流程标准化

TimeBasedManagement©2005TBMConsultingGroup,Inc.AllRightsReserved.SMLTBMConsultingGroup,Inc.isthesolelicenseeofLeanSigma,aservicemarkofMaytagCorporation.流程标准化RoutingStandardization1-2©2005TBMConsultingGroup,Inc.AllRightsReserved.SML议程Agenda目的/结果Purpose/results与流线生产有关的问题Issuesrelatingtoflow流程标准化六步骤6stepstoroutingstandardization1-3©2005TBMConsultingGroup,Inc.AllRightsReserved.SML学习内容WhatYou’llLearn根据相似流程，将成品(零件)分类Howtogroupproducts(parts)intofamiliesaccordingtocommonroutings如何简化零件流程Howtosimplifypartroutings根据零件系列，将流线生产单元文件化，并予以实施Howtoimplementanddocumentflowproductioncellsaroundpartfamilygroups1-4©2005TBMConsultingGroup,Inc.AllRightsReserved.SML及时生产原理JITPrinciples跟上“节拍”时间Paceto“takt”time达成流线生产Createflowproduction结合“拉动”系统Incorporate“pull”system1-5©2005TBMConsultingGroup,Inc.AllRightsReserved.SML流程标准化的目的PurposeofRoutingStandardization减少独特流程的数量Reducethenumberofuniqueroutings简化个别零件的流程Simplifyindividualpartroutings制定标准化工作Developstandardwork1-6©2005TBMConsultingGroup,Inc.AllRightsReserved.SML贵司的流程象哪个？WhichIsYourProcess?PartAPartBPartCPartDPartENon-FlowPartsA&CPartsB&DPartEFlow流线型非流线型零件零件零件零件零件零件零件零件1-7©2005TBMConsultingGroup,Inc.AllRightsReserved.SML不良流线的原因CausesofPoorFlow演化式增长Evolutionarygrowth人员安排变化Staffingchanges标准成本会计Standardcostaccounting产能高峰Capacitypeaks共用设备Sharedequipment数量变化Quantityvariations流程技术Processtechnology流程变化Routingvariations外部交接点Externalhandoffs回环工序Loopbacks换模时间太长Setupstoolong不同零件的数量Numberofdifferentparts超级机器Supermachine大批量Largebatches流程思维Processthinking必要的操作(修理)As-requiredoperations(repair)1-8©2005TBMConsultingGroup,Inc.AllRightsReserved.SML变化的种类TypesofVariation数量变化Quantityvariation产品变化Productvariation1-9©2005TBMConsultingGroup,Inc.AllRightsReserved.SML变化的程度DegreeOfVariation%ofVolume%ofPartNumbersCharacterization9010Verylowvariety8020Mostcommonamongmfrsclaiminghighvariety70306040Highvariety,maximumvariation(veryrare)5050产量比例零件数量比例特征种类很少制造业里最常见，种类非常多种类极多，变化极大(很罕见)1-10©2005TBMConsultingGroup,Inc.AllRightsReserved.SML流程标准化六步骤6StepsToRoutingStandardization1.进行零件-数量(P-Q)分析Preparepart-quantity(P-Q)analysis2.进行流程分析Prepareprocessrouteanalysis3.根据相似流程，对零件进行分类Grouppartsbyroutingsimilarity4.定义设备可用性Defineequipmentavailability5.简化零件流程Simplifypartroutings6.实施新的流程系列，并将其文件化Implementanddocumentnewprocessfamilygroups1-11©2005TBMConsultingGroup,Inc.AllRightsReserved.SML零件-数量(P-Q)分析Part-Quantity(P-Q)Analysis*由于圆整问题，各个比例之和并不等于100%Individualpercentagesdon’tequal100%duetorounding零件代号PartNumber数量Quantity数量比例%ofQuantity累计数量比例CumulativeQuantity(%)ABCD5684152524%24%2316848022%46%2351536017%63%9851228513%76%756511457%83%216981306%89%189961055%94%45646804%98%15695653%100%*1-12©2005TBMConsultingGroup,Inc.AllRightsReserved.SML零件-数量(P-Q)关系图Part-Quantity(P-Q)ChartBQuantityAPartNumberDCumulativeQuantity(%)10020030040050060010075502580%数量零件代号累计数量比例1-13©2005TBMConsultingGroup,Inc.AllRightsReserved.SML流程分析ProcessRouteAnalysis工作中心WorkCenter零件Part#数量Quantity车削Lathe镗Bore机加工Mach焊Weld磨Grind机加工Mach铣Mill检验Insp568415252316848023515360985122857565114521698130189961054564680156956511111111123422222223333333344544444421-14©2005TBMConsultingGroup,Inc.AllRightsReserved.SML零件系列(1)PartFamilyGroup(1)工作中心WorkCenter零件Part#数量Quantity车削Lathe镗Bore机加工Mach焊Weld磨Grind机加工Mach铣Mill平衡Bal检验Insp568115065101004233903210804533501234576432157468998321569871234576899876534211-15©2005TBMConsultingGroup,Inc.AllRightsReserved.SML零件系列(2)PartFamilyGroup(2)=外部工序Outsideprocess工作中心WorkCenter零件Part#数量Quantity车削Lathe磨Grind热处理HTTreat滚光Tumble喷涂Coating内圆磨IDGrind机加工Mach检验Insp12891757651100644475165851111222233334444555566667777888899991-16©2005TBMConsultingGroup,Inc.AllRightsReserved.SML定义设备可用性DefineEquipmentAvailability识别现有设备Identifyexistingavailableequipment分配设备予各个流程组别Allocateequipmenttoprocessgroups识别潜在瓶颈问题Identifypotentialbottlenecks1-17©2005TBMConsultingGroup,Inc.AllRightsReserved.SML简化零件流程SimplifyPartRoutings简化操作顺序Simplifythesequenceofoperations同一系列的所有零件都制定标准化流程Developastandardrouteforallpartsinafamily减少工序数量Reducethenumberofoperations消除单元外的交接点Eliminateout-of-cellhandoffs避免回环工序Eliminateloop-backs避免共用装卸中心Eliminatesharedloadcenters考虑使用标准化流程模块Considerusingstandardroutingtemplates消除替换流程Eliminatealternativeroutings1-18©2005TBMConsultingGroup,Inc.AllRightsReserved.SML将新的系列文件化，并予以实施Implement&DocumentNewFamilyGroups制定工场布置图Establishalayout更改所有文件Changealldocumentation立即开始Startimmediately定下确实的完成日期Establishafirmcompletiondate