeliverySupplierPickUpDocumentPickUpDocumentPlantLinesideOperation第9頁/共26頁3.SupplyBase(供應(yīng)基地)在CCI工廠附近為對制造周期有特殊要求的零件設(shè)立的基地（通常是些定序的分裝件）(按先后需求排序是合格供應(yīng)商的職責(zé)):------在送到生產(chǎn)線之前供應(yīng)商擁有庫存供應(yīng)數(shù)量最低化:零件或分裝件的單一供應(yīng)點總供應(yīng)基地的最小化（供應(yīng)商數(shù)量）

基于總材料傳送成本決定貨源第10頁/共26頁4-1.TransportationandReceiving

運(yùn)輸與接收每天運(yùn)送頻率預(yù)警：貨車司機(jī)在供應(yīng)商處檢查貨物貨物不符時協(xié)商Suppliers(供應(yīng)商)MON.-8:00amTUE.-8:00amWED.-8:00amTHU.-8:00amFRI.-8:00amCBA第11頁/共26頁4-1.TransportationandReceiving運(yùn)輸與接收LeadLogisticsProvider(LLP):On-sitesinglepointofcontactforplant.(現(xiàn)場單一聯(lián)系)Routeplanningandscheduling.(路線計劃與安排)Visualroute/dockboard.(目視化路線/接收板)PlantReceiving:工廠接收Visualboard(目視化欄板)-Canlookatboardandseewhatishappening(看欄板就可以知道情況)Scheduled，

daily/weekly日/周計劃-Whenmaterialwillarriveatplant(什么時候零件能到達(dá)工廠)Levelunloadplan(平衡卸貨計劃)PlantLLPTransportationRouteBoardxx#1#2#3#4RouteTime第12頁/共26頁定義：不直接把材料從供應(yīng)商處運(yùn)送到線旁，而是暫時將其集中存放的區(qū)域。目的：組織控制不直接由供應(yīng)商送到生產(chǎn)線的材料庫存量、產(chǎn)量和物流4-2.CentralMaterialArea(集中材料區(qū)域)第13頁/共26頁4-2.CentralMaterialArea(集中材料區(qū)域)第14頁/共26頁KeyConcepts(主要概念):Organizebybulk/cartontoseparateequipment&minimizespacerequirements(用大箱或紙箱裝零件來隔離設(shè)備，減少空間需求)1locationperpartnumber(一個零件一個存放點)Minimizespace(空間最小化)Minimizedeliverylead-time(運(yùn)送時間最小化)4-2.CentralMaterialArea(集中材料區(qū)域)KeyBenefits(主要益處):Optimizespace,manpower&equipment(優(yōu)化空間、人員及設(shè)備)Min.impactofproductionpullfluctuations(減少生產(chǎn)拉動波動的影響)SupportF.I.F.O.(支持先進(jìn)先出)第15頁/共26頁Definition

(定義):Amethodofmaterialreplenishmentbasedonconsumption,authorizedbytheuser,whosendsasignaltomanufacture,ship,ordeliveryaproductataspecifictime,place,andquantity.

(使用者認(rèn)可的，通過向生產(chǎn)、運(yùn)輸部門發(fā)出信號，要求在一定時間內(nèi)在具體地方運(yùn)送定量產(chǎn)品的一種補(bǔ)充消耗物料的方法。)AflexibletoolthatenablesJust-in-Time.

(一個能確保JIT的靈活工具)Connectsoperationstomaterialsupply.(連接生產(chǎn)與材料供給.)

5.InternalPull/Delivery(內(nèi)部拉動/運(yùn)送)第16頁/共26頁5-1.TypesofInternalPullSystems

(內(nèi)部物流的拉動系統(tǒng)的種類)EmptyContainerPullProcess(空箱拉動系統(tǒng))PullCardProcess(卡片拉動系統(tǒng))ElectronicPullSystem(EPS)(電子拉動系統(tǒng))“Nothingmoveswithoutapullsignal(無信號無拉動).”第17頁/共26頁P(yáng)ullCardProcess(卡片拉動系統(tǒng)):Description(定義):

Amaterialpullsystemthatusescardstocommunicatereplenishmentrequirements(使用卡片來傳遞供貨信息的物流拉動系統(tǒng))(投遞卡片)(掃描卡片)(運(yùn)送材料）第18頁/共26頁EPSProcess(EPS系統(tǒng)):(材料需求)(電子識別)(材料提取，分運(yùn)）(材料運(yùn)送)(交貨結(jié)束)第19頁/共26頁EmptyContainerPullProcess(空箱拉動系統(tǒng))Using

LocationReplenishProductionTeamMember生產(chǎn)人員PushOutPushInEMPTYFULL第20頁/共26頁Simpledesign(簡單設(shè)計)Designtoenablemultiplepartnumbersperdelivery

(能夠每次多零件運(yùn)送的設(shè)計)Standardizeequipmentandcomponentsthroughouttheplant(numberoftypes,hitches,chassis)(整個工廠設(shè)備及零件標(biāo)準(zhǔn)化（種類、栓、底盤的數(shù)目）)Designformanualmanipulation(pushandpull).(人工操作（推或拉）的設(shè)計)6.MobileEquipment

(運(yùn)輸設(shè)備):NOYESExample(實例):LinesideDelivery(線旁運(yùn)送)第21頁/共26頁DollyExamples(手推車實例)Bulkcontainerdollybase(Standard)(大箱手推車基座)(標(biāo)準(zhǔn))SwivelTurntableBase(旋轉(zhuǎn)轉(zhuǎn)盤基座)第22頁/共26頁7.PartPresentation

(零件展示）Returnablecontainers(回收空箱)Oneortwohoursusagepercontainer(每個箱一到兩小時的用量)Hand-carriedorhand-manageable(dolly)(手提或手推)Easypartpick(容易提取)Properpartslabeling(合適的標(biāo)簽)Stackable(層疊)Simpledesign(設(shè)計簡單)PartPresentation(零件擺設(shè)):WithinWorkstation(在工位內(nèi))Withinarm’sreachatpointofinstallation(安裝點在手臂可及處)Lessthan5feetinheight(lineofsight)(高度低于5英尺)HandManageable(人工操作)5feetPartASmallLotContainer(小裝箱)Bringthepartstotheoperator(零件運(yùn)送到操作工身旁)第23頁/共26頁

零件展示實例能夠人力或自動移動裝螺絲螺栓的圍兜減少運(yùn)動浪費(fèi)小件包裝第24頁/共26頁LeanMaterialFlow