精益生产之线平衡模式LineBalanceModels中英文版
合集下载
- 1、下载文档前请自行甄别文档内容的完整性,平台不提供额外的编辑、内容补充、找答案等附加服务。
- 2、"仅部分预览"的文档,不可在线预览部分如存在完整性等问题,可反馈申请退款(可完整预览的文档不适用该条件!)。
- 3、如文档侵犯您的权益,请联系客服反馈,我们会尽快为您处理(人工客服工作时间:9:00-18:30)。
4
• 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 ing Objectives
10
Primary Issues in Typical Control
Process Environments
Large or erratic batches Excessive WIP Poor floor space utilization Low employee efficiency Long/erratic cycle times Poor balance of operations and labor across process steps Conveyance, standby and motion waste Disorganized workspace and component/supply storage High variability of demand on multiple processing centers, e.g., call
How to design and implement a process supported by a line balancing model that ensures optimal use of: People Floor space Capital Assets Material
Line Balance Model
12
Control
Line Balance – Design Principles
Minimize Batch Size/Transfer Quantity/Work In Process Minimize/Stabilize Cycle Time Maximize Labor Efficiency Optimize number of workstations/process steps Balance tasks/labor across workstations Maximize space utilization Minimize takt variance Minimize NVA (conveyance, standby, and motion wastes) Minimize the need to re-balance as demand requirements change Minimize volume variability (combine product category demand) Maximize flexibility to allow for product introductions and discontinuations
3
• Brainstorming • Pull Systems • Setup Reduction • TPM • Process Flow • Benchmarking • Affinity • DOE • Hypothesis Testing • Force Field • Tree Diagrams • Gantt Charts
Approaches to Line Balance
Exercise
RD011202
Measure Analyze Improve Control
Lean Six Sigma
Line 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
Analyze
• Propose Critical X’s • Prioritize Critical X’s • Verify Critical X’s • Estimate the Impact of
Each X on Y • Quantify the Opportunity • Prioritize Root Causes • Conduct Root Cause
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
• 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
• 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
分析
改进
控制
• Cp & Cpk • 供应链加速器分析 • 多变动图i • 盒状图 • 交互作用图 • 回归分析 • ANOVA • C&E 矩阵图 • FMEA
• 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&R
Revised 1-12-02
Line Balance Model
Control
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
RD011202
Lean Six Sigma Improvement Process Road Map
Define
• Identify Problem • Develop List of Customers • Develop List of CTQ’s
from Voice of the Customer • Finalize Project Focus and Key Metrics • Complete PDF
Line Balance Model
7
益处
能够设计和实施一个线平衡的生产线 了解典型流程环境中的问题及如何影响那些问题
Control
Line Balance Model
8
Control
Line Balance Model
A 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.
Control
Control
• Implement Process Changes and Controls
• Write Control Plan • Calculate Final Financial/ • Process Metrics • Transition Project to
Future Owners • Identify Project • Translation Opportunities
centers/flow lines
Line Balance Model
11
典型的流程环境
中的主要问题
Control
大批量或 反复无常的批量 过多的 WIP 地方利用的差 较低的员工效率 长的/反复无常的周期时间 流程步骤中差的生产平衡和劳动力 传送、备用和启动浪费 无规则的工作地点和元件/供应存储 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
Revised 1-12-02
Line Balance Model
• Cp & Cpk • SupplyChainAccelerator
Analysis • Multi-Vari • Box Plots • Interaction Plots • Regression • ANOVA • C&E Matrices • FMEA
In addition, the user will be able to visually see unbalanced areas and where tasks can be shifted to balance the process.
The Line Balance techniques are applicable in transactional as well as manufacturing, e.g., order entry operations.
Measure
• Map Business Process • Map Value Stream • Develop Data
Collection Plan • Conduct Measurement
System Analysis • Collect Data • Conduct Process
Capability Analysis
Analysis on Critical X’s
Improve
• Critical X’s Confirmed • Develop Potential
Solutions • Select Solution • Optimize Solution • Pilot Solution
Define
Measure
Analyze
Improve
• Project ID Tools • Project Definition Form • Net Present Value
Analysis • Internal Rate of Return
Analysis • Discounted Cash Flow
Analysis • PIP Management Process • RACI • Quad Charts
Line Balance Model
9
线平衡模型
Control
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 。
除此,用户将能直观地看到不平衡的区域和使流程平衡所做 的任务。
线平衡 方法与生产互动一样是可行的,如订单进入生产。
Line Balance Model
求 • 定出项目焦点和重要指标 • 完成 PDF
测量
• 绘制业务流程图 • 绘制价值流程图 • 制定数据收集计划 • 测量系统分析 • 收集数据 • 过程能力分析
定义
测量
• 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 • RACI • Quad 表
• Process Mapping • Value Analysis • Brainstorming • Multi-Voting Techniques • Pareto Charts • C&E/Fishbone Diagrams • FMEA • Check Sheets • Run Charts • Control Charts • Gage R&R
What’s in It for Me?
Able to design and implement a balanced process line Understand the issues in a typical process environment
and how to impact those issues
Know how to maximize productivity
Line Balance Model
5
学习目标
Control
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: 人 地方 固定资产 材料
知道如何使生产率最大化
Line Balance Model
6
Control
Control
• Check Sheets • Run Charts • Histograms • Scatter Diagrams • Control Charts • Pareto Charts • Interactive Reviews • Poka-Yoke
精益6 过程改善流程
定义
• 选定题目 • 列出客户 • 从顾客之声中列出关建需
Measure Analyze Improve Control
Lean Six Sigma
Line Lean Six Sigma Improvement Process
Road Map
Definition – Line Balance Model
Design Principles
Value Definitions
• 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 ing Objectives
10
Primary Issues in Typical Control
Process Environments
Large or erratic batches Excessive WIP Poor floor space utilization Low employee efficiency Long/erratic cycle times Poor balance of operations and labor across process steps Conveyance, standby and motion waste Disorganized workspace and component/supply storage High variability of demand on multiple processing centers, e.g., call
How to design and implement a process supported by a line balancing model that ensures optimal use of: People Floor space Capital Assets Material
Line Balance Model
12
Control
Line Balance – Design Principles
Minimize Batch Size/Transfer Quantity/Work In Process Minimize/Stabilize Cycle Time Maximize Labor Efficiency Optimize number of workstations/process steps Balance tasks/labor across workstations Maximize space utilization Minimize takt variance Minimize NVA (conveyance, standby, and motion wastes) Minimize the need to re-balance as demand requirements change Minimize volume variability (combine product category demand) Maximize flexibility to allow for product introductions and discontinuations
3
• Brainstorming • Pull Systems • Setup Reduction • TPM • Process Flow • Benchmarking • Affinity • DOE • Hypothesis Testing • Force Field • Tree Diagrams • Gantt Charts
Approaches to Line Balance
Exercise
RD011202
Measure Analyze Improve Control
Lean Six Sigma
Line 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
Analyze
• Propose Critical X’s • Prioritize Critical X’s • Verify Critical X’s • Estimate the Impact of
Each X on Y • Quantify the Opportunity • Prioritize Root Causes • Conduct Root Cause
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
• 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
• 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
分析
改进
控制
• Cp & Cpk • 供应链加速器分析 • 多变动图i • 盒状图 • 交互作用图 • 回归分析 • ANOVA • C&E 矩阵图 • FMEA
• 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&R
Revised 1-12-02
Line Balance Model
Control
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
RD011202
Lean Six Sigma Improvement Process Road Map
Define
• Identify Problem • Develop List of Customers • Develop List of CTQ’s
from Voice of the Customer • Finalize Project Focus and Key Metrics • Complete PDF
Line Balance Model
7
益处
能够设计和实施一个线平衡的生产线 了解典型流程环境中的问题及如何影响那些问题
Control
Line Balance Model
8
Control
Line Balance Model
A 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.
Control
Control
• Implement Process Changes and Controls
• Write Control Plan • Calculate Final Financial/ • Process Metrics • Transition Project to
Future Owners • Identify Project • Translation Opportunities
centers/flow lines
Line Balance Model
11
典型的流程环境
中的主要问题
Control
大批量或 反复无常的批量 过多的 WIP 地方利用的差 较低的员工效率 长的/反复无常的周期时间 流程步骤中差的生产平衡和劳动力 传送、备用和启动浪费 无规则的工作地点和元件/供应存储 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
Revised 1-12-02
Line Balance Model
• Cp & Cpk • SupplyChainAccelerator
Analysis • Multi-Vari • Box Plots • Interaction Plots • Regression • ANOVA • C&E Matrices • FMEA
In addition, the user will be able to visually see unbalanced areas and where tasks can be shifted to balance the process.
The Line Balance techniques are applicable in transactional as well as manufacturing, e.g., order entry operations.
Measure
• Map Business Process • Map Value Stream • Develop Data
Collection Plan • Conduct Measurement
System Analysis • Collect Data • Conduct Process
Capability Analysis
Analysis on Critical X’s
Improve
• Critical X’s Confirmed • Develop Potential
Solutions • Select Solution • Optimize Solution • Pilot Solution
Define
Measure
Analyze
Improve
• Project ID Tools • Project Definition Form • Net Present Value
Analysis • Internal Rate of Return
Analysis • Discounted Cash Flow
Analysis • PIP Management Process • RACI • Quad Charts
Line Balance Model
9
线平衡模型
Control
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 。
除此,用户将能直观地看到不平衡的区域和使流程平衡所做 的任务。
线平衡 方法与生产互动一样是可行的,如订单进入生产。
Line Balance Model
求 • 定出项目焦点和重要指标 • 完成 PDF
测量
• 绘制业务流程图 • 绘制价值流程图 • 制定数据收集计划 • 测量系统分析 • 收集数据 • 过程能力分析
定义
测量
• 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 • RACI • Quad 表
• Process Mapping • Value Analysis • Brainstorming • Multi-Voting Techniques • Pareto Charts • C&E/Fishbone Diagrams • FMEA • Check Sheets • Run Charts • Control Charts • Gage R&R
What’s in It for Me?
Able to design and implement a balanced process line Understand the issues in a typical process environment
and how to impact those issues
Know how to maximize productivity
Line Balance Model
5
学习目标
Control
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: 人 地方 固定资产 材料
知道如何使生产率最大化
Line Balance Model
6
Control
Control
• Check Sheets • Run Charts • Histograms • Scatter Diagrams • Control Charts • Pareto Charts • Interactive Reviews • Poka-Yoke
精益6 过程改善流程
定义
• 选定题目 • 列出客户 • 从顾客之声中列出关建需
Measure Analyze Improve Control
Lean Six Sigma
Line Lean Six Sigma Improvement Process
Road Map
Definition – Line Balance Model
Design Principles
Value Definitions