MaterialMovementinaLeanManufacturingOperation

優(yōu)化生產(chǎn)中物流活動(dòng)TotalSystemsDevelopment

全體系生產(chǎn)提升優(yōu)化生產(chǎn)中的物流活動(dòng)第1頁(yè)JIT生產(chǎn)(按時(shí),準(zhǔn)量生產(chǎn)):Whatismeantbytheterm,“Just-In-Time”?JIT生產(chǎn)意味著什么?DoesitmeanJITSupply?按時(shí),準(zhǔn)量供給?DoesitmeanJITProduction?按時(shí),準(zhǔn)量生產(chǎn)?優(yōu)化生產(chǎn)中的物流活動(dòng)第2頁(yè)So,whatisJust-In-Time?

那么,什么是按時(shí)準(zhǔn)量生產(chǎn)?Theconceptofproducingthenecessaryunitsinthenecessaryquantitiesatthenecessarytimeisdescribedbytheshort-phrase“Just-In-Time”.JIT生產(chǎn)是:在必需時(shí)間內(nèi)生產(chǎn)必需數(shù)量必需部品概念.優(yōu)化生產(chǎn)中的物流活動(dòng)第3頁(yè)Forexample….Inbuildingshoes:Thenecessarysubassembliesoftheproceedingprocess(uppersandbottoms)shouldarriveattheassemblylineatthetimeneededintheamountsneeded.舉例說(shuō)明:在生產(chǎn)成品鞋時(shí)候:制鞋所必需部件(鞋幫和鞋底)要按時(shí),準(zhǔn)量,準(zhǔn)型號(hào)地抵達(dá)制造車間.優(yōu)化生產(chǎn)中的物流活動(dòng)第4頁(yè)IfweachieveJIT:

假如我們做到按時(shí),準(zhǔn)量生產(chǎn):Unnecessaryinventorieswillbeeliminated.無(wú)須要庫(kù)存就會(huì)消除Storesandwarehouseswillnotbeneeded.儲(chǔ)存區(qū)和倉(cāng)庫(kù)也能夠取消Materialcarryingcostswillbediminished.資材搬運(yùn)成本降低優(yōu)化生產(chǎn)中的物流活動(dòng)第5頁(yè)However….TorelysolelyonacentralplanningapproachthatinstructstheproductionschedulestoallprocessessimultaneouslyisnotlikelytoresultinaJITprocessforalloperations.不過：?jiǎn)渭兊匾蕾囉?jì)劃生產(chǎn)方法,使全部工序同時(shí)生產(chǎn)，并不能完全實(shí)現(xiàn)全部步驟按時(shí)，準(zhǔn)量生產(chǎn).優(yōu)化生產(chǎn)中的物流活動(dòng)第6頁(yè)TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每七天生產(chǎn)計(jì)劃Typically,onecontroloperationreceivesthecustomers’ordersanddisseminatesschedules.

通常，生產(chǎn)控制部門接收客戶定單，然后制訂并傳達(dá)計(jì)劃.

ProductionControl生產(chǎn)控制優(yōu)化生產(chǎn)中的物流活動(dòng)第7頁(yè)TransferWasherAssemblyMachining加工Welding焊接Assembly組裝Shipping裝船WeeklySchedule每七天生產(chǎn)計(jì)劃ProductionControl生產(chǎn)控制IIIIIITheproblemcomeswhenachangeismadeeitherbecausetheorderchangesorequipmentbreaksdown.

不過當(dāng)定單有改變或設(shè)備出現(xiàn)問題時(shí)候，就會(huì)發(fā)生一些問題：庫(kù)存庫(kù)存庫(kù)存庫(kù)存優(yōu)化生產(chǎn)中的物流活動(dòng)第8頁(yè)Theresultisexcessinventory…

結(jié)果是造成過多庫(kù)存……withintheplantasWork-In-Process…在本車間工序內(nèi)積壓過多庫(kù)存…supplierssendinginpartsthatarenotneeded…上一道工序發(fā)來(lái)并不需要部件優(yōu)化生產(chǎn)中的物流活動(dòng)第9頁(yè)Additionally另外,Weneedextrafloorspacetostorethematerial.我們需要額外空間來(lái)堆放材料Needexpeditorstosatisfythechangesinschedule.需要人力和時(shí)間投入來(lái)改變生產(chǎn)計(jì)劃Runovertimetomakeuppartsthatwenowneed.用加班時(shí)間來(lái)生產(chǎn)現(xiàn)在所需部件優(yōu)化生產(chǎn)中的物流活動(dòng)第10頁(yè)Toyotarethoughthowtocommunicateschedules.

豐田企業(yè)對(duì)調(diào)整生產(chǎn)計(jì)劃做了改進(jìn):Toyotadiscoveredadifferentwaytomanagetheirschedule,豐田使用不一樣方法來(lái)制訂調(diào)整生產(chǎn)計(jì)劃Theystoppedtryingtoguesswhatthecustomerwillwant.他們并不去猜測(cè)客戶需求優(yōu)化生產(chǎn)中的物流活動(dòng)第11頁(yè)Instead相反..Eachdepartmenthadinstalledasmallinventoryofeachproduct.每個(gè)車間都保持少許庫(kù)存Downstreamprocessescometothesupplyingdepartmentsandtakewhatitneeds.下一道工序到上一道工序去取他們所需部件Thisallowstheprocessesupstreamtosimplyreplacewhatwastaken.這么,上一工序只要補(bǔ)充被取走部件即可.優(yōu)化生產(chǎn)中的物流活動(dòng)第12頁(yè)TheToyotaProductionSystem

TPS豐田體系….Islikelytobethemoststudiedanddiscussedoperationsprogramintheworld.是極可能被全世界研究和討論體系NumerousbooksandpapershavebeenwrittenaboutTPS.出版了很多關(guān)于TPS書籍和其它資料ManyhavecometocharacterizeTPSas“l(fā)eanproduction”orNOS.許多人認(rèn)為豐田體系(TPS)實(shí)際上就代表優(yōu)化生產(chǎn)或NOS優(yōu)化生產(chǎn)中的物流活動(dòng)第13頁(yè)LeanManufacturing(NOS)

NOS優(yōu)化生產(chǎn)Regardlessofanyauthor’sopinionorrational,allagreethatthefoundationofleanmanufacturing(NOS)isthecontinualpursuittoeliminatewaste.盡管大家觀點(diǎn)有些不一樣,但全部些人都認(rèn)為NOS基礎(chǔ)是連續(xù)不停地降低浪費(fèi)Wasteisdefinedasanythingthatconsumesresourcesortime,butdoesnotaddvaluetotheproduct.浪費(fèi)是任何花費(fèi)資源或時(shí)間,但不增加產(chǎn)品價(jià)值活動(dòng)優(yōu)化生產(chǎn)中的物流活動(dòng)第14頁(yè)ExcessInventoryisWaste

多出庫(kù)存是一個(gè)浪費(fèi)Excessinventoryhidesproblems多出庫(kù)存會(huì)隱藏一些問題SeaofInventory大量庫(kù)存RawMaterial

原資材FinishedGoods

成品LongTransportation過長(zhǎng)運(yùn)輸時(shí)間VendorDelivery

供給商運(yùn)輸Absenteeism缺勤Commun-icationProblemPoor

Scheduling計(jì)劃不力MachineBreakdown設(shè)備停機(jī)QualityProblems質(zhì)量問題LineImbalance線內(nèi)不平衡LongSet-UpTime過長(zhǎng)調(diào)整時(shí)間LackofHouse-Keeping倉(cāng)儲(chǔ)管理問題溝通問題優(yōu)化生產(chǎn)中的物流活動(dòng)第15頁(yè)OurgoalformaterialsmanagementinNOS

NOS資材管理目標(biāo)Theidealstateisasmoothflowofmaterialsthroughoutourownfactory理想狀態(tài)是物料在整個(gè)工廠內(nèi)順暢流動(dòng).Wewanttotietogetherprocessesthatareseparatedbylargephysicaldistances.使那些有一定距離而相對(duì)分離生產(chǎn)流程緊密結(jié)合起來(lái)Weneedtoimprovecommunicationinregardstomaterialmovement.在物流方面要加強(qiáng)各工序間溝通優(yōu)化生產(chǎn)中的物流活動(dòng)第16頁(yè)ThePushSystem

”推進(jìn)“生產(chǎn)體系Intraditionalmanufacturing,variousproductionschedulesarereleasedtoallprocesses;componentmakingandassembly.在傳統(tǒng)生產(chǎn)中,各種生產(chǎn)計(jì)劃被傳到達(dá)各個(gè)工序,部件生產(chǎn)和組裝部門.優(yōu)化生產(chǎn)中的物流活動(dòng)第17頁(yè)ThePushSystem(cont.)”推進(jìn)“Thesepart-makingprocessesproducethepartsinaccordancetotheirschedulesandtransportthepartstothenextprocess.部件生產(chǎn)部門按照收到計(jì)劃生產(chǎn)并把成品部件運(yùn)輸?shù)较乱坏拦ば?優(yōu)化生產(chǎn)中的物流活動(dòng)第18頁(yè)ThePushSystem(cont.)”推進(jìn)“Thismethodmakesitdifficulttopromptlyadapttochanges.這種方法使生產(chǎn)極難快速對(duì)改變作出反應(yīng)Eachproductionschedulemustbechangedateachprocesssimultaneously.每個(gè)工序生產(chǎn)計(jì)劃都必需同時(shí)改變以適應(yīng)同時(shí)生產(chǎn)優(yōu)化生產(chǎn)中的物流活動(dòng)第19頁(yè)ThePushSystem(cont.)”推進(jìn)”TheResult造成:Thecompanymustholdextrainventoryamongallprocesses.企業(yè)不得不在各個(gè)工序保持額外庫(kù)存Thiscreatesanimbalanceofstockbetweenprocesses.各工序間庫(kù)存達(dá)不到平衡優(yōu)化生產(chǎn)中的物流活動(dòng)第20頁(yè)ThePullSystem

“拉動(dòng)”生產(chǎn)體系Incontrast,inaPULLSYSTEM,eachprocesswillwithdrawthepartsitneedsfromtheproceedingprocess.相反,“拉動(dòng)”生產(chǎn)體系要求各個(gè)工序僅需從上一道工序提取自己所需要部件.BA“production”kanban“withdrawal”kanbanProduct部件Product部件Market供給超市SupplyingProcess供給工序CustomerProcess客戶工序“生產(chǎn)”指示板“拒收”指示板優(yōu)化生產(chǎn)中的物流活動(dòng)第21頁(yè)ThePullSystem(cont.)”拉動(dòng)”體系Sinceonlythefinal-assemblyprocesscanaccuratelyknowthenecessarytimingandquantityofpartsrequired,theyaretheonlyonestoreceiveaschedule.因?yàn)橹挥兄圃鞙?zhǔn)確地了解所需時(shí)間和部件數(shù)量,以只要制造收到生產(chǎn)計(jì)劃即可.優(yōu)化生產(chǎn)中的物流活動(dòng)第22頁(yè)AssemblyStock-fit準(zhǔn)備Stitching縫紉Assembly制造Shipping裝船WeeklySchedule每七天生產(chǎn)計(jì)劃FinalAssemblyreceivesascheduleandpullsfromtheMarketPlace.StitchingandStock-fitreplenishestheMarketPlace.制造接收生產(chǎn)計(jì)劃,并借助“供給超市”拉動(dòng)生產(chǎn).縫紉和準(zhǔn)備向“供給超市”補(bǔ)充部件.ProductionControl生產(chǎn)控制優(yōu)化生產(chǎn)中的物流活動(dòng)第23頁(yè)ThePullSystem(cont.)”拉動(dòng)”體系Withtheschedule,thefinal-assemblygoestothesupplyingdepartmentsandwithdrawswhatpartsareneeded.依據(jù)生產(chǎn)計(jì)劃,制造到供給車間去提取所需部件.優(yōu)化生產(chǎn)中的物流活動(dòng)第24頁(yè)ThePullSystem(cont.)”拉動(dòng)“生產(chǎn)Theprecedingoperationthenproducesthereplacementsofthepartswithdrawnbythesubsequentprocess.這么,前一道工序開始生產(chǎn)被下一道工序提走部件以補(bǔ)充所需.BAssembly制造Stitching縫紉A“production”kanban“withdrawal”kanbanProduct部件Product部件Market供給超市“生產(chǎn)”指示板“拒收”指示板優(yōu)化生產(chǎn)中的物流活動(dòng)第25頁(yè)Markets“供給超市”Marketsarethestoragelocationsforallthepartspriortogoingtothenextoperation.

“供給超市”是為下一道工序儲(chǔ)存所需各種部件區(qū)域.Marketssimplyareorganizedcollectionsofpurchasedpartsandwork-in-process.

組建“供給超市”只是為了搜集購(gòu)置部件和線上庫(kù)存.Ifpartsarealreadystoredinyourplant,thenyoucanconstructmarkets.

假如工廠內(nèi)有儲(chǔ)存部件,那就能夠設(shè)置此體系.優(yōu)化生產(chǎn)中的物流活動(dòng)第26頁(yè)CautionsaboutMarkets

關(guān)于“超市體系”警告:Don’tgetcaughtupinotherpeople’sphilosophy.不要受別觀點(diǎn)影響:Marketsdonothavetobelocatednexttothereceivingdocks.超市不一定要靠近部件接收區(qū)Marketsdonothavetobelargeinsize.

規(guī)模不一定很大Youcanhaveseveralmini-marketsifspaceisdifficulttoget.若空間不夠,可設(shè)多個(gè)分散小超市.Useyourowncommonsense利用自己常識(shí)來(lái)處理問題!優(yōu)化生產(chǎn)中的物流活動(dòng)第27頁(yè)RulesfordevelopingMarkets

設(shè)置“超市”規(guī)則:Haveastoragelocationforeverypart.

為每一部件設(shè)置儲(chǔ)存區(qū)Determinethemaximumofanyonepartthatwillbestored.為任一需儲(chǔ)存部件設(shè)置最大庫(kù)存標(biāo)準(zhǔn)Provideadequatestoragespace.

提供適當(dāng)儲(chǔ)存區(qū)域Safetyisapriority.

要優(yōu)先考慮安全原因.優(yōu)化生產(chǎn)中的物流活動(dòng)第28頁(yè)LessonsLearnedaboutMarkets

設(shè)置超市需注意幾點(diǎn):Haveanoverflowspotandameanstomonitor.

設(shè)置庫(kù)存限制和監(jiān)控方法Trytoreservespacesforfutureparts.

提前考慮，為以后部件留出儲(chǔ)存空間Preferably,donotstorethesamepartinmorethanonelocation.同一部件最好儲(chǔ)存在一個(gè)區(qū)域Makesureaislewayscanaccommodateforklifts.

確保過道可容納或通行搬運(yùn)工具.優(yōu)化生產(chǎn)中的物流活動(dòng)第29頁(yè)Determinecustomerdemand確定客戶需求Takttimeisareferencenumberthatgivesyouasenseforthepaceatwhicheachprocessneedstobeproducing.

TAKT節(jié)拍時(shí)間為了解并調(diào)整各個(gè)工序生產(chǎn)速度提供參考依據(jù)Tocalculatetakttime,dividetheavailabletimebythecustomerdemand.

用可利用生產(chǎn)時(shí)間除以客戶需求量，即為節(jié)拍時(shí)間.優(yōu)化生產(chǎn)中的物流活動(dòng)第30頁(yè)Forourplant對(duì)我們企業(yè)來(lái)說(shuō):Oneshiftisninehoursthereisone60-minutelunch9小時(shí)一個(gè)班次,其中有1個(gè)小時(shí)就餐休息時(shí)間Work-time工作時(shí)間8Hrs.X60min/hr=480minutes8小時(shí)X60=480分鐘480minutespershiftThereis28,800secondspershift480分鐘每個(gè)班次,即28,800秒每個(gè)班次優(yōu)化生產(chǎn)中的物流活動(dòng)第31頁(yè)Customerdemand客戶需求Thecustomerneeds2,000pairseachday.客戶天天需要2,000足鞋WeworkoneshifteachdayinAssembly,6daysperweek.制造車間天天一個(gè)班次,每七天工作6天Customerdemandis客戶需求是:2,000Pairs/28,800sec2,000足/28,800秒or1PAIRevery14.4seconds

或每14.4秒需要產(chǎn)一足鞋優(yōu)化生產(chǎn)中的物流活動(dòng)第32頁(yè)Marketsetupsandlocations

供給超市準(zhǔn)備和位置選定Locatespacewithintheplantthatcanbeusedasamarket(s).

選定企業(yè)可作為超市位置Minimizethenumberofmarkets.Ifmaybenecessarytostartwithseveralsmallones,latertocombineintoone.

盡可能降低超市數(shù)量,若有必要可先設(shè)置幾個(gè)小超市,以后再合并成大超市.優(yōu)化生產(chǎn)中的物流活動(dòng)第33頁(yè)Manpowerandequipmentneeded

人員和設(shè)備要求PartsaredeliveredtothelinebyMaterialHandlersusinghand-carts.搬運(yùn)人員用手推車將部件運(yùn)到生產(chǎn)線TheMaterialHandlerhasadesignatedroutethatcoversallthestationshe(orshe)isresponsiblefor.搬運(yùn)人員按照指定運(yùn)輸路線負(fù)責(zé)自己工作區(qū)域Hedeliversallpartsneededonthatdeliverycycle,retrievesallemptycontainers搬運(yùn)人員必須循環(huán)搬運(yùn)所需部件,并取回空部件箱優(yōu)化生產(chǎn)中的物流活動(dòng)第34頁(yè)Training培訓(xùn)Thepeoplewhoareaffectedbythenewsystemneedtounderstandwhythecompanyhasimplementedtheprogram.新體系所包括到人員需要知道為何企業(yè)實(shí)施此體系Thosewhoaretosupportitmustunderstandhowitworks.支持新體系人員需知道體系是怎樣運(yùn)作Allpeoplemustreceiveadequatetraininginorderforthesystemtobebothrobustandsu