推式与拉式系统-jit

及時化生產系統1及時化(justintime，JIT)概述提出者：豐田汽車副社長，大野耐一(TaiichiOhno)。意義將需要的物品在必須的時間供應必須的品質與數量到需要的地點。目的消除混亂使系統彈性化降低籌置與前置時間存量最小化消除浪費及時化生產系統2JIT目標和建築架構的歸納產品設計流程設計人員因素製造規劃避免中斷使系統有彈性排除浪費平衡迅速的流程最終目標支援目標建築架構及時化生產系統3常見的資源浪費1超額生產(overproduction)等候時間(waitingtime)不必要的運送(unnecessarytransporting)存貨(inventory)加工浪費(processingwaste)不必要的生產步驟產出瑕疵品及時化生產系統4常見的資源浪費2無效的工作方法(inefficientworkmethod)不佳的佈置和物料搬運模式，增加在製品存貨產品不良再製成本消費者不滿意造成銷售損失及時化生產系統5WasteinOperations及時化生產系統6WasteinOperations及時化生產系統7WasteinOperations及時化生產系統8ThePrinciplesoftheTOYOTAProductionSystem(TPS)1Allworkmustbecompletelyspecifiedastocontent,sequence,timing,andoutcome.Everycustomer-supplierconnectionmustbedirect,unambiguouslyspecifyingthepeopleinvolved,theformandquantityoftheservicesorgoodstobeprovided,thewaytherequestsaremadebyeachcustomer,andtheexpectedtimeinwhichtherequestswillbemet.及時化生產系統9ThePrinciplesoftheTOYOTAProductionSystem(TPS)2Thepathwayforeveryserviceandproductmustbesimpleanddirect.Anyimprovementtothesystemmustbemadeinaccordancewiththescientificmethod,undertheguidanceofateacher,atthelowestpossibleorganizationallevel.及時化生產系統10BasicElementsofJIT1標準的零件(產品設計)模組化設計(產品設計)高產能的系統(產品設計)可同時生產(產品設計)將員工視為資產(人員/組織的要素)訓練員工，使其變成多能工(人員/組織的要素)持續改善(人員/組織的要素)成本會計(人員/組織的要素)領導與專案管理(人員/組織的要素)及時化生產系統11BasicElementsofJIT2Cellularlayouts(製程設計Pullproductionsystem(製造規劃與控制)Flexibleresources(製程設計)Kanbanproductioncontrol(製造規劃與控制)Small-lotproduction(製程設計)Quicksetups(製程設計)Uniformproductionlevels(製造規劃與控制)Qualityatthesource(製程設計)Totalproductivemaintenance(製造規劃與控制)Suppliernetworks(製造規劃與控制)及時化生產系統12FlexibleResourcesMultifunctionalworkers(多能工)PerformmorethanonejobGeneralpurposemachines(通用設備)PerformseveralbasicfunctionsStudyoperators&improveoperations及時化生產系統13CellularLayoutsGroupdissimilarmachinesinmanufacturingcelltoproducefamilyofpartsWorkflowsinonedirectionthroughcellCycletimeadjustedbychangingworkerpaths及時化生產系統14ManufacturingCellwithWorkerRoutesWorker1Worker2Worker3Cell1及時化生產系統15WorkerRoutesLengthenedasVolumeDecreasesCell5Worker2Cell2Worker1Cell1Worker3Cell3Cell4及時化生產系統16推式與拉式系統推式系統(pushsystem)(例如，MPR)當工作在某工作站完成時，產出就被推往下一站。拉式系統(pullsystem)(例如，JIT)工作移動的控制落於下一站;每一工作站從前一站拉拔所需產出。及時化生產系統17KanbanProductionControlSystem(看板生產管制系統)KanbancardindicatesstandardquantityofproductionDerivedfromtwo-bininventorysystem(雙倉制)KanbanmaintainsdisciplineofpullproductionProductionkanban(生產看板)authorizesproductionWithdrawalkanban(提領看板)authorizesmovementofgoods及時化生產系統18ASampleKanban及時化生產系統19TheOriginofKanbana)Two-bininventorysystemb)KanbaninventorysystemReordercardBin1Bin2Q-RKanbanRRQ=orderquantityR=reorderpoint-demandduringleadtime及時化生產系統20TypesofKanbans—Dualkanbans及時化生產系統21Single-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2StorageareaEmptycontainersFullcontainersAssemblyline1Assemblyline2及時化生產系統22StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline2及時化生產系統23StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline2及時化生產系統24StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline2及時化生產系統25StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline2及時化生產系統26StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline2及時化生產系統27StorageareaEmptycontainersFullcontainersSingle-CardKanbanSystemReceivingpostKanbancardforproduct1Kanbancardforproduct2FabricationcellO1O2O3O2Assemblyline1Assemblyline2及時化生產系統28看板系統—singlekanban及時化生產系統29Dualkanbanvs.singlekanbanDualkanbanIsusedwhenmaterialisnotnecessarilymovingbetweentwoconsecutiveprocesses,orwhenthereismorethanoneinputtoaprocessandtheinputsaredispersedthroughoutthefacility.SinglekanbanIsusedwhentheprocessesaretightlylinked.及時化生產系統30TypesofKanbansKanbanSquareMarkedareadesignedtoholditemsSignalKanbanTriangularkanbanusedtosignalproductionatthepreviousworkstationMaterialKanbanUsedtoordermaterialinadvanceofaprocessSupplierKanbansRotatebetweenthefactoryandsuppliers及時化生產系統31TypesofKanbans—kanbansquareandkanbanracks及時化生產系統32TypesofKanbans—signalkanbans及時化生產系統33看板管理系統之規則不要把不良品交給後製程。由後製程到前製程來領取零件。前製程僅生產將被後製程領用去的數量。生產必須平衡。看板只做為微調整的手段，其張數必須減到最少。製程必須安定化、合理化。及時化生產系統34Single-CardKanbanSystemKANBANPartNumber:1234567ZLocation:Aisle5Bin47LotQuantity:6Supplier:WS83Customer:WS116EachcontainermusthaveacardAssemblyalwayswithdrawsfromfabrication(pullsystem)ContainerscannotbemovedwithoutakanbanContainersshouldcontainthesamenumberofpartsOnlygoodpartsarepassedalongProductionshouldnotexceedauthorization及時化生產系統35看板(容器)數量之決定1K=容器數量。d=工作中心之計劃使用率