计划生产的精益方法论Heijunka-中文版

ACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISEHeijunkaCookbook计划生产的精益方法论ACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE1.选择生产线AnalyzeHistoricalSalesDataDetermineBuildStrategyCalculateTaktTimeLevelLoadSequenceUnderstandwhatismade明白要做什么型号3000400016种硬件配置79个零件编号23个供应商每年14,000台DASH2493种定单组合ACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE2.识别特殊型号或配置产品有多少种不同的型号?每种型号不同在哪里?举例:Dash3000/4000病人监护仪16种不同的硬件配置:•3000or4000•有没有复写器•有没有RF•NellcororMasimoAnalyzeHistoricalSalesData首先搞清楚产品DetermineBuildStrategyCalculateTaktTimeLevelLoadSequenceUnderstandwhatismadeModelParameterRecorderNetworkPartNo.13000NellcorWriterNoRF2015999-00223000NellcorNoWriterNoRF2015999-00333000NellcorWriterRF2015999-00443000NellcorNoWriterRF2015999-00553000MasimoWriterNoRF2015999-00663000MasimoNoWriterNoRF2015999-00773000MasimoWriterRF2015999-00883000MasimoNoWriterRF2015999-00994000NellcorNoWriterNoRF2015999-010104000NellcorWriterNoRF2015999-011114000NellcorWriterRF2015999-012124000NellcorNoWriterRF2015999-013134000MasimoNoWriterNoRF2015999-014144000MasimoWriterNoRF2015999-015154000MasimoWriterRF2015999-016164000MasimoNoWriterRF2015999-017ACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE3.做一个产品系谱AnalyzeHistoricalSalesDataDetermineBuildStrategyCalculateTaktTimeLevelLoadSequence哪些零件是每个型号都要用上的?哪些零件是用在部分型号上的?Understandwhatismade首先搞清楚产品产品系谱不是简单的BOM.它在了解一种零件的组装频率上起了很大的作用ACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE4.要明白哪些零件装到产品里每个组件都包括哪些零件(规格和数量)UnderstandwhatismadeSubassembliesHOUSINGSPEAKERGROUNDPLUGPOWERSUPPLYBRACKETBATTERYCOVERASSEMBLYFOOTPADDASMASIMODASNELCORECPUCPUw/RFSIDECOVERWRITER4000Display3000DISPLAY3000Handlew/oRF3000Handlew/RF4000Handlew/oRF4000Handlew/RFQtyPart#Name1419029-002Bracket12000414-001CblAssy1412048-001Washer1411323-001Nut1421955-002Insulator1420647-001SIL-PAD1801394-001ACPWRSupply42000540-001Screw14535-001Ty-wrapPOWERSUPPLYAnalyzeHistoricalSalesDataDetermineBuildStrategyCalculateTaktTimeLevelLoadSequence首先搞清楚产品ACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE5.收集以往的销售数据不能预测未来…历史是最好的销售预言家Understandwhatismade分析以往的销售数据DetermineBuildStrategyLevelLoadCalculateTaktTimeSequenceAnalyzehistoricalsalesdataSalesOrder#Model#QuantityShipDateQuarter1096558DSH40-BAA-AEB-AXX63/2111099117DSH40-BAA-ALB-AXX103/2111098190DSH40-BAA-XEA-AXX83/2111098190DSH40-BAA-XEB-AXX33/2111099218DSH40-BAA-XIB-AXX63/2111098370DSH40-CAA-AEB-AXX33/2111097422DSH40-CAB-XIB-XXX13/2111098677DSH40-CHB-XAA-XXX1003/2111097832DSH40-DAA-XAD-XXX53/2111099226DSH30-BAA-AAB-XXX13/2211099209DSH30-BAA-ACA-XXX23/2211098592DSH30-BAA-AEB-XXX13/2211099143DSH30-BAA-XAD-XXX13/2211099330DSH30-BAA-XEA-XAX63/2211099305DSH30-CAA-AAD-XXX13/2211100616DSH30-DBB-XCB-XXX103/2211100043DSH30-DCB-XCB-AXX43/2211098242DSH30-DHB-XAA-XXX33/221ACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE6.按照不同的部件分解销售数据AnalyzehistoricalsalesdataSalesOrder#DASMASIMODASNELLCORSIDECOVERWRITERRF3000Display4000Display3000Handlew/oRF3000Handlew/RF4000Handlew/oRF4000Handlew/RF1096558060600600601099117010010001000100109819008800080080109819003300030030109921806600060060109837003030030030109742201100010010109867701001000001000010001097832055000500501099226010101010001099209020202020001098592010101010001099143011001010001099330066066006001099305010101010001100616010100010010000110004304400404000109824203300303000Understandwhatismade分析以往的销售数据DetermineBuildStrategyLevelLoadCalculateTaktTimeSequenceACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE7.总量数据Analyzehistoricalsalesdata计算出每个季度的总量DASMASIMODASNELLCORSIDECOVERWRITERRF3000Display4000Display3000Handlew/oRF3000Handlew/RF4000Handlew/oRF4000Handlew/RFQ1200289738411902691231324814748932367551387Q220029957011445533125825628909971887663700Q3200294571716052181352270611799402119553711Q420021158767181232912472398117211622334505768Q12003774907123893486523469537771730834920Total2002399525696052134950881091447153992870722722566Past5quarters4769347672902283595313260566847691043731063486Past4quarters387230926100201447221001241943876807025553099Understandwhatismade分析以往的销售数据DetermineBuildStrategyLevelLoadCalculateTaktTimeSequenceACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE8.计算出组件的百分比用总量数据来计算出每个季度已销售组件的百分比Analyzehistoricalsalesdata举例:在2002年第四季度卖出的所有仪表板里66%的产品有NellcorDAS组件.DASMASIMODASNELLCORSIDECOVERWRITERRF3000Display4000Display3000Handlew/oRF3000Handlew/RF4000Handlew/oRF4000Handlew/RFQ120022%98%72%28%9%61%39%55%6%36%3%Q2200221%79%58%42%16%48%52%39%9%45%8%Q3200220%80%63%37%6%51%49%47%5%47%2%Q4200234%66%65%35%9%46%54%40%6%50%3%Q1200333%67%50%50%27%51%49%37%14%36%13%Total200219%81%64%36%10%52%48%45%6%45%4%Past5quarters22%78%61%39%14%52%48%44%8%43%6%Past4quarters27%73%59%41%15%49%51%41%8%45%6%Understandwhatismade分析以往的销售数据DetermineBuildStrategyLevelLoadCalculateTaktTimeSequenceACTIONWORKOUTgLEANENTERPRISELEANLEANENTERPRISE9.选择数据预测未来的销售情况如何选择:•市场的变化?•产品的稳定性?•Stageinproductlife?Analyzehistoricalsalesdata给市场变化下定义…2002年第一季度的数据不再具有代表性.DASMASIMODASNELLCORSIDECOVERWRITERRF3000Display4000Display3000Handlew/oRF3000Handlew/RF4000Handlew/oRF4000Handlew/RFQ120022%98%72%28%9%61%39%55%6%36%3%Q2200221%79%58%42%16%48%52%39%9%45