精益生产之2箱补充拉系统2Bin-Replenishment-Pull(中课件.pptx

1、2022年8月16日星期二精益生产之精益生产之2箱补充拉系箱补充拉系统统2-Bin_Replenishment_Pull(中中MeasureAnalyzeControlImproveLean Six Sigma2-Bin 补充拉系统u2-箱补充拉系统的介绍u线旁VS使用点库存u2-箱数据的要求和计算u库存部署选择u卡触发2-箱流程u1-箱系统u附录RD011202Lean Six Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemDevelop List of CustomersDevelo

2、p List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Cri

3、tical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalcu

4、late Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureDefineProject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess

5、MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp&CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBe

6、nchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-02Learning ObjectivesuUnderstand the various types of bin replenishment systemsuKnow the benefits of a bin s

7、ystemuUnderstand when to use a bin SystemuBe able to size(calculate)all the parameters for a bin system课程目的u理解箱补充系统的不同类型u知道一个箱系统的好处u理解何时使用一个箱系统u能够去计算一个箱系统的所有参数Whats in It for Me?uBe able to apply this tool to a Black Belt projectuAble to implement a Bin system我学到了什么?u能够在黑带项目中应用这个工具u能够实施一个箱系统2-Bin Re

8、plenishment Pull IntroductionuA 2-Bin Replenishment Pull System is a simplified version of a standard replenishment pull system and maintains the benefits:nEstablishes strategically located buffers of parts within a processlRaw materiallManufactured partslPurchased partslFinished goodsnDe-couples th

9、e supplying process from the consuming process via the buffer inventorynPart replenishment is“triggered”based on consumption2-箱补充拉系统的介绍u2-箱补充拉系统是一个标准的补充拉系统的简化版本，其好处是：n在一个流程中建立战略性的零件缓冲区l原材料l制造的零件l采购的零件l成品n通过缓冲库存将供应过程和消耗过程联系起来n零件的补充是基于消耗而触发的What Is a 2-Bin Replenishment?uFor many parts in a process,a

10、2-Bin system can be used to replenish the parts versus a synchronous supply:nA bin has enough parts/supplies to cover a calculated period of usage at the point-of-use.nWhen the bin runs out,a 2nd bin is there to take its place while the“1st”is being refilled/replenished.uThere are two primary replen

11、ishment locations:Line-Side and Point of Use2-箱补充拉系统是什么?u对于在流程中的众多零件而言，一个2-箱系统可以被用来补充零件相对于同步供应:n一箱有足够零件/供应品以满足在使用点上已计算出的用量周期。n当第一箱用完了后，在补充/重新装料时，第二箱取代第一箱的位置继续满足使用。u有两个主要的补充地点：线旁和使用点Benefits of 2-Bin ReplenishmentuOrganized and overall cleaner appearance of stored materialsuReduced frequency of order

12、s submitted to the stockroom/vendoruReduced number of trips for re-supplyuBetter management of inventory on the shop flooruMore predictable inventory costsuImprove employee productivity by:nEliminating part/supply shortages at the point-of-usenReduce time wasted by personnel/supervision retrieving s

13、upplies/inventory from the stockroom and/or vendorsnEliminate lost or misplaced materialu2-Bin Replenishment can be used for office/safety supplies,production inventory,production supplies even at home!2-箱补充拉系统的好处u存储的材料外观非常清洁和有条理u提交给库房/供应商的频率减少u重复供应的差错数量减少了u现场库存的管理更好u库存成本更具有预测性u提高员工生产率:n排除在使用点的零件/供应

14、短缺n减少由于人员/管理等，从库房和/或供应商重新找回供应/库存的时间浪费n排除材料的丢失或放错地方u2-箱补充可以被使用在办公室，安全供应，生产库存，生产供应甚至在家里!When to Use 2-Bin Replenishment PulluRepetitive product offering/processuRelatively consistent demand/volume(low variability)uPart/supply shortages are a consistent/costly problemuPart/supply inventory costs are“ou

15、t of control”due to:nLost or misplaced parts/suppliesnLack of issue/dispersal discipline or control何时使用2-箱补充拉系统u重复的产品供应/流程u重复稳定的需求(底变异)u零件/供应短缺是常事，且是一个代价很大的问题u零件/供应库存成本是失控的，由于：n零件/供应品丢失或放错地方n缺乏投料/分发的一致性或控制What Is a Bin?uDoesnt necessarily look like a“bin”nCan be a standard plastic bin(Acro-bin)nCan

16、also be the box/container the part/supply is shipped in(also called a“standard pack”purchasing definition)uWhen the box/container method is used,a“bin”can be one standard pack or several standard packs.Examples:n1 box of screwsn2 boxes of screwsn1 drum of oiln30 bags of connectorsn1 roll of labelsn4

17、 tubes of sealant一箱是什么?u这并不是说一定要看上去像个“箱子”n它可以是一个标准的塑料箱n它也可以是用于零件运输的一个盒子或容器(也可以用采购的定义被称为一个“标准包”)u当盒子/容器方式使用了后,一个“箱”可以是一个标准的包或几个标准包。例如：n1 盒螺钉n2 盒螺钉n1 打油n30 包连接器n1 卷标贴n4 管子密封剂2-Bin Replenishment Data Parameters/NeedsuDemand/Usage(DMD)nTypically expressed in terms of Average Daily Usage(ADU)in unitsuLea

18、d Time(LT)nThe time it takes from when a trigger is sent to when replenishment arrivesnIn this case,can also be thought of as“Restocking Time”uOrder Frequency(OF)nIf orders/triggers are sent at scheduled times(i.e.,not every day,such as once per week)nTypical 2-Bin systems do not use an Order Freque

19、ncy,as replenishment can occur every day/shift(or more)uBox/Container QuantitynIf stock/supply room or vendor does not break down shipping quantity,then the bin quantity may be set equal to some multiple of the box/container quantity(standard pack)that the part/supply is shipped inuSafety StocknTypi

20、cally 1/2 the max(LT,OF)*DMD,may be set otherwise dependent on individual conditions2-箱补充系统数据参数/要求u需求/使用(DMD)n一般来说用平均每天用量（ADU）来表达u交货期(LT)n从补充需求触发到补充品到达的时间。n在这里，也可以被认为是“再进货时间”。u订单频率(OF)n如果订单/触发信号的发放是按预定时间（如：并不是每天，而是每周一次）n2-箱系统是不需要用订单频率的。补充可以发生在每天、每班（或更多）u盒子/容器数量n如果库房或供应商没有列出运输数量的明细分类，那么箱数量可以设定为等于运送零件

21、/供应品的若干盒子/容器数量u安全库存n一般来说的设定为1/2 max(LT,OF)*DMD,否则根据独立的情况来看12FullBin/CardMove 1 to 2 when 2 is pulled,Send TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)Locations or Work-In-Process(WIP)2-Bin Replenishment(“Line-Side”Stocking)uReduces part/supply shortages increasing productivityuFacilitates WIP

22、reductionuWill result in significant productivity improvements in stock/supply roomuReduces/eliminates stockroom impact on lot sizesuMay simplify inventory/cycle count processesLine-SideStorageLTOF2SS/2DMDOF),LTmax(Quantity Bin12添满的箱/卡当 2 被拉动时，移动 1 到 2，发送触发信号使用的部件空的箱/卡使用点位置使用点位置(POU)或工作库存或工作库存(WIP)2

23、-箱补充(“线旁”库存)u减少零件/供应品库存，增加生产效率u促进 WIP的降低u将导致在库房里的显著的生产力提高u降低/消除库房在批数量上的影响u可以简单化存货/周转的计算流程线旁库存线旁库存LTOF2SS/2DMDOF),LTmax(箱数量 FullBin/CardPull from 1 until empty,send trigger and pull from 2 until empty,send trigger,etc.UseComponentsEmptyBin/Card2-Bin Replenishment(“Point-of Use”Stocking)LTOF1SS/2DMDOF

24、),LTmax(Quantity Binu2-Bin POU stocking is used when re-stocking is not an issue.Point-Of-Use(POU)Locations or Work-In-Process(WIP)2拉动从1开始直到用完为止,发送触发信号，然后拉动从2开始直到用完为止，发送触发信号,等等.使用部件2-箱补充(“使用点”库存)LTOF1SS/2DMDOF),LTmax(箱数量u当重新备库存不是一个问题时，使用2-箱 POU 库存 2添满的箱/卡空的箱/卡使用点位置使用点位置(POU)或工作库存或工作库存(WIP)2-Bin Repl

25、enishment CalculationsuBin Quantity=Max(LT,OF)+SS/2nIf replenishing in standard packs,Bin Quantity is rounded up to the nearest standard pack multipleuExample:nCalculate the Bin Quantity for the following(standard pack replenishment):lPart Number:40567lDescription:Rubber GloveslDemand/Usage:25 pairs

26、/daylLead Time:2 days(trigger-stock/supply room-replenishment)lOrder Frequency:N/AlBox Quantity:50 pairsnBin Quantityl=Max(2 days,N/A)*25 pairs/day+.5*Max(2 days,N/A)*25 pairs/day/2l=63 pairsnBut we have to round up to the nearest standard pack,so:lBin Quantity=100 pairs=2 boxes2-箱补充的计算u箱数量=Max(LT,O

27、F)+SS/2n如果是标准包的补充，箱数量应该是近似于标准包的倍数u举例:n计算下列数据的箱数量(标准包补充):l零件号码:40567l描述:橡胶手套l需求/用量:25 双/天l交货时间:2 天(触发 库房 补充)l订单频率:不适用l箱数量:50 双n箱数量l=Max(2 天,N/A)*25 双/天+.5*Max(2 天,N/A)*25 双/天/2l=63 双n但是但是我们要取一个近似标准箱的数量，所以:l箱数量=100 对=2 箱Exercise#1:2-Bin ReplenishmentuCalculate the Bin Quantity for the following supply

28、 item in a 2-Bin Line-Side Replenishment process directly linked to the supplier:nPart Number:80886nDescription:Printer PapernDemand/Usage:22 reams/daynLead Time:4 days(trigger-purchasing-supplier-receiving-replenishment)nOrder Frequency:5 daysnBox Quantity:10 reamsuBin Quantity n=Max(,)*+.5*Max(,)*

29、/2n=.uBut we have to round up to the nearest standard pack,so:nBin Quantity=.练习#1:2-箱补充u如下供应品的2-箱线旁补充流程直接连接着供应商，计算箱数量:n零件号码:80886n描述:打印纸n需求/用量:22 令/天n交货时间:4 天(触发 采购 运输 收货 补充)n订单频率:5 天n箱数量:10 令u箱数量 n=Max(,)*+.5*Max(,)*/2n=.u但是但是我们要取一个近似标准包的数量，所以:n箱数量=.Exercise#2:2-Bin ReplenishmentuCalculate the Bin

30、Quantity for the following assembly item in a 2-Bin Line-Side Replenishment process linked to the warehouse:nPart Number:A44B2nDescription:4 Dia.Steel ExtrusionnDemand/Usage:225 ft/daynLead Time:1 day(trigger-warehouse-replenishment)nOrder Frequency:N/AnExtrusion Length:30 ftuBin Quantity n=Max(,)*+

31、.5*Max(,)*/2n=.uBut we have to round up to the nearest standard pack,so:nBin Quantity=.练习#2:2-箱补充u如下组装线2-箱线旁补充流程直接连接着供应商，计算箱数量:n零件号码:A44B2n描述:直径4“的钢铁拉丝n需求/用量:225 英尺/天n交货时间:1 天(触发 仓库 补充)n订单频率:不适用n拉丝长度:30 英尺u箱数量 n=Max(,)*+.5*Max(,)*/2n=.u但是但是我们要取一个近似标准包的数量，所以:n箱数量=.2-Bin ReplenishmentBin Labeling and

32、InformationuEach Bin/Storage Location should have a barcode label or tag.nMake sure not to use a permanent label applied to a rack/bin,because you will eventually want to resize and may have to make new labels!nLabels for Line Side Bins/Tags for Resupply BinsuPart Number,Description,and Location are

33、 Printed.uBin Quantity should not be printed(requires too many label changes when resizing trigger mechanism or system will have Bin Quantity)uEach Bin Location should be unique to avoid confusion when restocking.uExamples are in the Appendix.LocationPart NumberDescriptionLocationPart NumberDescript

34、ion2-箱补充箱标贴和信息u每个箱/库存 地点都应该有一个条码标贴或标签u确保不要用永久的标签贴在一个货架/箱。因为你将会调整大小，且贴上一个新的标贴！n在线旁的需要重新补充的箱上的标贴u被打印的零件号码,描述,地点等u箱数量不应该被打印出来(当调整大小时需要太多的标签变化 触发机制或系统将有箱数量)u每个箱地点必须是独一无二的以避免在重新补充库存时混淆u举例在附件里.地点地点零件号码零件号码描述描述地点地点零件号码零件号码描述描述Notes on a 1-Bin SystemuA one bin system is an exception to the 2-bin for very sl

35、ow moving parts/supplies.u1-bin parts are not stored in 2-bins because of:nHigh inventory costnSpace requirementsnRacking/storage costu1-bins are replenished upon stock out at the Line-Side location.uStock out impact should be low because:nParts/supplies are very low users.nParts/supplies are also a

36、t point of use when Line-Side stock out occurs.nParts/supplies are stocked in nearby stock/supply room easy to replace.1-箱系统的注意u对于流动非常缓慢的零件/供应品来说，一个1-箱系统是2-箱系统的例外.u1-箱零件不象2-箱那样被存储，因为:n高库存成本n空间需要n货架/仓储成本u在线旁的地点库存短少时，1-箱被补充。u库存短少的影响应该是微弱的，因为:n零件/供应品是非常少的使用者。n当线旁的存货短缺发生时，零件/供应品也同样在使用点.n零件/供应品被存放在库房附近容易

37、补充.11FullBin/CardMove 1 to 2 when 2 is pulled,Send TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)Locations or Work-In-Process(WIP)1-Bin Replenishment(Typically from“Line-Side”)uReduces part/supply shortages increasing productivityuFacilitates WIP reductionuWill result in significant productivity

38、 improvements in stock/supply roomuReduces/eliminates stockroom impact on lot sizesuMay simplify inventory/cycle count processesLine-SideStorageLTOF1SS/2DMDOF),LTmax(Quantity Bin111-箱补充(特别是从“线旁”)LTOF1添满的箱/卡空的箱/卡当 2 被拉动时，移动 1 到 2，发送触发信号使用点位置使用点位置(POU)或工作库存或工作库存(WIP)u减少零件/供应品库存，增加生产效率u促进 WIP的降低u将导致在库房

39、里的显著的生产力提高u降低/消除库房在批数量上的影响u可以简单化存货/周转的计算流程线旁库存线旁库存SS/2OF),LTmax(箱数量 使用的部件DMDLine POU1-Bin Replenishment Transactionsu1-Bin System inventory transactions mirror those of the 2-Bin systemnFrontflush for reducing transactions but reduce overall inventory accuracynBackflush for increasing inventory accu

40、racy(slightly)but increase number of system transactions11-bin Card Part XYZTriggerReplenishment1-bin Card Part XYZ线线 POU1-箱补充事务处理u1-箱系统库存交接与2-箱系统相似n前端堆积前端堆积 减少交接过程但降低总体库存量的准确性n后端堆积后端堆积 增加了库存准确性（幅度轻微）但增加了系统处理的事务量11-箱卡箱卡零件零件 XYZ触发触发补充补充1-箱卡箱卡零件零件 XYZTakeawaysuKnow the the various types of Bin Repleni

41、shment systemsuBe able to describe the benefits of a Bin systemuHow to size(calculate)all the parameters for a Bin system总结u知道箱补充系统的不同类型u能够描述一个箱系统的利益u能够去计算一个箱系统的所有参数MeasureAnalyzeControlImproveLean Six SigmaAPPENDIX2-Bin Replenishment PullMeasureAnalyzeControlImproveLean Six Sigma附录2-箱补充拉系统Instructi

42、ons for Typical Card Triggered 2-Bin ReplenishmentThis process uses green and red cards to trigger replenishment;“bins”are actually the box/container the part/supply is shipped in.1.Employee removes a bin and drops its green 2-bin card into the mailbox:nPull parts from“bin”with green card before usi

43、ng any with the red card.2.At same time(s)each day,the cards are picked up from the mailbox and returned to the stock/supply room.3.The stock/supply room pulls proper amount of parts/material(noted on card,set equal to the calculated“bin”quantity).4.Inventory transactions are performed(depending on

44、issue method),and the materials and cards are delivered to the storage location.5.Employee stocks material in storage location and returns card to its proper place.nWhen stock/supply room replaces the material,ensure that the red card is placed on the full bin.lAlways leaves you a full red bin remai

45、ning when green bin runs out.lIf not,you could run down both bins and stock out before either is replaced;if a red card is in the replenishment process,a part shortage is imminent act fast!典型的卡触发2-箱补充的介绍这个流程用绿色和红色卡来触发补充；“箱”是实际用来发货零件/供应品的盒子/容器.1.员工清掉一个箱后，将绿色的2-箱卡放入邮箱:n在使用有红色卡的零件前，先从有绿卡的箱中拉零件2.每天的同一时候

46、,邮箱卡片被收集并返回到库房中.3.库房拉动零件/材料的适合数量(在卡上注明，将之设定为计算出的“箱”数量).4.库存处理被执行了(根据发放的方式),然后材料和卡被传送到仓储地点.5.员工将物料放在仓储地点然后将卡返回到适合的地方.n当库房补充材料时，确保红色卡被放在添满的箱上.l当绿箱被放出去使用时，始终保持红卡箱中的零件已经被填满.l如果不是这样，在任一箱补充前你将用尽每个箱存货；如果红卡在补充过程中，零件短缺现象即将出现尽快采取行动。Maintaining a Card Triggered 2-Bin ProcessuCheck periodically for lost cards a

47、nd replace.nBest time is right after replenishment;any cards not replaced or in the mailbox are lost.uPolice the proper use of cards:nSupervisor/Lead drop green cards when green bin is empty.nSupervisor/Lead drop red cards on stock out investigate!nSupervisor/Lead ensure cards are replaced when part

48、s are restocked.nGreen bins are completely used before red bins.uResize bins when demand changes.uAdd cards for new parts,delete cards for obsolete parts.保持卡触发2-箱系统的过程u定期检查卡片是否丢失并更换.n最佳时间是在补充之后，如果卡片未被更换或未在邮箱都视为丢失u维持卡片的合理使用:n当绿卡箱用完变空时，主管/组长投放绿卡.n当存货用完时，主管/组长投放红卡 调查!n当零件重新补充时，主管/组长确保卡片被更换.n在用红卡箱前，确保绿卡

49、箱已经被用完.u当需求改变时需要重新调整箱的数量.u新增的零件要增加不同的卡，过期的死库存零件要将卡片毁尸灭迹.Bin 1Bin 2Example Card Triggered Line-Side 2-Bin RackBin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 12-Bin MailboxOrder Cards1.Always pull material from bin with GREEN

50、 card if it is there.2.Store/supply room replaces material and switches RED card to material just replaced.3.The cards are attached to magnetic strip labels(for ease of movement for resizing).Bin 1Bin 1Bin 2Bin 1Bin 2举例：由卡触发的线旁2-箱货架Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin