1、2022-8-16精益生产之线平衡模式LineBalanceModels精益生产之线平衡模式精益生产之线平衡模式LineBalanceModels精益生产之线平衡模式LineBalanceModelsLine Lean Six Sigma 改善过程路径定义 线平衡模型设计原则价值定义线平衡方法练习RD011202精益生产之线平衡模式LineBalanceModelsLean Six Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemDevelop List of CustomersDevel
2、op 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 Cr
3、itical 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 PlanCalc
4、ulate 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 FlowB
6、enchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-02精益生产之线平衡模式LineBalanceModels精益6 过程改善流程分析分析控制控制改进改进定义定义选定题目列出客户从顾客之声中列出关建需求定出项目焦点和重要指标完成 PDF测量测量绘制业务流程图绘制价值
7、流程图制定数据收集计划测量系统分析收集数据过程能力分析分析分析提出关键因子区分关键因子验证关键因子评枯每个关键因子对结果的影响量化机会根本原因排序寻找根本原因针对关键因子改进改进关键因子确认发掘潜在的解决方法选择方案优化方案实行方案控制控制过程变革和控制制定控制计划计算最终财务过程指标项目过渡给未来项目管理者项目鉴 别转化机会测量测量定义定义项目编号工具项目定义表净现值分析内部回报率分析折算现金流分析？（按现值计算的现金流量分析）PIP管理过程RACIQuad 表过程图价值分析脑力风暴投票归类法柏拉图因果图/鱼骨图FMEA查检表运行图控制图量具 R&RCp&Cpk供应链加速器分析多变动图i盒状
8、图交互作用图回归分析ANOVAC&E 矩阵图FMEA脑力风暴拉系统减少设置TPM流程图标杆管理亲和图DOE 假设检验力场分析图树状图甘特图查检表运行图柱状图散布图控制图柏拉图互动回顾愚巧法Revised 1-12-02精益生产之线平衡模式LineBalanceModelsLearning ObjectivesuHow to design and implement a process supported by a line balancing model that ensures optimal use of:nPeople nFloor spacenCapital AssetsnMateri
9、aluKnow how to maximize productivity精益生产之线平衡模式LineBalanceModels学习目标u如何设计和实施由“线平衡模型”支持的一个流程以确保优化配置：n人 n地方n固定资产n材料u知道如何使生产率最大化精益生产之线平衡模式LineBalanceModelsWhats in It for Me?uAble to design and implement a balanced process lineuUnderstand the issues in a typical process environment and how to impact tho
10、se issues精益生产之线平衡模式LineBalanceModels益处u能够设计和实施一个线平衡的生产线u了解典型流程环境中的问题及如何影响那些问题精益生产之线平衡模式LineBalanceModelsLine Balance ModeluA Line Balancing Model allows the user to view task times across a process to identify bottlenecks and thus calculate output rates(throughput)and Takt Times.uIn addition,the use
11、r will be able to visually see unbalanced areas and where tasks can be shifted to balance the process.uThe Line Balance techniques are applicable in transactional as well as manufacturing,e.g.,order entry operations.精益生产之线平衡模式LineBalanceModels线平衡模型u线平衡模型允许用户在一个流程中确定瓶颈问题，并计算产出比率（产能）和Takt Times。u除此，用户
12、将能直观地看到不平衡的区域和使流程平衡所做的任务。u线平衡 方法与生产互动一样是可行的，如订单进入生产。精益生产之线平衡模式LineBalanceModelsPrimary Issues in Typical Process EnvironmentsuLarge or erratic batches uExcessive WIPuPoor floor space utilizationuLow employee efficiencyuLong/erratic cycle times uPoor balance of operations and labor across process ste
13、psuConveyance,standby and motion wasteuDisorganized workspace and component/supply storageuHigh variability of demand on multiple processing centers,e.g.,call centers/flow lines精益生产之线平衡模式LineBalanceModels典型的流程环境中的主要问题u大批量或 反复无常的批量 u过多的 WIPu地方利用的差u较低的员工效率u长的/反复无常的周期时间 u流程步骤中差的生产平衡和劳动力u传送、备用和启动浪费u无规则的
14、工作地点和元件/供应存储u对于多重的流程中心，需求变化差异大2，如电话中心/流出线精益生产之线平衡模式LineBalanceModelsLine Balance Design PrinciplesuMinimize Batch Size/Transfer Quantity/Work In ProcessuMinimize/Stabilize Cycle TimeuMaximize Labor EfficiencyuOptimize number of workstations/process stepsuBalance tasks/labor across workstationsuMaxim
15、ize space utilizationuMinimize takt varianceuMinimize NVA(conveyance,standby,and motion wastes)uMinimize the need to re-balance as demand requirements change uMinimize volume variability(combine product category demand)uMaximize flexibility to allow for product introductions and discontinuations精益生产
16、之线平衡模式LineBalanceModels线平衡 设计原则u使批量规模/转移质量/在制品最小化u将周期时间最小化/稳定化u使劳动效率最大化u优化配置工作站/流程步骤u平衡任务/工作站里的劳动u最大限度利用空间u使 takt 的变化最小化u最小化 NVA(运送、备用和启动浪费)u根据需求的变化使再平衡的需求最小化u使批量差异最小化(综合产品种类需求)u使柔性最大化以允许产品引入和非持续性精益生产之线平衡模式LineBalanceModelsValue DefinitionsuValue Add:Adding form,fit,or function to the product.A task
17、 or activity for which the customer would be willing to pay.nExample Assembler screwing a bolt into a piece of aluminum required to hold the window togethernExample Financial Services employee adding credit history to a credit applicationuBusiness Value Add:A task that is required to build a window
18、but for which the customer is not willing to paynExample The time it takes for an assembler to grab a part that is at point-of-use and ready it for assembly nExample The time it takes for a Financial Services employee to secure a credit application and ready it for processing uNon-Value Add:A task t
19、hat is not required and should be eliminated because it is wastefulnExample Assembler having to search around their area to retrieve a part for assemblynExample Financial Services employee having to look for missing information needed to add credit history information精益生产之线平衡模式LineBalanceModels价值定义u
20、增值:增加产品的形式、或功能。客户愿意付费的任务或活动。n如 在铝合金中装配螺钉以把窗子固定在一起n如 给员工在应用信用方面 提供信用历史的财务服务u业务增值:所需的一项任务是一扇窗子，但是客户不愿付费n如 装配商花时间抓住一个零件在使用点上进行装配n如 为员工提供财务服务是花时间确保信用的应用精益生产之线平衡模式LineBalanceModelsLine Balance ApproachesuTwo Different Approaches:nApproach#1 Long Term Planner:lGiven the inputs of average productivity,asse
21、mbly/processing time,and forecasted output(demand),and hours per shift,calculate the number of assemblers/processors and average takt time it will take to satisfy the demand.nApproach#2 Day-to-Day Scheduler:lGiven the inputs of average productivity,assembly/processing time,number of assemblers/proce
22、ssors,and desired output(demand),calculate the hours per shift and takt rate it will take to satisfy the demand.uWhats the difference?nLong Term Planner allows management to understand staffing increments based upon some forecasted demand on a line by line basis.nDay-to-Day scheduler allows line sup
23、ervision to calculate process parameters(takt rate,hours to work)based on the number of units to process and the number of people who show up to work that day.精益生产之线平衡模式LineBalanceModels线平衡步骤u两种不同的方法:n方法#1 长期计划员:l作出平均投入生产率、装配/加工时间、及预计的产量（需求），每班的时间，计算装配工/操作工的数量，及满足需求所花的平均时间。n方法#2 日常安排员:l作出平均投入生产率,装配/
24、加工时间，装配工/操作工的数量，理想的产量（需求），计算每班所用的时间和满足需求的takt 比率。u区别是什么?n长期计划员允许管理来了解在以生产线为基础上的需求预测而增加员工。n日常安排员允许生产的监督来计算流程参数（takt比率，工时），这个参数是基于 加工单元数量和人员数量。精益生产之线平衡模式LineBalanceModelsApproach#1Long Term Planner精益生产之线平衡模式LineBalanceModels途径#1长期计划员精益生产之线平衡模式LineBalanceModelsInput1.Demand requirements2.Labor efficien
25、cy3.Assemble/process tasks and times4.Hours per shift or number of assembler/stationsOutput 1.Takt rate2.Number of Assemblers/Processors OR Number of hours per shift3.Staffing levels at varying demandProcess Balance Model:Design processOr精益生产之线平衡模式LineBalanceModels投入投入1.需求需要2.劳动效率3.装配/加工任务和时间4.每班时间或
26、装配工/工作站数量 产出产出 1.Takt 比率2.装配工/操作工数量或每班时间3.在变化基础上的员工水平Process Balance Model:设计流程Or精益生产之线平衡模式LineBalanceModelsProcess Balance Model:StepsStep 1:Understand present state process operation(gather and document data)Step 2:Determine total time required to process unit(value add and business value add)Step
27、 3:Determine maximum operating parameters and plug parameters into yellow cellsStep 4:Determine target unit/day output requirement and plot on table to determine number of shift hours to work to achieve requirementStep 5:Plot current operating range to determine labor reduction required to meet oper
28、ating goalsStep 6:Group tasks in logical and efficient manner that does not violate design principles精益生产之线平衡模式LineBalanceModels过程平衡模型 步骤Step 1:了解目前的生产流程状况(收集数据并文件化)Step 2:确定处理单元所需的全部时间（增值和业务增值）Step 3:确定最大的运行参数并将参数插入黄格中Step 4:将目标单元/天所需的产量在桌面上标出以确定达到需要的每班工作时间Step 5:标出目前的运行变化以确定满足生产目标所需减少的劳动力Step 6:在不
29、影响设计原则的情况下，按逻辑和效率态度将任务分解精益生产之线平衡模式LineBalanceModelsStep 1 Understand present state process operation(gather and document activity time actuals)Note:Time should include customer value add,business value add,and non-value add times for each step/operation/taskStep 2Determine total(current)time require
30、d to process unit.Note:Model should automatically calculate total time entered in seconds,minutes,and hoursProcess Balance Model:Steps 1 and 2精益生产之线平衡模式LineBalanceModels步骤步骤 1 了解现在过程状况(收集、记录活动时间)注意:时间应该包括 CVA、BVA、与每一步骤、作业、与任务的时间步骤步骤2决定全部（目前）需要完成任务的时间。注意：模型应该可以自动计算时间。过程平衡模型步骤 1 和 2精益生产之线平衡模式LineBalan
31、ceModelsStep 3Determine maximum operating parameters and plug parameters into highlighted cells-All other cells are calculated automatically(Example calculations are located at the end of this section.)Process Balance Model:Step 3精益生产之线平衡模式LineBalanceModels步骤步骤 3决定最大的作业参数与加乘参数到设定的格位中。其他的格位可自动计算。(计算案
32、例在本节最后。)过程平衡模型步骤 3精益生产之线平衡模式LineBalanceModelsStep 4Determine target unit/day output requirement and plot on table to determine#of shift hours to work to achieve requirementProcess Balance Model:Step 4This line says that I need to work an 8 hour shift with 12 processors to achieve a 400 unit/day outp
33、ut requirement精益生产之线平衡模式LineBalanceModels步骤步骤 4决定需要的目标单位/日表，并图示需要完成任务需要的工作时间。过程平衡模型:步骤 4这行说明我需要使用12人，8小时班来完成每天 400 单位的需要精益生产之线平衡模式LineBalanceModelsuModel will build the following graph which shows how we should plan to:nStaff in equal increments(to limit having to re-balance line)nVary hours worked
34、to get complete coverage of demand requirementsProcess Balance Model:Step 4(Cont.)精益生产之线平衡模式LineBalanceModelsu模型可建立如下图说明:n每一阶段需要的人力n完成任务需要的工作时间过程平衡模型:步骤 4(续.)精益生产之线平衡模式LineBalanceModelsStep 5 Plot current operating range to determine labor reduction required to meet operating goalsProcess Balance Mo
35、del:Step 5The model has calculated that at a rate of 150 units/day,the area should be working a 6 hour shift with 7 processors.This is 2 fewer processors than their current environment.精益生产之线平衡模式LineBalanceModels步骤 5 绘制目前的作业范围来决定完成目标可节约的人力过程平衡模型:步骤 5在 150 单位/天的需求下,需要每班 6 小时，7 位作业员.比目前人力少两人精益生产之线平衡模式
36、LineBalanceModelsStep 6 Group process tasks in logical and efficient manner that does not violate design principles(eg-(task time takt rate time)Process Balance Model:Step 6精益生产之线平衡模式LineBalanceModels步骤步骤 6 合乎逻辑与共效率的团队工作不违反设计原则(例-(task time takt rate time)过程平衡模型:步骤 6精益生产之线平衡模式LineBalanceModelsThis w
37、orksheet provides a summary of inputs used and outputs generated for each window category that is run through the model.This worksheet is automatically created and updated by the model.Model Summary精益生产之线平衡模式LineBalanceModels这个工作表提供了在本模式运行下的按窗口分类的投入和产出的总结。这份表格是自动生成的并能通过该模式更新。模型总结精益生产之线平衡模式LineBalanc
38、eModelsApproach#1:Calculation Notes(Step 3)uMax Labor EfficiencynBest in class is 65%nAssumption is that labor efficiency declines the more tasks each processor is asked to performuMax hrs per shiftnShould be set to 11 hours to obtain optimal coverage of requirementsuMax Demand(units/hour)=Max Deman
39、d Requirement/Max hrs per shiftuMax Demand(units/minute)=Max Demand(units/hour)/60uTakt Time(seconds/unit)=60/Max Demand(units/minute)nThis is the amount of time between products exiting-This is also the maximum amount of process time that any one workstation should perform without compromising the
40、line flowuTotal Assemblers/Processors=(Total Process Time(hrs)*Max Dmd Req(units/shift)/Max hrs per shift)/Max Labor EfficiencynThe result is rounded up to the next whole assemblernThis is the number of assemblers/processors I should have to process the maximum demand requirement at the maximum labo
41、r efficiency uWorkstation Time(secs/workstation)=Total Process Time(hrs)*60*60/Total Processorsn1 processor =1 workstation nThis is the optimal amount of time that tasks should be grouped by to balance the line uLabor Productivity(Units/Labor Hour)=Max Demand(units/hour)/Total Processors精益生产之线平衡模式Li
42、neBalanceModels途径#1:计算说明(步骤 3)u最高劳动效率n最好是 65%n假设劳动效率下降，需要每个操作工做更多的工作u每班最多工时n应该设为11个小时以最好地满足需要u最大需求(units/hour)=最大需求需要/每班最多工时u最大需求(units/minute)=最大需求(units/hour)/60uTakt 时间(seconds/unit)=60/最大需求(units/minute)n这是现有产品之间的时间量 -这也是每个工作站的最多的流程时间 u全部装配工/操作工=(Total Process Time(hrs)*最大需求需要(units/shift)/Max h
43、rs per shift)/最高劳动效率n这个结果接近下次的全部操作工n这是在最高劳动效率下的满足了最高需求下的操作工人数 u工作站时间(secs/workstation)=Total Process Time hrs)*60*60/Total Processorsn1 操作工 =1 工作站 n这是将任务分组的最佳时间 u劳动生产率(Units/Labor Hour)=最大需求(units/hour)/全部操作工精益生产之线平衡模式LineBalanceModelsApproach#1:Team Exercise1.Go to the Virtual Coach Exercise Tab an
44、d open the file titled:Windows R Us Line Balancing Exercise.doc2.Read the scenario and complete steps 1 through 4 using the spreadsheet titled:Windows R Us Line Balancing Data.xls3.Prepare a 5 minute presentation with your team answers.uYou have 45 minutes to build this part of a line balance model.
45、uDetailed instructions are on the next slide.精益生产之线平衡模式LineBalanceModelsApproach#1:小组练习1.看虚拟辅导练习并打开以下抬头的文件:Windows R Us Line Balancing Exercise.doc2.读情节并完成第1到第4步，使用有以下抬头的工作表格:Windows R Us Line Balancing Data.xlsu准备5分钟的展示u你有45 分钟的时间来建这个线平衡模型部分 u具体的指导显示在下一个幻灯片上.精益生产之线平衡模式LineBalanceModelsExercise Obje
46、ctivesuTeach the student how to balance a line mathematicallyuTeach the student the method to re-lay out the line to realize the mathematical balanceuThe exercise will develop:nTakt Time chartnSkill MatrixnProposed time calculation精益生产之线平衡模式LineBalanceModels练习的目标u教学生怎样用数学方法来平衡一条线u教学生对线进行再布局的方法以实现数学上
47、的平衡u这个练习将制作出:nTakt 时间图表n技能距阵n拟定时间的计算精益生产之线平衡模式LineBalanceModelsExercise Instructions1.Using the Excel spreadsheet,look at the“Current times”tab to complete the“Current Takt Time Chart.”2.Look at the“Current Staffing”tab to complete the“Skill Matrix”tab.3.Use the three tabs and re-divide the tasks to
48、 have a balanced number of tasks with the same number of people and same sequence as the original line.Note:nA proposed layout is not to be made.nCurrent extrusion data is not to be developed.nImprovements tab is not to be completed.精益生产之线平衡模式LineBalanceModels练习指南1.使用 Excel工作表格,看“目前的时间”以完成“Current T
49、akt Time Chart.”2.看“Current Staffing”完成“Skill Matrix”3.使用这三个表重新分配任务，用同样的认输和程序在原来的生产线上平衡任务数量。Note:n不必做出一个拟定的布局n不用做出目前的数据n不必完成改进表精益生产之线平衡模式LineBalanceModelsAssembly Balance Model:Day-to-Day ScheduleruStep 1:Understand current state operation(gather and document data around layout,process flow,etc.).uS
50、tep 2:Determine total time required to process unit(customer value add,business value add,current non-value add).uStep 3:Determine maximum operating parameters and plug parameters into takt rate calculator.uStep 4:Review outputs:takt rate and number of hours to work to achieve requirement.Use this o
