精益生产之2箱补充拉系统2-Bin_Replenishment_Pull(中

MeasureAnalyzeControlImproveLeanSixSigma2-BinReplenishmentPullIntroductionto2-BinReplenishmentPullLine-sideversusPoint-of-UseStocking2-BinDataNeedsandCalculationsInventoryDispositionOptionsCardTriggered2-BinProcess1-BinSystemsAppendixRD011202MeasureAnalyzeControlImproveLeanSixSigma2-Bin补充拉系统2-箱补充拉系统的介绍线旁VS使用点库存2-箱数据的要求和计算库存部署选择卡触发2-箱流程1-箱系统附录RD011202Improve2-BinReplenishmentPull3LeanSixSigmaImprovementProcessRoadMapAnalyzeControlImproveDefine•IdentifyProblem•DevelopListofCustomers•DevelopListofCTQ’sfromVoiceoftheCustomer•FinalizeProjectFocusandKeyMetrics•CompletePDFMeasure•MapBusinessProcess•MapValueStream•DevelopDataCollectionPlan•ConductMeasurementSystemAnalysis•CollectData•ConductProcessCapabilityAnalysisAnalyze•ProposeCriticalX’s•PrioritizeCriticalX’s•VerifyCriticalX’s•EstimatetheImpactofEachXonY•QuantifytheOpportunity•PrioritizeRootCauses•ConductRootCauseAnalysisonCriticalX’sImprove•CriticalX’sConfirmed•DevelopPotentialSolutions•SelectSolution•OptimizeSolution•PilotSolutionControl•ImplementProcessChangesandControls•WriteControlPlan•CalculateFinalFinancial/•ProcessMetrics•TransitionProjecttoFutureOwners•IdentifyProject•TranslationOpportunitiesMeasureDefine•ProjectIDTools•ProjectDefinitionForm•NetPresentValueAnalysis•InternalRateofReturnAnalysis•DiscountedCashFlowAnalysis•PIPManagementProcess•RACI•QuadCharts•ProcessMapping•ValueAnalysis•Brainstorming•Multi-VotingTechniques•ParetoCharts•C&E/FishboneDiagrams•FMEA•CheckSheets•RunCharts•ControlCharts•GageR&R•Cp&Cpk•SupplyChainAcceleratorAnalysis•Multi-Vari•BoxPlots•InteractionPlots•Regression•ANOVA•C&EMatrices•FMEA•Brainstorming•PullSystems•SetupReduction•TPM•ProcessFlow•Benchmarking•Affinity•DOE•HypothesisTesting•ForceField•TreeDiagrams•GanttCharts•CheckSheets•RunCharts•Histograms•ScatterDiagrams•ControlCharts•ParetoCharts•InteractiveReviews•Poka-YokeRevised1-12-02Improve2-BinReplenishmentPull4LearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentouseabinSystemBeabletosize(calculate)alltheparametersforabinsystemImprove2-BinReplenishmentPull5课程目的理解箱补充系统的不同类型知道一个箱系统的好处理解何时使用一个箱系统能够去计算一个箱系统的所有参数Improve2-BinReplenishmentPull6What’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystemImprove2-BinReplenishmentPull7我学到了什么?能够在黑带项目中应用这个工具能够实施一个箱系统Improve2-BinReplenishmentPull82-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofastandardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedpartsPurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartreplenishmentis“triggered”basedonconsumptionImprove2-BinReplenishmentPull92-箱补充拉系统的介绍2-箱补充拉系统是一个标准的补充拉系统的简化版本，其好处是：在一个流程中建立战略性的零件缓冲区原材料制造的零件采购的零件成品通过缓冲库存将供应过程和消耗过程联系起来零件的补充是基于消耗而触发的Improve2-BinReplenishmentPull10WhatIsa2-BinReplenishment?Formanypartsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedperiodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe“1st”isbeingrefilled/replenished.Therearetwoprimaryreplenishmentlocations:Line-SideandPointofUseImprove2-BinReplenishmentPull112-箱补充拉系统是什么?对于在流程中的众多零件而言，一个2-箱系统可以被用来补充零件相对于同步供应:一箱有足够零件/供应品以满足在使用点上已计算出的用量周期。当第一箱用完了后，在补充/重新装料时，第二箱取代第一箱的位置继续满足使用。有两个主要的补充地点：线旁和使用点Improve2-BinReplenishmentPull12Benefitsof2-BinReplenishmentOrganizedandoverallcleanerappearanceofstoredmaterialsReducedfrequencyoforderssubmittedtothestockroom/vendorReducednumberoftripsforre-supplyBettermanagementofinventoryontheshopfloorMorepredictableinventorycostsImproveemployeeproductivityby:Eliminatingpart/supplyshortagesatthepoint-of-useReducetimewastedbypersonnel/supervisionretrievingsupplies/inventoryfromthestockroomand/orvendorsEliminatelostormisplacedmaterial2-BinReplenishmentcanbeusedforoffice/safetysupplies,productioninventory,productionsupplies–evenathome!Improve2-BinReplenishmentPull132-箱补充拉系统的好处存储的材料外观非常清洁和有条理提交给库房/供应商的频率减少重复供应的差错数量减少了现场库存的管理更好库存成本更具有预测性提高员工生产率:排除在使用点的零件/供应短缺减少由于人员/管理等，从库房和/或供应商重新找回供应/库存的时间浪费排除材料的丢失或放错地方2-箱补充可以被使用在办公室，安全供应，生产库存，生产供应—甚至在家里!Improve2-BinReplenishmentPull14WhentoUse2-BinReplenishmentPullRepetitiveproductoffering/processRelativelyconsistentdemand/volume(lowvariability)Part/supplyshortagesareaconsistent/costlyproblemPart/supplyinventorycostsare“outofcontrol”dueto:Lostormisplacedparts/suppliesLackofissue/dispersaldisciplineorcontrolImprove2-BinReplenishmentPull15何时使用2-箱补充拉系统重复的产品供应/流程重复稳定的需求(底变异)零件/供应短缺是常事，且是一个代价很大的问题零件/供应库存成本是失控的，由于：零件/供应品丢失或放错地方缺乏投料/分发的一致性或控制Improve2-BinReplenishmentPull16WhatIsaBin?Doesn’tnecessarilylooklikea“bin”Canbeastandardplasticbin(Acro-bin)Canalsobethebox/containerthepart/supplyisshippedin(alsocalleda“standardpack”–purchasingdefinition)Whenthebox/containermethodisused,a“bin”canbeonestandardpackorseveralstandardpacks.Examples:1boxofscrew