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123Dc98High98Low303830653880650090002003601205008020030080400803502704035080Dk1260106092045•?•••?••••-()•-•-2-46“”7••()••••••ABC•-•8“”9•••••••••-•10“”11DFT••••12“”13“18031945”14“”15#6•()()••-42••30%()BOM•--()•--16•••-()•-••-DC••-••DCTAKT-17-“”1888=1(60)“Rhythm”19•()••(4)•-•SOE--204808=60“Rhythm”21•••••••410312•DC•22()TAKT=Hx(60min/hr)x(S)Dc23•TAKT=HxSSumDc•-•24••••DFT•25#7••••••OMS••26#2ProductSynchronization•DefinitionofProcesses•RelationshipofProcesses•BuildingtheProcessMap•WhereweStart•WhereweareGoing•AChallengetoAchieve•AlwaysCreatesDiscussions27Flow-Speed-Response--•WorkStepsgroupedtoaTimeTarget-FlowOverallProcessataRateorRhythm-•TotalProductCycleTimeTPc/t-OneLongestPath--EliminateScheduling,Queue,andWait--SystematicEliminationofNon-ValueAdded--ProduceInOnlytheTimeitTakestodoWork-•FlattenedBillsofMaterial-MovementIn&OutofStockEliminated--ReducedNumber&NeedforTransactions--IncreasedResponseinEngineeringChange-28StaffingtoDailyRateProcessFormingBaseAssyTestPackTotalOperations54104326DcResourcesDc4.23.59.23.72.82.4DRResReqDR3.537.83.22.42029inSERIESorPARALLEL?..?Time?..??30FeederProcessesFEEDERPROCESS31REWORKLOOP(s)REWORK&REPEATRE-ENTERSAMEPLACE32OPTIONALWORKOPTIONAL&PROCESSPROCESSFANSOUT33FAMILYOFPRODUCTS34WALLTOWALL35#3IdentificationofProducts•AssociateDemandwiththeseProducts•ManyKinds?WhoAreOurCustomers?-FinishedProductsweShip(SKUs)--FieldReplaceableUnits-()-SisterPlantProducts--OptionsandFeatures--RepresentativeProducts-•ProductsonHorizon-ProductsDevelopment-•InvolvingOrderObtainment/Acquisition/36#4ProcessMap•SearchforCommonality•ProductsSharingCommonProcesses-OperationswithMethodSheets-OMS-Training&Certification--ContinuousProcessImprovement-•Understanding&AccomodatingVariations37PROCESSESRELATIONSHIPSXXX20%80%100%12.49.06.2DUCTS38#5DemandatCapacity•MarketDriven•ViewingtheBusinessinDays•FutureLooking•WithFlexibilityforMixandDemandFluctutations•VarietyofUses-Plant&Equipment(DC)-(Dc)-KanbanSizing(DK)-(DKK)-DailyDemandManagement(DR)-(DR)39History•MarketDriven,FuturePointTarget•ShipmentHistory•OrdersPicture-Cancellations-•ForecastInput-Acquisition&Fullfillment-OrdersForecast12...9...6...3...2...1.3???2?5?81.540#6ProcessFactorsInfluencingDemand•ProductDefinition(alwaysrequired)()-4Wheels&2Axles-30%(Option)ofPBOMRequires-SameProcessConsumedMultipleTimes-MultiplePassesthroughProcess•RecoverableYield-Rework(sometimesrequired)-•Non-RecoverableYield-Scrap-41TAKTTimeTargets•TranslaesCustomerDemandtoaUnitofTime(usuallyminutes)()•GermanforRhythm•VariesbyProcess•NoDatafromSOEsNeededtoCalculate-Volume&TimeSOE-•CreatesFlowSymphonyintheMidstofMixedModelVariety42SumofDemandsatCapacity•MixedModelVolume•VariesofVolumesbyProcess•DrivesTAKTTimewithnoKnowledgeofWorkContentTimes43EffectiveWorkHours•ActualWorkTime•ClockHoursminus-BreaksandLunch--EmployeeInvolvementMeetings--JobPreparation,SuitUp,CleanUp-()•MostRepresentativeShift•VisiblyVerifiedAssumptions•X60ConvertstoMinutes44TAKTTimeinMinutes()TAKT=Hx(60min/hr)x(S)xDC45#7SequenceofEvents•OneCorrectWaytoDoWork•BringingQualitytothePointWhereWorkisPerformed•TimeEstimatesforLineDesign•ValueAddedAnalysis•EssentialBuildingBlock-OperationswithMethodSheets-OMS-Training&Certification--ContinuousProcessImprovement-4647SOETimeEstimatesSOE•Generous,butReasonable-AllowTimeforTQC(#1Priority)-TQC(#1)-FromStarttoFinishofaTask--SumoftheParts=theWhole-(WristWatchversusStopWatch)-=()-EmployeeFlexinginFlowProcess-•RepresentativeofTypicalAssociates•SeveralObservations(3to5)(35)•UnitofMeasureUsuallyMinutes(.05)(0.05)48ValueAddedWorkContentValueAddedWorkTotalWorkContent=%???•WhatDoesThisMeasure?•ThePerfectSOE?SOE•WhereareYourProducts?49QualityCriteriaisaFailure..ProductDesignProcessDesignVerify&TQC-SuccessiveChecksTQC50SuccessiveChecks-TQC-TQC1100=1%Defects(partsperHundred)1%()1100X1100X1100=.0001%Defects(PartsperMillion).0001%()51KeyDFTDataSummaryDFT•ProductSynchronization•Products&MarketDrivenDemand•SequenceofEvents-SOE•DFTQualityOperations&MethodsDFT-OMS52DFMFUNDAMENTALSFactoryReengineeringDFTData&QualityElementsDFT53#8MixedModelLineDesign•DFTDeployed-CycleTimeLineDesignDFT-•ProductDemand&AttributesLinkedwithProcesstoProduce•HighestMixPossible•SynchronizedFlow•WorkGroupedtoTimeTargets•SumDC,ATW,TAKT,ResourcesDc,Atw54LINEDESIGNCALCULATIONSpRODUCTSABCDE...X24108164....7DCREQANDOPTIONSYIELDSCRAPSumDCAtwTAKTResourcesSOETOTALTIMESSOE55RESOURCEREQUIREMENTSLINEDESIGN:ONCETODCDcDAILYREQUIREMENT:DAILYTODRDRATW=SUM(DCXAT)SUM(DC)ATWTAKT=RESOURCES,LABOR/MACH./56TIMESINDFTDFT•TAKTTime-VolumeDrivenTimeTargets(byprocess)-()•ActualTimes(AT)(AT)-FromtheSequenceofEvents-SOE•Operations-WorkGroupedtoaTAKTTimeTarget-•Balance-BetweenActualTimeatOperations&TAKTTime(notbetweenoperations)-()57#9FamilyofProducts•TheOverallVision•CommonalityoverDifference-SimilarProcesses--TypesofWork&TimesofWork--FacilitiesandEquipment--SetupTimesandCharacteristics--MaterialPresentation--Yields-•ExploitingMix-2+2=3-2+2=358FACTORYREENGINEERINGSTAMPINGTESTCOILASSEMBLYLACEBRAZINGTESTWIPSTOCKROOMSTOCKFINALASSYLINEFUNCTIONALPRODUCTIONTHR
本文标题:DFT的JIT教材
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