TOC生产管理

TOC(Drum-Buffer-Rope)295205Tel:[phone]Fax:[phone]©2005TOCGreatChinaInc.AllRightsReserved™–VAIT––™TOC–DBR–()–(BufferManagement)–(BufferManagement)™™DBR&3©2005TOCGreatChinaInc.AllRightsReservedV?V–PlantV,A,I,T4©2005TOCGreatChinaInc.AllRightsReservedA?A–PlantV,A,I,T5©2005TOCGreatChinaInc.AllRightsReservedI?I–PlantV,A,I,T6©2005TOCGreatChinaInc.AllRightsReservedT?T–PlantV,A,I,T7©2005TOCGreatChinaInc.AllRightsReserved™/–Forecast––––Layout,–,––setup–,™––™––™––––––(efficiency)™–FIRSTPASSYIELD–REWORK–8©2005TOCGreatChinaInc.AllRightsReserved™….™….9©2005TOCGreatChinaInc.AllRightsReservedWeakestLinkPhysicalViewofSystemPhysicalViewofSystemPhysicalViewofSystem2012161510CauseEffectEffectEffectEffectEffectWeakestLinkRootCauseFlowof“Goal”unitsÆFlowofCause-EffectÆLogicalViewofSystemLogicalViewofSystemLogicalViewofSystemTOCDrum–Buffer–Rope“”10©2005TOCGreatChinaInc.AllRightsReservedWeakestLink….“Acentplusacentplusa…willaccumulatetoafortune…”RealistGlobalImprovement=∑LocalImprovement“Acentplusacentplusa…willaccumulatetoafortune…”RealistGlobalImprovement=∑LocalImprovement“IfIfindtheleveragepointIcanmovetheearth...”ArchimedesGlobalImprovement≠∑LocalImprovement“IfIfindtheleveragepointIcanmovetheearth...”ArchimedesGlobalImprovement≠∑LocalImprovement—11©2005TOCGreatChinaInc.AllRightsReservedTOC–DBR(5focusingstep)1.(Identify)()2.(Exploit)3.(Subordinate)4.(Elevate)5.12©2005TOCGreatChinaInc.AllRightsReservedProcessA2ProcessA2ProcessA1ProcessA1ProcessA3(CCR)ProcessA3(CCR)ProcessA4ProcessA4ProcessA5ProcessA5InInOutOutCCRBufferShippingBufferDRUMROPEROPEBufferManagement1223340TOC–DBR()13©2005TOCGreatChinaInc.AllRightsReservedTimeserialTaTbTcTdt1t2Ta:LotinputTd:LotEndTb:LotstartatbottleneckTc:LotFinishatbottleneckt1:Buffertime(frominputtobottleneckstart)t2:Buffertime(frombottleneckfinishtoend)Customerrequiredate=TdTd-t2=TcTc–processtimeatbottleneck=TbTb–t1=TaTOC–DBR()14©2005TOCGreatChinaInc.AllRightsReservedM1M2M3M4ShippingScheduleOrder1:Due3/2Order2:Due3/3Order3:Due3/4Order4:Due3/9Order5:Due3/9ConstraintSchedule2/20-Order1+52/24-Order22/25-26-Order32/26-27-Order4ThisistheDrumShippingbufferof5workingdaysMaterialsreleaseschedule:Order1:2/6Order5:2/6Order2:2/10Order3:2/11Order42/12ThisistheRopeTheconstraint'sbufferof10workingdaysTOC–DBR()15©2005TOCGreatChinaInc.AllRightsReservedTimeserialTOC–DBR(Drum)16©2005TOCGreatChinaInc.AllRightsReserved5/1304:005/1302:005/130:005/1222:005/1220:005/1218:005/1216:005/1312:005/1310:005/1308:005/1306:005/1320:005/1318:005/1316:005/1314:005/1404:005/1402:005/140:005/1322:005/1408:005/1406:00TOC–DBR(BufferManagement)™030500004030500002030500006030500007030500008030500009030500012030500013030500014030500016030500003030500005030500010030500011;ST_BAOK17©2005TOCGreatChinaInc.AllRightsReserved1.Inputcontrol3.Bottleneckcontrol5.OutputCheck2.BufferManagement4.BufferManagementTimeBufferTimeBufferTimeBufferTimeBufferTOC–DBR()18©2005TOCGreatChinaInc.AllRightsReservedBMindex(Statistics)DBR(planning)BM(Control)ProduceDBRAdjustPriorityActionAbnormalityProcessManpowerEquipmentResource(BufferManagement)19©2005TOCGreatChinaInc.AllRightsReservedup20%AvailableFloorSpacedown50%MaterialHandlingup75%CustomerSatisfactiondown94%OrderProcessingLead-Timedown93%ProductionLead-TimeFordMotorCompany20©2005TOCGreatChinaInc.AllRightsReserveddown30%CycleTimeup35%ThroughputFlatOperatingExpensedown40%Inventoryup28%WaferOutput*Sixmonthsafterimplementation.HarrisSemiconductor21©2005TOCGreatChinaInc.AllRightsReserved030403050306W30W31W32W33W34W35W36W37W38W39W40ALL90%-C/TAvg-C/T™3W28–W402003/641.9%27.3%(I)22©2005TOCGreatChinaInc.AllRightsReserved030403050306W30W31W32W33W34W35W36W37W38W39W40A90%-C/TAvg-C/T™A–A43.8%35.2%90%38.0%–W402003/4A3.4%113.5%90%18.3%(I)23©2005TOCGreatChinaInc.AllRightsReserved030403050306W30W31W32W33W34W35W36W37W38W39B90%-C/TAvg-C/T030403050306W30W31W32W33W34W35W36W37W38C90%-C/TAvg-C/T030403050306W30W31W32W33W34W35W36W37W3890%-C/TAvg-C/T,,™–(I)24©2005TOCGreatChinaInc.AllRightsReserved(II)25©2005TOCGreatChinaInc.AllRightsReserved(II)26©2005TOCGreatChinaInc.AllRightsReserved(II)27©2005TOCGreatChinaInc.AllRightsReservedDBR&™TOC-DBRMESWIPERPMESTOC-DBRTOCDBRMES28©2005TOCGreatChinaInc.AllRightsReservedFivefocusingSteps1.(Identify)()2.(Exploit)3.(Subordinate)4.(Elevate)5.WeakestLinkQ&A()295205Tel:[phone]Fax:[phone]