4 ANPS 一件流生产方式 (简体字)

One-Piece-FlowProduction一件流生产方式One-Piece-FlowProduction一件流生产方式FunctionofOne-Piece-Flow一件流的作用NewProductionSkill新生产技术↓AconceptandskillsofcompletelyeliminatingMUDA彻底消除无駄的生产思想及技法↓Trytofindoutmorepotentialproblemsforkaizen要设法发挥更多的潜在问题以改善↓Trytoletpotentialproblemstobevisualized要设法使潜在问题被看出来↓OnepieceflowisaconceptandskillsofcompletelyexposingpotentialMUDAS一件流就是能完全暴露潜在无駄的思想及技法Horizontal(Functional)Layout水平机能别布置SingleSkillOperator单能工Multi-Machineoperation多机台操作TransportationNecessary需要搬运ReduceFrequencyofTransportation减少搬运次数IncreaseTransportationBatchSize增加搬运批量IncreaseWIP增加在制品IncreaseSpace增加空间IncreaseThroughputTime交期时间变长One-Piece-FlowProduction一件流生产方式FeaturesofConventionalBatchProduction传统批量生产的特征One-Piece-FlowProduction一件流生产方式FeaturesofOne-Piece-Flow一件流生产的特征Thefinalgoaloflineisone-piece-flow.流线生产的终极目标是一件流One-Piece-Flowmeans一件流的意义：ProcessonepieceInspectonepiecetransferonepiecetonextprocess加工一件检查一件传送一件到下工序Vertical(Product)Layout垂直式产品别布置Multi-Processoperation多任务序操作Multi-Skilloperator多能工One-Piece-FlowProduction一件流生产方式Advantagesofone-piece-flow一件流之优点ProductionType生产方式BatchSize批量生产OnePieceFlow一件流生产WIP在制品LeadTime交期时间Space空间需求Defects不良品Manpower人员需求Productivity劳働生产力VisualManagement目视管理MarketResponse市场反应High高Long长More多High高Fixed固定Low低Difficult难Difficultandslow难且慢Almostzero极低Short短Less少Low低Flexible变化Higher较高Easy易Easyandfast易且快One-Piece-FlowProduction一件流生产方式WhatisLeadTime(LT)何谓交期时间LT交期时间＝ProcessTime加工时间＋InspectionTime检查时间＋TransportationTime搬运时间＋StagnationTime停滞时间Reason原因：TransportationBatchSizeistoolarge搬运批量太大Result结果：StagnationTimebecomeslonger停滞时间变长ProcessSequence工程顺序ProcessTime加工时间TransportationBatchSize搬运批量LT交期时间＝1min分X5pcs件(ProcessTime加工时间)＋1min分X995pcs件(StagnationTime停滞时间)＝1000min分TransportationBatchSize搬运批量：1PC件LT交期时间＝1min分X5pcs件＝5min分One-Piece-FlowProduction一件流生产方式WhyLeadTimeissolong为何交期时间太长123451min分1min分1min分1min分1min分200pcs件200pcs件200pcs件200pcs件200pcs件Kaizen(1)Basicconceptforproduction生产的基本观念One-Piece-FlowProduction一件流生产方式BasicRulesforOne-Piece-Flow(1/4)一件流基本做法WIPStagnation物有停滞HavehundredMUDAS,noanybenefit有百害无一利Towardtoachieveone-piece-flow朝一件流生产迈进From“Turbulenceflow”to“Rectifiedflow”从“乱流“变为“整流“One-Piece-FlowProduction一件流生产方式BasicRulesforOne-Piece-Flow(2/4)一件流基本做法(2)BasicsteptoachieveOne-Piece-Flow实现一件流的基本步骤Oneline一条线Bigsize大批量Slowmove流动慢Morelines多线化Smallsize小批量Fastmove流动快Finalgoal目标Onepieceflow一件流Coating涂装2Inspection检查4Assembly装配3Forming成型1123412341234123412341234(3)Byprocessdivide工程分割One-Piece-FlowProduction一件流生产方式BasicRulesforOne-Piece-Flow(3/4)一件流基本做法TurbulenceFlow乱流RectifiedFlow整流Processdivide,One-piece-flow工程分割,一件流A1A2B1B2B3B4C1C2A2A1B1B2B3B4C1C2A1B1B2C1A2B3B4C2(4)Mergerseparate合流分离One-Piece-FlowProduction一件流生产方式BasicRulesforOne-Piece-Flow(4/4)一件流基本做法TurbulenceFlow乱流RectifiedFlow整流MergerSeparate,One-piece-flow合流分离,一件流A1A2A3C1B2C2C3B1A1A2A3B1B2C1C2C3A1B1C1A2B2C2A3C3B3(1)PrinciplesofLayout排线方面的原则Lineupmachinebysequenceofprocess机器依照工程顺序排列Ascloseraspossibleincounterclockwise依照逆时钟方向尽量靠拢ByUturnshapemovement排出U型流动Putthefirstprocessandlastprocessonthesameendpoint首尾工序排在同一端One-Piece-FlowProduction一件流生产方式PrinciplesfordesignofOne-Piece-Flow(1/4)一件流設計原則One-Piece-FlowProduction一件流生產方式PrinciplesfordesignofOne-Piece-Flow(2/4)一件流設計原則(2)PrinciplesofEquipment设备方面的原则Oneprocesshaveonemachine一个工序有一台机器Smallcapacityiseasierforlinerequirement小产能设备较佳Higherrateofavailabilityisimportant可动率高很重要Jidokamachineisakeyinfluencefactor自働化设备是重要影响因素(3)Principlesofmaterials材料方面的原则Onepieceflow一件流动Quickchangeover快速切换Synchronization同步生产Nostagnation不要停滞One-Piece-FlowProduction一件流生产方式PrinciplesfordesignofOne-Piece-Flow(3/4)一件流設計原則One-Piece-FlowProduction一件流生产方式PrinciplesfordesignofOne-Piece-Flow(4/4)一件流設計原則(4)Principlesofman人员方面的原则Multi-processoperation多任务序操作Multi-skillsoperator多能工技能Walkingoperation走动作业OperatorinsideofUturncell作业者在U型内侧