精益生产改善路径图

KAIZENROADMAPTAKT/CustomerDemandCapacity/TOCAnalysisLoad/LineBalanceAnalysisValueStreamMappingSpaghettiMapCellDesign/DevelopNewLayoutDevelopContinuousFlowOn-goingContinuousImprovement(As-is&Tobe)(As-is&Tobe)(Tobe)(As-is)(As-is)Understandcurrentsituation/BaselineUnderstandcurrentsituation/BaselineUnderstandVOCUnderstandcurrentProcessWasteeliminationCostdownKAIZENROADMAP1.VOC-Takttime•TaktTime=DemandRateTaktTime=AvailabletimeRequestedQtyＡＢ①KAIZENROADMAP2.Capacityanalysis020004000600080001000012000140001600018000JanFebMarAprMajJunJulAugSepOktNovDecVOCvsCapacityvsOutputCustomerdemandcapacityRealoutput0100200300400500600MachineB(3pc)540(Capacity)MachineA(3pc)MachineC(2pc)242(Capacity)360(Capacity)360(Load)180(Load)135(Load)3.Load/LineBalanceLoad/CapacitycumulativeA、FormachineBloadexceeditscapacity(242-180=62H);B、TokeepOTDitshouldarrangeoverworktime62HformachineB(Load/capacityadjustment)KAIZENROADMAP3.Load/LinebalanceKAIZENROADMAP29.227.029.026.226.528.024.223.022.00.05.010.015.020.025.030.035.0010203040506070809T.T=33TOC=29.2UtilizationlossBalancelossLinebalance(%)=(∑C.T/∑29.2*n)×100%=89.5%Linebalanceloss(%)=1-Linebalance(%)=10.5%5.4KnittingDipping2ndWashing/dryingHeattransfermarkingPackingBottleneckOver-WIPandwastewillgeneratediflinenotbalanced9.75.49.7Linebalance(%)=(Capability5.4*n/∑capability)×100%=52.7%Linebalanceloss(%)=1-Linebalance(%)=47.3%Productionloss=Averagecapability-currentcapability=8.3-5.4=2.93.Load/Linebalance7.09.7BottleneckEOLRKAIZENROADMAPCapacitycalculation---EOLR产能计算ProcessProcess1Process2Process3Process4Process5Capacity100pc/H75pc/H110pc/H80pc/H125pc/HKAIZENROADMAPProductionControlMRPDailyShipScheduleWeeklyScheduleDailyOrderWeeklyFAXForecast(2months)CuttingsewingFormingFINISHEDGOODSRAWMATERIALCustomerSupplierVSM-CurrentC/T=?(TCT1)People:?Uptime=?C/O=?minBatchsize=?FTY=?Shift:1(8H)?Monthlydemand:11000pr?Dailydemand:500pr?Packing10days?80sec?3days?1day?58sec?2days?10days?30sec?140sec?DTD=26day?MCT=308sec(25person?)PcsC/T=?secDTD=26days?VA=308sec?VAR%=VA/DTD*100%=?EOLR?EOLR?EOLR?EOLR?C/T=?(TCT2)People:?Uptime=?C/O=?minBatchsize=?FTY=?Shift:1(8H)?C/T=?(TCT3)People:?Uptime=?C/O=?Batchsize=?FTY=?Shift:1(8H)?C/T=?(TCT4)People:?Uptime=?C/O=?Batchsize=?FTY=?Shift:1(8H)?WIP?Distance?Distance?Distance?WIP?WIP?WIP??KAIZENROADMAP4.ValueSteamMappingPartAPartBPartCPartDPartENon-FlowPartsA&CPartsB&DPartEFlowNon-FlowVS.FlowDifferentfactorycomparisonKAIZENROADMAP5.SpaghettiMapTraditionalLayoutMaterialFlowinaProcess-OrientatedLayout以工序为导向的物料流程Machinesgroupedtogetheraccordingtotheirfunction按照机器的功能将一样的机器放在一起KAIZENROADMAP5.SpaghettiMapWorkshopLayoutDrillAreaMillAreaTumbleBenchAreaBroachFPIShot/GlassPeenHeatTreatInspectionCastClean1234567891011121314151617EXAMPLEKAIZENROADMAP5.CellDesignCellDesignKAIZENROADMAPLayoutImprovementBeforeAfterGrinder6Grinder5Grinder7Grinder4Mill2Lathe1Roll8Lathe3Lathe1FromRMpileToWIProomLathe3Mill2Lathe1Lathe2Grinder4Grinder5Grinder6Grinder6Grinder6RMhouseSemi-FP/FPhouseKAIZENROADMAP