多品种小批量轮番生产计划模型(英文)
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• Availability (parts quality, organizational interruptions, OEE)
3
Case study: Production program based on change over optimization - units allocation
? ? ? ? ?
? ? ? ? ? ? ? ? ? ?
number Change over/day ?
4
Example:
How often should we produce different part numbers ? Introduction EPEI = Every Part Every Interval
remaining time for change overs max number of change overs = 4
cycle time = 27 sec / pc change over time = 10 min
availability 95%
availability = 95 %
max productivity packaging/delivery volume 40 pcs
– Models with high frequent and constant demand (high runner) – Models with low frequent and/or uneven demand (low runner)
• Customer tact or demand quantity/frequency per model • Capacity (offered by production ):
– Personnel (Shift model) – MAE (OEE, change over time)
• Leveling period and withdrawal sequence • Lot-size • Planning period:
– replanning frequency of the leveling board
• Leveling the quantity and production sequence takes place at the manufacturing resource.
• A preferably fine leveling simulates a ‘perfect’ customer who picks up regularly in small portions.
Time stack
Takt Time = 920 min x 60 sec / 1840 pcs = 30 sec / pc
5
Case study: production program based on change over optimization
• Leveling supports the Continuous Improvement Process implying a reduction in lot size and therefore in replenishment lead time.
• Shortened replenishment lead times yield in increased flexibility (easy and fast adjustment to unanticipated disruptions such as changes in customer demand).
• Through a consistent customer demand, stock can be held on a minimum from the preliminary processes to the suppliers.
2
2
Parameters for leveling
• Distinction into high and low runner:
36.800 pcs
Current demand / day
280 280 280 240 200 160 160 120
24 24 16 16 8
4 4 4 4 4 4 2 2 2 2
1840 pcs
EPEI ?
recorded fluctuations
+/- 10 % +/- 50 % +/- 50 % +/- 20 % +/- 25 % +/- 20 % +/- 15 % +/- 10 %
Product
A B C D E F G H
a b ቤተ መጻሕፍቲ ባይዱ d e
f g h i j k l m n o
23 TTNr.
Current demand / month
5,600 5,600 5,600 4,800 4,000 3,200 3,200 2,400
480 480 320 320 160
80 80 80 80 80 80 40 40 40 40
企业实践案例（英文资料）： “多品种 - 小批量轮番生产”
均衡化生产计划与排程模型
Production Fluctuation in lot size
Customer
1
Leveling method: Leveling the quantity per model and consistency of the model order.
Current situation:
time in min. 2 shifts =
23 part numbers *) customer demand 1840 pcs / day 2 shifts, 8 hrs/shift 2 x 10 min breaks per shift
breaks = 40 min
customer demand / day x cycle time 1840 x 27 = 828 min
960 min 920 min 48 min 872 min
828 min
*) overview part number and volume distribution see data sheet
3
Case study: Production program based on change over optimization - units allocation
? ? ? ? ?
? ? ? ? ? ? ? ? ? ?
number Change over/day ?
4
Example:
How often should we produce different part numbers ? Introduction EPEI = Every Part Every Interval
remaining time for change overs max number of change overs = 4
cycle time = 27 sec / pc change over time = 10 min
availability 95%
availability = 95 %
max productivity packaging/delivery volume 40 pcs
– Models with high frequent and constant demand (high runner) – Models with low frequent and/or uneven demand (low runner)
• Customer tact or demand quantity/frequency per model • Capacity (offered by production ):
– Personnel (Shift model) – MAE (OEE, change over time)
• Leveling period and withdrawal sequence • Lot-size • Planning period:
– replanning frequency of the leveling board
• Leveling the quantity and production sequence takes place at the manufacturing resource.
• A preferably fine leveling simulates a ‘perfect’ customer who picks up regularly in small portions.
Time stack
Takt Time = 920 min x 60 sec / 1840 pcs = 30 sec / pc
5
Case study: production program based on change over optimization
• Leveling supports the Continuous Improvement Process implying a reduction in lot size and therefore in replenishment lead time.
• Shortened replenishment lead times yield in increased flexibility (easy and fast adjustment to unanticipated disruptions such as changes in customer demand).
• Through a consistent customer demand, stock can be held on a minimum from the preliminary processes to the suppliers.
2
2
Parameters for leveling
• Distinction into high and low runner:
36.800 pcs
Current demand / day
280 280 280 240 200 160 160 120
24 24 16 16 8
4 4 4 4 4 4 2 2 2 2
1840 pcs
EPEI ?
recorded fluctuations
+/- 10 % +/- 50 % +/- 50 % +/- 20 % +/- 25 % +/- 20 % +/- 15 % +/- 10 %
Product
A B C D E F G H
a b ቤተ መጻሕፍቲ ባይዱ d e
f g h i j k l m n o
23 TTNr.
Current demand / month
5,600 5,600 5,600 4,800 4,000 3,200 3,200 2,400
480 480 320 320 160
80 80 80 80 80 80 40 40 40 40
企业实践案例（英文资料）： “多品种 - 小批量轮番生产”
均衡化生产计划与排程模型
Production Fluctuation in lot size
Customer
1
Leveling method: Leveling the quantity per model and consistency of the model order.
Current situation:
time in min. 2 shifts =
23 part numbers *) customer demand 1840 pcs / day 2 shifts, 8 hrs/shift 2 x 10 min breaks per shift
breaks = 40 min
customer demand / day x cycle time 1840 x 27 = 828 min
960 min 920 min 48 min 872 min
828 min
*) overview part number and volume distribution see data sheet