精益生产之连续流
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创建连续流 Creating Continuous Flow
赵克强 博士 精益企业中国 总裁
www.LeanChina.org
1
Байду номын сангаас
什么是连续流 What is CCF?
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops
2
什么是连续流 What is CCF?
2
为什么要创建连续流
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory 缩短工序间的距离，减少走动的浪费 Shorten the distance between work stations and minimize non-value added movement
5
如何执行连续流-3
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time?
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time? 如何分配工作？ How will you distribute the work among the operators?
9
总 结 Summary
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory 缩短工序间的距离，减少走动的浪费 Shorten the distance between work stations and minimize non-value added movement 缩短Lead Time Shorten lead time
3
如何执行连续流-1
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items?
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items? 什么是节拍时间？ What is the takt time?
7
执行连续流的挑战 Challenges
8
执行连续流的挑战 Challenges
工作平衡 Line Balance
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix
7
什么样的工艺适用连续流 Applications
手工制造 Manual production 半自动制造 Semi automated manufacturing 冲压、注塑成型、油漆以及全自动生产不适用 Not applicable at stamping, injection molding, and complete automated processes
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving
5
如何执行连续流-2
设备是否满足节拍时间的要求？ Can your equipment meet the takt time? 如何选择合适的自动化水平？ How much automation? 如何安排设备的布局以达成单件连续流？ How can the physical process be laid out so one person can make one piece as efficiently as possible?
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days U型生产是另一范例 U cell is another example 单件流是最高境界 Single piece flow is the ideal
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days U型生产是另一范例 U cell is another example 单件流是最高境界 Single piece flow is the ideal 真正的连续流不需要看板 A real single piece flow no longer needs Kanban
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time? 如何分配工作？ How will you distribute the work among the operators? 如何下达生产计划？ How will you schedule the pacemaker?
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving 持续改善 Continuous Improvement 纪律 Discipline 物料补给 Material Replenishment
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory 缩短工序间的距离，减少走动的浪费 Shorten the distance between work stations and minimize non-value added movement 缩短Lead Time Shorten lead time 增加人均生产率 Increase productivity
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving 持续改善 Continuous Improvement 纪律 Discipline
8
总 结 Summary
9
总 结 Summary
创建连续流必须结合公司的营运目标 A continuous flow needs to be connect with the company business goals
9
总 结 Summary
创建连续流必须结合公司的营运目标 A continuous flow needs to be connect with the company business goals 建立连续流的前提是一个稳定的质量与生产系统 A continuous flow is built on a stable quality and production system
4
如何执行连续流-2
5
如何执行连续流-2
设备是否满足节拍时间的要求？ Can your equipment meet the takt time?
5
如何执行连续流-2
设备是否满足节拍时间的要求？ Can your equipment meet the takt time? 如何选择合适的自动化水平？ How much automation?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days U型生产是另一范例 U cell is another example
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items? 什么是节拍时间？ What is the takt time? 贵工厂生产一件产品有哪些工作步骤？ What are the work elements necessary to make one piece? 如何测定工作步骤的工时？ What is the actual time required for each work element?
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving 持续改善 Continuous Improvement
7
什么样的工艺适用连续流 Applications
手工制造 Manual production 半自动制造 Semi automated manufacturing 冲压、注塑成型、油漆以及全自动生产不适用 Not applicable at stamping, injection molding, and complete automated processes Takt Time 太短或太长不适用 Not applicable for the processes with a takt time more than 120 sec. or less than 10 sec.
什么样的工艺适用连续流 Applications
7
什么样的工艺适用连续流 Applications
手工制造 Manual production
7
什么样的工艺适用连续流 Applications
手工制造 Manual production 半自动制造 Semi automated manufacturing
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items? 什么是节拍时间？ What is the takt time? 贵工厂生产一件产品有哪些工作步骤？ What are the work elements necessary to make one piece?
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time? 如何分配工作？ How will you distribute the work among the operators? 如何下达生产计划？ How will you schedule the pacemaker? 当顾客需求波动时，定拍工序应如何调整？ How will the pacemaker react to changes in customer demand? 6
赵克强 博士 精益企业中国 总裁
www.LeanChina.org
1
Байду номын сангаас
什么是连续流 What is CCF?
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops
2
什么是连续流 What is CCF?
2
为什么要创建连续流
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory 缩短工序间的距离，减少走动的浪费 Shorten the distance between work stations and minimize non-value added movement
5
如何执行连续流-3
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time?
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time? 如何分配工作？ How will you distribute the work among the operators?
9
总 结 Summary
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory 缩短工序间的距离，减少走动的浪费 Shorten the distance between work stations and minimize non-value added movement 缩短Lead Time Shorten lead time
3
如何执行连续流-1
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items?
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items? 什么是节拍时间？ What is the takt time?
7
执行连续流的挑战 Challenges
8
执行连续流的挑战 Challenges
工作平衡 Line Balance
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix
7
什么样的工艺适用连续流 Applications
手工制造 Manual production 半自动制造 Semi automated manufacturing 冲压、注塑成型、油漆以及全自动生产不适用 Not applicable at stamping, injection molding, and complete automated processes
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving
5
如何执行连续流-2
设备是否满足节拍时间的要求？ Can your equipment meet the takt time? 如何选择合适的自动化水平？ How much automation? 如何安排设备的布局以达成单件连续流？ How can the physical process be laid out so one person can make one piece as efficiently as possible?
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days U型生产是另一范例 U cell is another example 单件流是最高境界 Single piece flow is the ideal
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days U型生产是另一范例 U cell is another example 单件流是最高境界 Single piece flow is the ideal 真正的连续流不需要看板 A real single piece flow no longer needs Kanban
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time? 如何分配工作？ How will you distribute the work among the operators? 如何下达生产计划？ How will you schedule the pacemaker?
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving 持续改善 Continuous Improvement 纪律 Discipline 物料补给 Material Replenishment
3
为什么要创建连续流
减少WIP Reduce work-in-process inventory 缩短工序间的距离，减少走动的浪费 Shorten the distance between work stations and minimize non-value added movement 缩短Lead Time Shorten lead time 增加人均生产率 Increase productivity
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving 持续改善 Continuous Improvement 纪律 Discipline
8
总 结 Summary
9
总 结 Summary
创建连续流必须结合公司的营运目标 A continuous flow needs to be connect with the company business goals
9
总 结 Summary
创建连续流必须结合公司的营运目标 A continuous flow needs to be connect with the company business goals 建立连续流的前提是一个稳定的质量与生产系统 A continuous flow is built on a stable quality and production system
4
如何执行连续流-2
5
如何执行连续流-2
设备是否满足节拍时间的要求？ Can your equipment meet the takt time?
5
如何执行连续流-2
设备是否满足节拍时间的要求？ Can your equipment meet the takt time? 如何选择合适的自动化水平？ How much automation?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days
2
什么是连续流 What is CCF?
生产线上畅通无阻 Flow without stops 流水线是最原始的连续流 Henry Ford assembly line is a good example in early days U型生产是另一范例 U cell is another example
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items? 什么是节拍时间？ What is the takt time? 贵工厂生产一件产品有哪些工作步骤？ What are the work elements necessary to make one piece? 如何测定工作步骤的工时？ What is the actual time required for each work element?
8
执行连续流的挑战 Challenges
工作平衡 Line Balance 标准工序 Standard Work 产品均衡 Product Mix 快速换模 Frequent Change Over 解决问题 Problem Solving 持续改善 Continuous Improvement
7
什么样的工艺适用连续流 Applications
手工制造 Manual production 半自动制造 Semi automated manufacturing 冲压、注塑成型、油漆以及全自动生产不适用 Not applicable at stamping, injection molding, and complete automated processes Takt Time 太短或太长不适用 Not applicable for the processes with a takt time more than 120 sec. or less than 10 sec.
什么样的工艺适用连续流 Applications
7
什么样的工艺适用连续流 Applications
手工制造 Manual production
7
什么样的工艺适用连续流 Applications
手工制造 Manual production 半自动制造 Semi automated manufacturing
4
如何执行连续流-1
如何选择产品系列？ Do you have the right end items? 什么是节拍时间？ What is the takt time? 贵工厂生产一件产品有哪些工作步骤？ What are the work elements necessary to make one piece?
6
如何执行连续流-3
如何确定操作员人数？ How many operators are needed to meet Takt time? 如何分配工作？ How will you distribute the work among the operators? 如何下达生产计划？ How will you schedule the pacemaker? 当顾客需求波动时，定拍工序应如何调整？ How will the pacemaker react to changes in customer demand? 6