精益生产-Bin_Replenishment_Pull(中英文对照).

1、Measure Analyze Control Improve Lean Six Sigma 2-Bin Replenishment Pull uIntroduction to 2-Bin Replenishment Pull uLine-side versus Point-of-Use Stocking u2-Bin Data Needs and Calculations uInventory Disposition Options uCard Triggered 2-Bin Process u1-Bin Systems uAppendix RD01120 2 Measure Analyze

2、 Control Improve Lean Six Sigma 2-Bin 补充拉系统 u2-箱补充拉系统的介绍 u线旁VS使用点库存 u2-箱数据的要求和计算 u库存部署选择 u卡触发2-箱流程 u1-箱系统 u附录 RD01120 2 Improve 2-Bin Replenishment Pull3 Lean Six Sigma Improvement Process Road Map AnalyzeControlImprove Define Identify Problem Develop List of Customers Develop List of CTQs from Voic

3、e of the Customer Finalize Project Focus and Key Metrics Complete PDF Measure Map Business Process Map Value Stream Develop Data Collection Plan Conduct Measurement System Analysis Collect Data Conduct Process Capability Analysis Analyze Propose Critical Xs Prioritize Critical Xs Verify Critical Xs

4、Estimate the Impact of Each X on Y Quantify the Opportunity Prioritize Root Causes Conduct Root Cause Analysis on Critical Xs Improve Critical Xs Confirmed Develop Potential Solutions Select Solution Optimize Solution Pilot Solution Control Implement Process Changes and Controls Write Control Plan C

5、alculate Final Financial/ Process Metrics Transition Project to Future Owners Identify Project Translation Opportunities MeasureDefine Project ID Tools Project Definition Form Net Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management Process RACI Quad C

6、harts Process Mapping Value Analysis Brainstorming Multi-Voting Techniques Pareto Charts C “bins” are actually the box/container the part/supply is shipped in. 1. Employee removes a bin and drops its green 2-bin card into the mailbox: nPull parts from “bin” with green card before using any with the

7、red card. 2.At same time(s) each day, the cards are picked up from the mailbox and returned to the stock/supply room. 3. The stock/supply room pulls proper amount of parts/material (noted on card, set equal to the calculated “bin” quantity). 4. Inventory transactions are performed (depending on issu

8、e method), and the materials and cards are delivered to the storage location. 5.Employee stocks material in storage location and returns card to its proper place. nWhen stock/supply room replaces the material, ensure that the red card is placed on the full bin. lAlways leaves you a full red bin rema

9、ining when green bin runs out. lIf not, you could run down both bins and stock out before either is replaced; if a red card is in the replenishment process, a part shortage is imminent act fast! Improve 2-Bin Replenishment Pull43 典型的卡触发2-箱补充的介绍 这个流程用绿色和红色卡来触发补充；“箱”是实际用来发货零件/供应品的盒子/ 容器. 1. 员工清掉一个箱后，将

10、绿色的2-箱卡放入邮箱: n在使用有红色卡的零件前，先从有绿卡的箱中拉零件 2. 每天的同一时候, 邮箱卡片被收集并返回到库房中. 3. 库房拉动零件/材料的适合数量 (在卡上注明，将之设定为计算出的“箱”数量). 4. 库存处理被执行了(根据发放的方式), 然后材料和卡被传送到仓储地点. 5. 员工将物料放在仓储地点然后将卡返回到适合的地方. n当库房补充材料时，确保红色卡被放在添满的箱上. l当绿箱被放出去使用时，始终保持红卡箱中的零件已经被填满. l如果不是这样，在任一箱补充前你将用尽每个箱存货；如果红卡在补充过程中， 零件短缺现象即将出现尽快采取行动。 Improve 2-Bin Re

11、plenishment Pull44 Maintaining a Card Triggered 2-Bin Process uCheck periodically for lost cards and replace. nBest time is right after replenishment; any cards not replaced or in the mailbox are lost. uPolice the proper use of cards: nSupervisor/Lead drop green cards when green bin is empty. nSuper

12、visor/Lead drop red cards on stock out investigate! nSupervisor/Lead ensure cards are replaced when parts are restocked. nGreen bins are completely used before red bins. uResize bins when demand changes. uAdd cards for new parts, delete cards for obsolete parts. Improve 2-Bin Replenishment Pull45 保持

13、卡触发2-箱系统的过程 u定期检查卡片是否丢失并更换. n最佳时间是在补充之后，如果卡片未被更换或未在邮箱都视为 丢失 u维持卡片的合理使用: n当绿卡箱用完变空时，主管/组长投放绿卡. n当存货用完时，主管/组长投放红卡 调查! n当零件重新补充时，主管/组长确保卡片被更换. n在用红卡箱前，确保绿卡箱已经被用完. u当需求改变时需要重新调整箱的数量. u新增的零件要增加不同的卡，过期的死库存零件要将卡片毁 尸灭迹. Improve 2-Bin Replenishment Pull46 Bin 1Bin 2 Example Card Triggered Line-Side 2-Bin Rac

14、k Bin 1Bin 2 Bin 1Bin 2 Bin 1Bin 2 Bin 1 Bin 1Bin 2 Bin 1 Bin 2 Bin 1Bin 2 Bin 1Bin 2 Bin 1Bin 2Bin 1Bin 2 Bin 1Bin 2 Bin 1Bin 2 Bin 1 Bin 1 2-Bin Mailbox Order Cards 1. Always pull material from bin with GREEN card if it is there. 2. Store/supply room replaces material and switches RED card to mate

15、rial just replaced. 3. The cards are attached to magnetic strip labels (for ease of movement for resizing). Bin 1 Bin 1 Bin 2 Improve 2-Bin Replenishment Pull47 Bin 1Bin 2 举例： 由卡触发的线旁2-箱货架 Bin 1Bin 2 Bin 1Bin 2 Bin 1Bin 2 Bin 1 Bin 1Bin 2 Bin 1 Bin 2 Bin 1Bin 2 Bin 1Bin 2 Bin 1Bin 2Bin 1Bin 2 Bin 1B

16、in 2 Bin 1Bin 2 Bin 1 Bin 12-箱邮箱 订单卡片 1. 如果这里有绿卡箱，那么必须要从绿卡箱里拉材 料. 2. 库房补充材料并将红卡换到刚补充的材料里. 3. 卡片最好是有磁性的 ( 这样在调整数量时可以方 便移动). Bin 1 Bin 1 Bin 2 Improve 2-Bin Replenishment Pull48 Example Card Triggered Line-Side 2-Bin System Improve 2-Bin Replenishment Pull49 举例： 由卡触发的线旁2-箱系统 Improve 2-Bin Replenishmen

17、t Pull50 Example Card Triggered Line-Side 2-Bin System u2-Bin Cards are Green and Red, per the process. uCards are placed into plastic sheaths to protect them from getting knocked off the racking. uClear plastic sheaths are attached to metal racking via sticky magnetic strip make resizing easier. uB

18、in labels are white sticky backed and placed inside of plastic sheath for protection. uA clear plastic sheath over a white label indicates that the bin is being replenished. Improve 2-Bin Replenishment Pull51 举例： 由卡触发的线旁2-箱系统 u根据流程的需要，2-箱卡是绿卡和红卡. u卡片可装入塑料套中以防止摩擦磕碰. u透明塑料套通过磁性体吸附到金属货架上以便容易的调整数量. u料箱标

19、签为白色的，贴在塑料套内背面加以保护. u塑料套显示出白色时表明料箱正在补充. Improve 2-Bin Replenishment Pull52 If a clear plastic sheath/pouch is used to house the label and the card, then a clear pouch over the rack label indicates that the part is on order an easy way to Poka-Yoke the process. Weatherstrip 40130 W/STRIP .270HT.187BK

20、 FS W Standard Pack: box Units per Pack:6000 STOCKOUT 4 Box(es) Have Been Ordered Location = A25 Physical = S-1000 2-Bin R1 - L3 - S3 Common Name Part Number Part Description Indicates Part is on Order Indicates Quantity on Order Line-Side Location Rack and Space Location Sample Bin/Rack Label Impro

21、ve 2-Bin Replenishment Pull53 如果一个空塑料套/袋用来收集标贴或卡片时，那么它在货架上 表示该零件已经是在途订单，这是很好的防错措施 挡风胶条挡风胶条 40130 W/STRIP .270HT.187BK FS W 标准包装: 盒 每包件数：6000 用完用完 4 箱已订货箱已订货 地点地点 = A25 物理位置物理位置 = S-1000 2-Bin R1 - L3 - S3 名称 零件号码 零件描述 指示零件在订货中 显示订货数量 线旁场所 货架和空间位置 箱/货架标签实例 Improve 2-Bin Replenishment Pull54 Weatherst

22、rip 40130 W/STRIP .270HT.187BK FS W Standard Pack: box Units per Pack:6000 Order: 4 Box(es) When No box(es) Are Left Location = A25 2-Bin Space = S-1000 2-Bin R2 - A - 4 Common Name Part Number Part Description Indicates Quantity on Order Line-Side Location Rack and Bin Location Cards are typically

23、colored light red or light green and laminated for protection. Sample 2-Bin Card Improve 2-Bin Replenishment Pull55 挡风胶条挡风胶条 40130 W/STRIP .270HT.187BK FS W 标准包: 盒子 每包数量:6000 订货订货: 当无剩余时，需要当无剩余时，需要 4 箱订货箱订货 地点地点 = A25 2-箱空间箱空间 = S-1000 2-Bin R2 - A - 4 卡片一般是亮红 或亮绿颜色， 并有压膜保护。 2-箱卡样板 名称 零件号码 零件描述 显示订货

24、数量 线旁场所 货架和空间位置 Improve 2-Bin Replenishment Pull56 Sample Rack Layout Front Bin 1Bin 2Bin 1Bin 2 Shelf 4 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Shelf 2 Bin 1Bin 2 Shelf 1 Rack 1 (Side A) 52404 Sash Lock 52404 Sash Lock 55081 Lift Block - 1/16 55081 Lift Block

25、- 1/16 55080 Lift Block - 1/8 55080 Lift Block - 1/8 53221 Glazing Tape 53221 Glazing Tape 57179 Upper Sash Lift Block 57179 Upper Sash Lift Block 56195 FOAM PAD 45872 Pivot Bar Screw 45872 Pivot Bar Screw 50160 Lock and Tilt Latch Screw 50160 Lock and Tilt Latch Screw 52404 Sash Lock 52404 Sash Loc

26、k 56195 FOAM PAD 53221 Glazing Tape 53221 Glazing Tape 55474 Mullion Screw 55474 Mullion Screw 56162 Q-LON 56162 Q-LON Bin 1Bin 2 Shelf 4 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2Bin 1Bin 2 Shelf 2 Shelf 1 Rack 1 (Side B) 44525 LH Tilt Latch 44525 LH Tilt Latch 44526 RH Tilt Latch 44526 RH T

27、ilt Latch 56761 Balancer Screw 56761 Balancer Screw 56391 Mull Plug 56391 Mull Plug 55230 PIVOT BAR 55230 PIVOT BAR 53221 Glazing Tape 53221 Glazing Tape 53221 Glazing Tape 53221 Glazing Tape 57092 Sill Lift Block 57092 Sill Lift Block 56162 Q-LON 56162 Q-LON 52404 Sash Lock 52404 Sash Lock 52404 Sa

28、sh Lock 52404 Sash Lock 52404 Sash Lock 52404 Sash Lock Rack layouts drawn in Excel/other make excellent implementation and upkeep maps to guide stocking/restocking efforts. Many times it is good to have parts/supplies on only one side of a rack that way you can “pull from one side” and “replenish f

29、rom the other.” Improve 2-Bin Replenishment Pull57 货架排布的样板 前面 Bin 1Bin 2Bin 1Bin 2 Shelf 4 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Shelf 2 Bin 1Bin 2 Shelf 1 Rack 1 (Side A) 52404 Sash Lock 52404 Sash Lock 55081 Lift Block - 1/16 55081 Lift Block - 1/16 55080 L

30、ift Block - 1/8 55080 Lift Block - 1/8 53221 Glazing Tape 53221 Glazing Tape 57179 Upper Sash Lift Block 57179 Upper Sash Lift Block 56195 FOAM PAD 45872 Pivot Bar Screw 45872 Pivot Bar Screw 50160 Lock and Tilt Latch Screw 50160 Lock and Tilt Latch Screw 52404 Sash Lock 52404 Sash Lock 56195 FOAM P

31、AD 53221 Glazing Tape 53221 Glazing Tape 55474 Mullion Screw 55474 Mullion Screw 56162 Q-LON 56162 Q-LON Bin 1Bin 2 Shelf 4 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2Bin 1Bin 2 Shelf 2 Shelf 1 Rack 1 (Side B) 44525 LH Tilt Latch 44525 LH Tilt Latch 44526 RH Tilt Latch 44526 RH Tilt Latch 5676

32、1 Balancer Screw 56761 Balancer Screw 56391 Mull Plug 56391 Mull Plug 55230 PIVOT BAR 55230 PIVOT BAR 53221 Glazing Tape 53221 Glazing Tape 53221 Glazing Tape 53221 Glazing Tape 57092 Sill Lift Block 57092 Sill Lift Block 56162 Q-LON 56162 Q-LON 52404 Sash Lock 52404 Sash Lock 52404 Sash Lock 52404

33、Sash Lock 52404 Sash Lock 52404 Sash Lock 货架布置一般可用EXCEL或其他工具来做优秀的实施，画张图来指导库存/再次补充库存的努力， 大多数是一侧取用零件/供应品，你可以“从一侧拉”并“从另一侧补充”。 Improve 2-Bin Replenishment Pull58 Sample Rack Layout Back Bin 1Bin 2 Shelf 4 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2 Shelf 2 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 1 Ra

34、ck 2 (Side A) 40130 W/STRIP 40130 W/STRIP 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55142 Red 24 55142 Red 24 55142 Red 24 55142 Red 24 55142 Red 24 55142 Red 24 55136 Blue 12 55136 Blue 12 55136 Blue 12 55136 Blue 12 55136 Blue 12 55136 Blue 12

35、55135 Blue 9 55135 Blue 9 55135 Blue 9 55135 Blue 9 55135 Blue 9 55135 Blue 9 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green

36、21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 40130 W/STRIP 40130 W/STRIP 40130 W/STRIP 40130 W/STRIP 56762 Red 9 56762 Red 9 55146 Green 24 5

37、5146 Green 24 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 4 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 2 Shelf 1 Rack 2 (Side B) 57033 Clear Label (specials)LA BEL 57033 Clear Label (specials) 55285 Blue 18 55285 B

38、lue 18 55138 Red 12 55138 Red 12 55139 Red 15 55139 Red 15 55140 Red 18 55140 Red 18 55286 Blue 21 55286 Blue 21 55147 Green 27 55147 Green 27 55149 Yellow 24 55149 Yellow 24 55141 Red 21 55141 Red 21 55149 Yellow 24 55149 Yellow 24 55141 Red 21 55141 Red 21 55144 Green 18 55144 Green 18 55303 Orang

39、e 12 55303 Orange 12 If a rack has a front and a back side, make sure to label both. Also, if a part/supply standard pack can be seen from both sides of the rack (large box/container), label ONLY one side to avoid confusion. Improve 2-Bin Replenishment Pull59 货架排布的样板 前面 Bin 1Bin 2 Shelf 4 Bin 1Bin 2

40、Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2 Shelf 2 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 1 Rack 2 (Side A) 40130 W/STRIP 40130 W/STRIP 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55142 Red 24 55142 Red 24 55142 Red 24 55142 Red 24 55142 Red 24 55142 Re

41、d 24 55136 Blue 12 55136 Blue 12 55136 Blue 12 55136 Blue 12 55136 Blue 12 55136 Blue 12 55135 Blue 9 55135 Blue 9 55135 Blue 9 55135 Blue 9 55135 Blue 9 55135 Blue 9 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 2

42、1 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55145 Green 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 55148 Yellow 21 40130 W

43、/STRIP 40130 W/STRIP 40130 W/STRIP 40130 W/STRIP 56762 Red 9 56762 Red 9 55146 Green 24 55146 Green 24 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 4 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 3 Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2 Shelf 2 Shelf 1 Rack 2 (Side

44、 B) 57033 Clear Label (specials)LA BEL 57033 Clear Label (specials) 55285 Blue 18 55285 Blue 18 55138 Red 12 55138 Red 12 55139 Red 15 55139 Red 15 55140 Red 18 55140 Red 18 55286 Blue 21 55286 Blue 21 55147 Green 27 55147 Green 27 55149 Yellow 24 55149 Yellow 24 55141 Red 21 55141 Red 21 55149 Yell

45、ow 24 55149 Yellow 24 55141 Red 21 55141 Red 21 55144 Green 18 55144 Green 18 55303 Orange 12 55303 Orange 12 如果货架是分正反面时，两面都要有标贴。同样，如果零件/供应品的包 装箱在货架两侧都可以看见，标签只在一侧标识，以防止混淆. Improve 2-Bin Replenishment Pull60 Measurement of 2-Bin Effectiveness 2-Bin Effectiveness is measured by: uStockouts when materi

46、al was in the stock/supply room nNumber of parts per day/week/month/year nIndicates that the bin is not sized correctly, OR the replenishment lead time is incorrect, or a lack of discipline in the process uAre parts organized? nYes/No nTypically a visual check of the process will suffice, BUT the pr

47、ocess must be audited at periodic intervals (once/month) uAre unscheduled replenishments being made? nHow many per day/week/month? nConsistent unscheduled replenishments may indicate that demand has increased and the bin needs to be resized. Improve 2-Bin Replenishment Pull61 2-箱效果的量测 2-箱效果可以由下列方法量测

48、: u当材料在库房时的物料短缺 n每天/周/月/年的零件数量 n指出箱数量不正确，或补充交货时间不正确，或过程缺乏组织性 u零件是否有组织的? n是/否 n一般可以目视检查过程的执行能力，但应定期对过程进行审核（每月 一次） u是否有计划外补充现象? n每天/周/月有多少次? n持续的计划外补充表明需求增加，箱数量需调整。 Improve 2-Bin Replenishment Pull62 2-Bin Line-Side Replenishment Backflushing Inventory 1. Parts are pulled from line POU location, backflushing relieves consumed inventory from line-side locati