精益生产之超市系统

SupermarketSystem超市系统ActivitySWNo.:4.5.7SupermarketSystemRevision#:004Lastimproved:06-Aug-2013Improvedby:A.MeesterObjectivesofthisModule这个模块的目标Participantswillbeableto:参与者能够•Identifywheresupermarketsareneededwithinavaluestreamtosupportapullsystem识别出在价值流的哪里需要设置超市来支持拉动系统•UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用PFEP数据库来正确的估算及维护超市•Linksupermarketstotheoverallkanbansystemsandconveyanceroutes将超市与整个看板体系及运输路线链接起来Topics主题•WhatisaSupermarket?什么是超市？•ThreeStepsofSupermarketDesign超市设计的3大步骤•SupermarketLocation超市地址•SupermarketSizing超市大小•PFEP(PlanforEveryPart)DatabasePFEP数据库•DesignDeliveryRoutes设计交付路线•RunningtheSupermarket运行超市•GroupExercises团队练习JargonBuster专业术语•Supermarket超市•PFEP(PlanforEveryPart)单个零件计划•Addresssystem地址系统•Kanban看板•Routes路线•VMI供应商管理库存JargonBusterPFEP?Supermarket?Addresssystem?WhatisaSupermarket?什么是超市Operation工序20Operation工序10PULL拉动Supermarkets超市Shipping出货Rawmaterials原材料In-processstock在制品库存Finishedgoods成品WhatisaSupermarket?什么是超市？•Adeliberatelydesignedmaterialstoresareawithcontrolledquantitiesofmaterials故意设定的区域储存可控数量的材料•Thedownstreamprocesstakeswhatisneededandthesupermarketowner(theupstreamprocess)replenishments下游工序拿取需要的材料，超市的所有人（上游工序）进行补料•Unliketraditionalstoresarea,noorderforms,paperworktransactions,orstockrequisitionsareneededotherthankanban不同于传统的储存区域，没有除看板以外的订单格式，纸质的交割或者物料申请HeijunkaBoxFinishedGoodsSupermarket成品超市143WhatisaSupermarket?什么是超市RawMaterialsSupermarket原材料超市25KanbanPost看板架1234CellKanbanPost看板架1234CellPartsSupermarket零件超市WhatisaSupermarket?什么是超市？Amaterialstoresareawhich:物料储存区：•Putsmaterialclosetopointofuse将物料放置在靠近使用点•Eliminatesshortages消除物料短缺现象•Setsminimumandmaximumlevelsforinventory设定最大库存及最小库存量•Usesfloorspaceefficiently更有效的利用空间•Simplifiesorderingandmaterialhandling订购及物料搬运简单化•Removesnonvalueaddedactivities:(receiving,puttingaway,kitting,counting,cycling,requisitions)消除不增值的动作：（收货，摆料，配料，点数，循环，申请）•Improvesmaterialflowintheproductcells改善生产线的物料流程•Andmakesthestatusofmaterialsvisible让物料状态可视化WhatisaSupermarket?什么是超市？•Simplevisualsystemsshowmaterialflow简单可视化的物料流•Location,addressandquantitycontrol位置，地址及数量管理WhatisaSupermarket?什么是超市？Supermarketsandmaterialpresentation超市及物料准备•Achieveexcellent6S实现卓越的6S•Presentmaterialsandtheirinformationvisibly让物料及信息更加目视化•Eliminatedefects消除不良•Usegravityfeeds使用重力送料•Reducemotionforloadingandunloading减少上料及退料的动作•MaintainFIFO维护先进先出ThreeStepsofSupermarketDesign超市设计的3大步骤1.Setsupermarketlocation设置超市的地址2.Wherewillsupermarketshelpusmost?超市设置在哪里更有帮助3.Determinesupermarketsizing定义超市大小•PFEPdatabasetodeterminequantitiesPFEP数据库来定义数量•Spacerequired空间的要求4.Designdeliveryroutes定义送货路线–Standardworkforwithdrawalanddeliveryofpartsandcontainers补料及送货及周转箱的标准作业Step1:SupermarketsLocation第一步：超市选址Typicalsupermarketlocations典型的超市地址•Attheendoftheproducerprocesswheneverpossible,asarule在有可能的情况下设置在在生产工序的尾部•Atpointofuse(VMI,Citems)在使用点（供应商管理库存，C类零件）•Atreceiving(forexternalsuppliers)在收货区（外部供应商）•Closetothepointofuseaspossible越靠近使用点越好•Directdeliverytothesupermarket直接交货到超市•Minimizerepeatedhandling将重复搬运减少到最少12Step1:SupermarketsLocation第一步：超市选址Step1:SupermarketsLocation第一步：超市选址StandardApproach标准的方法•Locatesupermarketsattheendofthesupplierprocessorproductionline将超市设置在供应流程的最尾端或生产线•Makeproblemsimmediatelyvisibletotheproducerprocess将问题立刻可视化的传递到生产工序•Donotsacrificevisibilityforthesakeofoptimizingtheworkofmaterialhandlers不为优化物料搬运工作的缘故而牺牲可视化Step1:SupermarketsLocation第一步：超市选址Line生产线F1Line生产线F2Line生产线F3Supermarket超市1Supermarket超市2Supermarket超市3Line生产线A1Line生产线A2Line生产线A3Step1:SupermarketsLocation第一步：超市选址CentralizedSupermarket集中化的超市•Duetohighvolumeandormix,thefacilitylayout,thesupermarketmaynotalwaysfitattheendoftheline因为大批量或多品种，工厂格局的原因，超市也许不能总是设置在生产线的尾部。•Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstreamanddownstreamprocesstominimizematerialhandling集中化的超市用于当他们设置在上游及下游工序来减少物料搬运•Supermarketsforincomingpartsforassemblymaybelocatednearthereceivingdock来料零件超市可以设置在靠近收货区Step1:SupermarketsLocation第一步：超市选址Line生产线F1Line生产线F2Line生产线F3ConsolidatedSupermarket统一的超市Line生产线A1Line生产线A2Line生产线A3GroupExercise#1团队练习#1Goseeactivity去现场看•Walkthroughthevaluestreamfromendtoend–Usevaluestreammapstoassist通过现场查看整个价值流—在价值流程图的帮助下•Identifylocationswithinsitevaluestreamswheresupermarketsareneeded在价值流程图中识别出哪里需要超市–Documentonfuturestatemapswhereapplicable将适用的地方在未来价值流程图上体现•Wherecanwe…哪里我们可以–Supportkanbansystemefforts?支持看板系统？–Minimizeinventorylevels?最小化库存水平？–Improvevisibilityandeliminateshortages?提升可视化及消除物料短缺？Step2:SupermarketSizing第二步：超市大小Howmuchofeachpartwillwekeeplineside?每个零件我们需要多少在生产线旁•Frequencyofconveyance运输的频率•Quantityofconveyance运输的数量•Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartofanoverallroute通过高频率小批量的交付来最小化生产线旁的物料Step2:SupermarketSizing第二步：超市大小Inordertodeterminesupermarketsize,weneedtoknow…为了定义超市的大小，我们需要知道•Usagevolume(quantity)用量的多少（数量）–Whatistheschedulingmethod?什么是计划的方法？–Hastheusagebeenleveled?用量被均衡化了吗？–Hasthemixbeensmoothed?生产种类被稳定了吗？–Isthereafrozentimewindow?有一个冻结的时间窗口吗？•Deliveryfrequencyupstream上游工序的交货频率•Deliveryquantity交货数量•Containersize周转箱大小•Locationofsignal信号的位置•Weight重量•Andmore等等ThePlanforEveryPa