工厂,价值流与现场成本控制

1.ABB20101020203030404PONCPONCPOCPOC05051.61.6––1.51.5––1.41.4––1.31.3––1.21.2––1.11.1––31.11.11.141=+2=-1251.21.21.2……61.31.31.3BCBAC71.41.41.4Man4MMethodsManchineMaterial1.51.51.58A(Man)1)2)3)4)5)6)7)8)9)10)B(Machine)1)2)3)4)5)6)7)8)9)10)4MC(Material)1)2)3)4)5)6)7)8)9)10)D(Methode)1)2)3)4)5)6)7)8)9)10)91010010120100/91001012020=1.61.61.6%%100%10100%100/H11“”“”2.62.6––2.52.5––2.42.4––2.32.3––2.22.2––2.12.1––122.12.12.11314IMon.+Wed.IIMon.+Wed.Cycle=45secC/Over=5min.2Shifts2%ScrapCycle=2secC/Over=90min.1Shifts10%Scrap3Days5Days4Min.8Min.2Days10.01Days0.01Days=0.1%VA20,000pc/monthSteelCoil2.22.22.215C/TC/OOperILeadTimeUptime()ShiftsTaktTime161718ValueValueStreamFlowDemandPullPerfect2.32.32.35S··TQMIETPM7“”19““””“”““””“”““””“”““””“”““””“”““””“”““””“”““””77““””-20L/T////-ValueaddedtimeManufacturingcycletimeX100%=10%10%2.42.42.421“”“”=+221b)a)2a)b)c)3a)b)23a)b)c)43241??241=1+10101101011=1+1221125i)ii)………26b)27C282.52.52.51231.2.3.4.5.291.2.3.4.6S1.SOP2.TPM3.4.QCC5.6S6.30()()()()2.62.62.63.63.6––3.53.5––3.43.4––3.33.3––3.23.2––3.13.1––313.13.13.1323.23.23.2•33••34•353.33.33.336SOP3.43.43.437=--•••••••••••••••••38393.53.53.5=×=(/)×=+=(/)×=[(+)/]×=×40BM41BM426417433.63.63.6444546•••••47PONCPONCPOCPOC4.64.6––PONCPONC4.54.5––PONCPONC4.44.4––PONCPONC4.34.3––4.24.2––PONCPONCPOCPOC4.14.1––PONCPONCPOCPOCPONCPONCPONC484.14.14.1=+=(+)+(+)+49“”505170%10%50%10%40%50%PONCPOCPriceOfNonConformancePriceOfConformance4.2PONCPOC4.24.2PONCPONCPOCPOC52•PONC•POC4.3PONCPOC4.34.3PONCPONCPOCPOC•••—:53•“”•--------•--------/4.4PONC4.44.4PONCPONC54(PONC)(PONC)(POC)(POC)PONC)(POC)PONC)PONC)PONC)POC)(POC)(POC)55/PONC)PONC)PONC)POC)PONC(PONC)POC)POC)56PONC123PONC57PONC12345•••••4.5PONC4.54.5PONCPONC58PONCPOCPONCTOP-QTOP-CISO9000TOP-QTOP-C4.6PONC4.64.6PONCPONC...10X4X2X1XR1R2R3R45912XZP-8AUDIT12XR1=R2=R3=R4=5.65.6––1231235.55.5––5.45.4––55SS5.35.3––QCDQCD5.25.2––5.15.1––605.15.15.1PDCA/SDCAPDCA/SDCASDCAPDCA61——5.25.25.2“”“”(QCD)QCD62“”——————JITQCD35.3QCD5.35.3QCDQCD6355SS5551.(Seiri)2.(Seiton)3.(Seiso)4.(Seiketou)35.(Shitsuke)5S5.45S5.45.455SS5MManpowerManpowerMachineMachineMethodsMethodsMaterialMaterialMeasurementMeasurement64——SDCAPDCA5.55.55.5JITJITJITJIT655.61235.65.6123123“”11662233MudaMuda67“”“”“”