丰田秘诀.ppt

1、世界一流的生产制造方式介绍-精益生产价值流如何发现价值流如何发现浪费浪费Value StreamLevels of Value Stream价值流的层次Single Plant 单一工厂单一工厂(door to door)Process Level 过程层次过程层次Multiple Plants多个工厂Across Companies跨越公司Begin Here由此由此开开始始Kaizen events改善活动Value Stream Mapping价值流绘图Macro VSM宏观价值流绘图ICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=6

2、2 secC/O=0REJ=6%U/T=100%2 Shifts27,600 sec.Avail.OCT=40 secD/R=40 secC/O=0REJ=7%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 h

3、ourREJ=3%U/T=85%27,600 sec.avail.EPE=2 weeksStamp200 tWeld1OCT=46 secD/R=46 secC/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly Sch

4、eduleTT=60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec.39 sec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 secICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=62 secC/O=0REJ=6%U/T=1

5、00%2 Shifts27,600 sec.Avail.OCT=40 secD/R=40 secC/O=0REJ=7%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 hourREJ=3%U/T=85%27,60

6、0 sec.avail.EPE=2 weeksStamp200 tWeld1OCT=46 secD/R=46 secC/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT=60 sec.Manche

7、sterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec.39 sec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 sec1.What is Takt Time?客户需求节拍时间为何？ICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=62 secC/O=0R

8、EJ=6%U/T=100%2 Shifts27,600 sec.Avail.OCT=40 secD/R=40 secC/O=0REJ=7%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 hourREJ=3%U/

9、T=85%27,600 sec.avail.EPE=2 weeksStamp200 tWeld1OCT=46 secD/R=46 secC/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT=60

10、sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec.39 sec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 sec2.Will you build to a finished goods supermarket or directly to customer order?价值流是到

11、成品超市为止，还是到顾客订单？0s39s46s62s40sTakt time60 secondsStamp Machine Weld Sub-assy Assy(auto-feed)3.Where can one-piece flow be implemented?The stamping press?那里可以执行一件流？在冲压过程？No why not?不行-为何不行？ICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=62 secC/O=0REJ=6%U/T=100%2 Shifts27,600 sec.Avail.OCT=40 secD/

12、R=40 secC/O=0REJ=7%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 hourREJ=3%U/T=85%27,600 sec.avail.EPE=2 weeksStamp200 tWeld1OC

13、T=46 secD/R=46 secC/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT=60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProduct

14、ionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec.39 sec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 sec4.What is the pacemaker process?引导程序在那里？ICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=62 secC/O=0REJ=6%U/T=100%2 Shifts27,600 sec

15、.Avail.OCT=40 secD/R=40 secC/O=0REJ=7%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 hourREJ=3%U/T=85%27,600 sec.avail.EPE=2 wee

16、ksStamp200 tWeld1OCT=46 secD/R=46 secC/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT=60 sec.ManchesterAvenue6-weekForec

17、astWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec.39 sec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 sec5.What pull systems will be usedbetween disconnected processes?不连贯程序可以使用何種拉引系统？What will this supermarket eliminate

18、?这个超市可以消除什么？0s39s46s62s40sTakt time60 secondsStamp Machine Weld Sub-assy Assy(auto-feed)Where else can one-piece flow be implemented?The machine and weld processes?还有别的地方可执行一件流吗？是车削和焊接過程吗？Yes!就是这里ICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=62 secC/O=0REJ=6%U/T=100%2 Shifts27,600 sec.Avail.OCT

19、=40 secD/R=40 secC/O=0REJ=7%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 hourREJ=3%U/T=85%27,600 sec.avail.EPE=2 weeksStamp200

20、 tWeld1OCT=46 secD/R=46 secC/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT=60 sec.ManchesterAvenue6-weekForecastWeeklyf

21、axProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days1 sec.39 sec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 secWhere else can one-piece flow be implemented?还有别的地方可执行一件吗？By establishingone-piece flowhere,what goes away?这里用一件流，什么会消失？VRK0s

22、39s46s62s40sTakt time60 secondsStamp Machine Weld Sub-assy Assy(auto-feed)Where else can one-piece flow be implemented?The assembly processes?还有别的地方可执行一件流吗？是组裝過程吗？Yes!正是ICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=62 secC/O=0REJ=6%U/T=100%2 Shifts27,600 sec.Avail.OCT=40 secD/R=40 secC/O=0REJ=7

23、%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 RFerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 hourREJ=3%U/T=85%27,600 sec.avail.EPE=2 weeksStamp200 tWeld1OCT=46 secD/R=46 sec

24、C/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,400 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT=60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60

25、/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days 1 sec.39 sec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 secWhere else can one-piece flow be implemented?The assembly processes?还有别的地方可执行一件流吗？是组裝過程吗？By establishingone-piece flowhere,what goes away?这里用一件流，什么会消失？

26、VRK187 seconds work =3.1 operators60 seconds TAKT =4 operators =3 operators (target)Where else can one-piece flow be implemented?Lets look at OCT to evaluate:还有别的地方可执行一件流吗？看看操作员周期时间？5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days 1 sec.39 sec.46 sec.62 sec.40 sec.MCTOCTOCTOCTOCTWhat is the total h

27、umanwork content to machine,weldand assemble one housing?完成一件的总人工时间是多久？39+46+62+40=187 secondsBut customer needs a housingevery 60 seconds但是顾客每60秒需要一件More important to assign 4th operator to other meaningful work第四位操作员做其它有意义的工作比较重要Takt time60 secondsMachine WeldWeldSub-AssemblyAssembly60 secs.60 sec

28、s.54 secs.58 x 3=174 secondsHighland Operator Loading Chart Future-State未来状态的操作员负荷表ICoils5 daysI4600 L2400 RI1100 L600 ROCT=62 secD/R=62 secC/O=0REJ=6%U/T=100%2 Shifts27,600 sec.Avail.OCT=40 secD/R=40 secC/O=0REJ=7%U/T=100%2 Shifts27,600 sec.Avail.ShippingStagingIII1600 L850 R1200 L640 R2700 L1440 R

29、FerrousMetals Co.500 ft coilsTues&ThursMachine1OCT=39 secD/R=39 secC/O=10 minREJ=4%U/T=100%2 Shifts27,600 sec Avail.MCT=1 secondC/O=1 hourREJ=3%U/T=85%27,600 sec.avail.EPE=2 weeksStamp200 tWeld1OCT=46 secD/R=46 secC/O=10 minREJ=5%U/T=80%2 Shifts27,600 sec.Avail.1x dailySub-Assembly1Assembly1MRP18,40

30、0 pcs/mo-12,000“L”-6,400“R”Tray=20 pcs2 ShiftsHighland ManufacturingSheet Metal HousingsCurrent State(Date)Daily ShipScheduleWeekly ScheduleTT=60 sec.ManchesterAvenue6-weekForecastWeeklyfaxProductionControlMRP90/60/30 dayForecastsDailyOrder5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days 1 sec.39 s

31、ec.46 sec.62 sec.40 sec.Lead Time=23.6 daysProcess Time=188 secWhere else can one-piece flow be implemented now that we have looked at OCT?看过操作员周期时间后，还有别的地方可执行一件流吗？By establishingone-piece flowhere,what goes away?这里用一件流，什么会消失？VRKSTD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95

32、%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%STD WK38%Prod.ImpSMED95%Highland Future State MapMRP4046 Trays1.5 days2 daysRLLRLLpitch=20 min.18,400 pcs/mo-12,000“L”-6,400“R”.Tra

33、y=20 pcs2 shifts920 pcs/dayTakt=460 min =60 sec 460 pcs.Pitch=60 sec x 20 pcs=20 min1234OCT=174 sec.D/R=58 sec.MCT=75 sec.C/O=57 secs.Rej=1%U/T=80%.MCT=1 sec.C/O=1 hourRej=1%U/T=85%STD WK38%Prod.ImpHighland ManufacturingHousingsFuture State(Date)KanbanSMEDKanbanKanban7.What are the Kaizen events,projects,and LeanTools that are needed to implement the future-state?需要何种改善活动、项目和精益工具来达成未来状态？相关案例分享相关案例分享