精益生产之2箱补充拉系统2-Bin_Replenishment_Pull(中

1、2-Bin Replenishment PullIntroduction to 2-Bin Replenishment PullLine-side versus Point-of-Use Stocking2-Bin Data Needs and CalculationsInventory Disposition OptionsCard Triggered 2-Bin Process1-Bin SystemsAppendixRD0112022-Bin 补充拉系统2-箱补充拉系统的介绍线旁VS使用点库存2-箱数据的要求和计算库存部署选择卡触发2-箱流程1-箱系统附录RD011202Lean Six

2、 Sigma Improvement Process Road MapAnalyzeControlImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem Anal

3、ysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect

4、 SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureDefineProject ID ToolsProject Definition FormNet Present Value Analysis

5、 Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp & CpkSupplyChainAccelerator AnalysisMulti-VariBox

6、 PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-

7、12-023Learning ObjectivesUnderstand the various types of bin replenishment systemsKnow the benefits of a bin systemUnderstand when to use a bin SystemBe able to size (calculate) all the parameters for a bin system4课程目的理解箱补充系统的不同类型知道一个箱系统的好处理解何时使用一个箱系统能够去计算一个箱系统的所有参数5Whats in It for Me?Be able to app

8、ly this tool to a Black Belt projectAble to implement a Bin system6我学到了什么?能够在黑带项目中应用这个工具能够实施一个箱系统72-Bin Replenishment Pull IntroductionA 2-Bin Replenishment Pull System is a simplified version of a standard replenishment pull system and maintains the benefits:Establishes strategically located buffer

9、s of parts within a processRaw materialManufactured partsPurchased partsFinished goodsDe-couples the supplying process from the consuming process via the buffer inventoryPart replenishment is “triggered” based on consumption82-箱补充拉系统的介绍2-箱补充拉系统是一个标准的补充拉系统的简化版本，其好处是：在一个流程中建立战略性的零件缓冲区原材料制造的零件采购的零件成品通过

10、缓冲库存将供应过程和消耗过程联系起来零件的补充是基于消耗而触发的9What Is a 2-Bin Replenishment?For many parts in a process, a 2-Bin system can be used to replenish the parts versus a synchronous supply:A bin has enough parts/supplies to cover a calculated period of usage at the point-of-use.When the bin runs out, a 2nd bin is ther

11、e to take its place while the “1st” is being refilled/replenished.There are two primary replenishment locations: Line-Side and Point of Use102-箱补充拉系统是什么?对于在流程中的众多零件而言，一个2-箱系统可以被用来补充零件相对于同步供应:一箱有足够零件/供应品以满足在使用点上已计算出的用量周期。当第一箱用完了后，在补充/重新装料时，第二箱取代第一箱的位置继续满足使用。有两个主要的补充地点：线旁和使用点11Benefits of 2-Bin Replen

12、ishmentOrganized and overall cleaner appearance of stored materialsReduced frequency of orders submitted to the stockroom/vendorReduced number of trips for re-supplyBetter management of inventory on the shop floorMore predictable inventory costsImprove employee productivity by:Eliminating part/suppl

13、y shortages at the point-of-useReduce time wasted by personnel/supervision retrieving supplies/inventory from the stockroom and/or vendorsEliminate lost or misplaced material2-Bin Replenishment can be used for office/safety supplies, production inventory, production supplies even at home!122-箱补充拉系统的

14、好处存储的材料外观非常清洁和有条理提交给库房/供应商的频率减少重复供应的差错数量减少了现场库存的管理更好库存成本更具有预测性提高员工生产率:排除在使用点的零件/供应短缺减少由于人员/管理等，从库房和/或供应商重新找回供应/库存的时间浪费排除材料的丢失或放错地方2-箱补充可以被使用在办公室，安全供应，生产库存，生产供应甚至在家里!13When to Use 2-Bin Replenishment PullRepetitive product offering/processRelatively consistent demand/volume (low variability)Part/supp

15、ly shortages are a consistent/costly problemPart/supply inventory costs are “out of control” due to:Lost or misplaced parts/suppliesLack of issue/dispersal discipline or control14何时使用2-箱补充拉系统重复的产品供应/流程重复稳定的需求 (底变异)零件/供应短缺是常事，且是一个代价很大的问题零件/供应库存成本是失控的，由于：零件/供应品丢失或放错地方缺乏投料/分发的一致性或控制15What Is a Bin?Does

16、nt necessarily look like a “bin”Can be a standard plastic bin (Acro-bin)Can also be the box/container the part/supply is shipped in (also called a “standard pack” purchasing definition)When the box/container method is used, a “bin” can be one standard pack or several standard packs. Examples:1 box o

17、f screws2 boxes of screws1 drum of oil30 bags of connectors1 roll of labels4 tubes of sealant16一箱是什么?这并不是说一定要看上去像个“箱子”它可以是一个标准的塑料箱它也可以是用于零件运输的一个盒子或容器 (也可以用采购的定义被称为一个“标准包” )当盒子/容器方式使用了后, 一个“箱”可以是一个标准的包或几个标准包。例如：1 盒螺钉2 盒螺钉1 打油30 包连接器1 卷标贴4 管子密封剂172-Bin Replenishment Data Parameters/NeedsDemand / Usage

18、 (DMD)Typically expressed in terms of Average Daily Usage (ADU) in unitsLead Time (LT)The time it takes from when a trigger is sent to when replenishment arrivesIn this case, can also be thought of as “Restocking Time”Order Frequency (OF)If orders/triggers are sent at scheduled times (i.e., not ever

19、y day, such as once per week)Typical 2-Bin systems do not use an Order Frequency, as replenishment can occur every day/shift (or more)Box/Container QuantityIf stock/supply room or vendor does not break down shipping quantity, then the bin quantity may be set equal to some multiple of the box/contain

20、er quantity (standard pack) that the part/supply is shipped inSafety StockTypically 1/2 the max (LT, OF) * DMD, may be set otherwise dependent on individual conditions182-箱补充系统数据参数/要求需求/使用 (DMD)一般来说用平均每天用量（ADU）来表达交货期 (LT)从补充需求触发到补充品到达的时间。在这里，也可以被认为是“再进货时间”。订单频率 (OF)如果订单/触发信号的发放是按预定时间（如：并不是每天，而是每周一次）

21、2-箱系统是不需要用订单频率的。补充可以发生在每天、每班（或更多）盒子/容器数量如果库房或供应商没有列出运输数量的明细分类，那么箱数量可以设定为等于运送零件/供应品的若干盒子/容器数量安全库存一般来说的设定为1/2 max (LT, OF) * DMD, 否则根据独立的情况来看19Stock Room or Vendor12FullBin/CardMove 1 to 2 when 2 is pulled,Send TriggerUseComponentsEmptyBin/CardPoint-Of-Use (POU) Locations or Work-In-Process (WIP) 2-Bi

22、n Replenishment (“Line-Side” Stocking)Reduces part/supply shortages increasing productivityFacilitates WIP reductionWill result in significant productivity improvements in stock/supply roomReduces/eliminates stockroom impact on lot sizesMay simplify inventory/cycle count processesLine-SideStorageLTO

23、F220库房或供应商12添满的箱/卡当 2 被拉动时，移动 1 到 2 ，发送触发信号使用的部件空的箱/卡使用点位置 (POU) 或工作库存 (WIP) 2-箱补充 (“线旁” 库存)减少零件/供应品库存，增加生产效率促进 WIP的降低将导致在库房里的显著的生产力提高降低/消除库房在批数量上的影响可以简单化存货/周转的计算流程线旁库存LTOF2SS/2DMDOF),LTmax(箱数量+*=21FullBin/CardPull from 1 until empty, send trigger and pull from 2 until empty, send trigger, etc.UseCo

24、mponentsEmptyBin/Card2-Bin Replenishment (“Point-of Use” Stocking)LTOF12-Bin POU stocking is used when re-stocking is not an issue.Stock Room or VendorPoint-Of-Use (POU) Locations or Work-In-Process (WIP) 222拉动从1开始直到用完为止, 发送触发信号，然后拉动从2开始直到用完为止，发送触发信号, 等等.使用部件2-箱补充(“使用点” 库存)LTOF1SS/2DMDOF),LTmax(箱数量+

25、*=当重新备库存不是一个问题时，使用2-箱 POU 库存 库房或供应商2添满的箱/卡空的箱/卡使用点位置 (POU) 或工作库存 (WIP) 232-Bin Replenishment CalculationsBin Quantity = Max(LT, OF) + SS/2If replenishing in standard packs, Bin Quantity is rounded up to the nearest standard pack multipleExample:Calculate the Bin Quantity for the following (standard

26、pack replenishment):Part Number:40567Description:Rubber GlovesDemand/Usage:25 pairs/dayLead Time:2 days (trigger - stock/supply room - replenishment)Order Frequency:N/ABox Quantity:50 pairsBin Quantity= Max (2 days, N/A) * 25 pairs/day + .5 * Max (2 days, N/A) * 25 pairs/day /2= 63 pairsBut we have

27、to round up to the nearest standard pack, so:Bin Quantity = 100 pairs = 2 boxes242-箱补充的计算箱数量 = Max(LT, OF) + SS/2如果是标准包的补充，箱数量应该是近似于标准包的倍数举例:计算下列数据的箱数量 (标准包补充):零件号码:40567描述:橡胶手套需求/用量:25 双/天交货时间:2 天 (触发 库房 补充)订单频率:不适用箱数量:50 双箱数量= Max (2 天, N/A) * 25 双/天 + .5 * Max (2 天, N/A) * 25 双/天 /2= 63 双但是我们要取一个

28、近似标准箱的数量，所以:箱数量 = 100 对 = 2 箱25Exercise #1:2-Bin ReplenishmentCalculate the Bin Quantity for the following supply item in a 2-Bin Line-Side Replenishment process directly linked to the supplier:Part Number:80886Description:Printer PaperDemand/Usage:22 reams/dayLead Time:4 days (trigger - purchasing

29、- supplier - receiving - replenishment)Order Frequency:5 daysBox Quantity:10 reamsBin Quantity = Max ( , ) * + .5 * Max ( , ) * /2= . But we have to round up to the nearest standard pack, so:Bin Quantity = = . 26练习 #1:2-箱补充如下供应品的2-箱线旁补充流程直接连接着供应商，计算箱数量:零件号码:80886描述:打印纸需求/用量:22 令/天交货时间:4 天 (触发 采购 运输

30、收货 补充)订单频率:5 天箱数量:10 令箱数量 = Max ( , ) * + .5 * Max ( , ) * /2= . 但是我们要取一个近似标准包的数量，所以:箱数量 = = . 27Exercise #2:2-Bin ReplenishmentCalculate the Bin Quantity for the following assembly item in a 2-Bin Line-Side Replenishment process linked to the warehouse :Part Number:A44B2Description:4 Dia. Steel Ext

31、rusionDemand/Usage:225 ft/dayLead Time:1 day (trigger - warehouse - replenishment)Order Frequency:N/AExtrusion Length:30 ftBin Quantity = Max ( , ) * + .5 * Max( , ) * /2= . But we have to round up to the nearest standard pack, so:Bin Quantity = = . 28练习 #2:2-箱补充如下组装线2-箱线旁补充流程直接连接着供应商，计算箱数量:零件号码:A44

32、B2描述:直径4“ 的钢铁拉丝需求/用量:225 英尺/天交货时间:1 天 ( 触发 仓库 补充 )订单频率:不适用拉丝长度:30 英尺箱数量 = Max ( , ) * + .5 * Max( , ) * /2= . 但是我们要取一个近似标准包的数量，所以:箱数量 = = . 291 2-Bin ReplenishmentBin Labeling and InformationEach Bin/Storage Location should have a barcode label or tag.Make sure not to use a permanent label applied t

33、o a rack/bin, because you will eventually want to resize and may have to make new labels!Labels for Line Side Bins/Tags for Resupply BinsPart Number, Description, and Location are Printed.Bin Quantity should not be printed (requires too many label changes when resizing trigger mechanism or system wi

34、ll have Bin Quantity)Each Bin Location should be unique to avoid confusion when restocking.Examples are in the Appendix.LocationPart NumberDescription2 LocationPart NumberDescription301 2-箱补充箱标贴和信息每个箱/库存 地点都应该有一个条码标贴或标签确保不要用永久的标签贴在一个货架/箱。因为你将会调整大小，且贴上一个新的标贴！在线旁的需要重新补充的箱上的标贴被打印的零件号码, 描述, 地点等箱数量不应该被打印

35、出来 ( 当调整大小时需要太多的标签变化 触发机制或系统将有箱数量)每个箱地点必须是独一无二的以避免在重新补充库存时混淆举例在附件里.地点零件号码描述2 地点零件号码描述31Notes on a 1-Bin SystemA one bin system is an exception to the 2-bin for very slow moving parts/supplies.1-bin parts are not stored in 2-bins because of:High inventory costSpace requirementsRacking/storage cost1-b

36、ins are replenished upon stock out at the Line-Side location.Stock out impact should be low because:Parts/supplies are very low users.Parts/supplies are also at point of use when Line-Side stock out occurs.Parts/supplies are stocked in nearby stock/supply room easy to replace.321-箱系统的注意对于流动非常缓慢的零件/供

37、应品来说，一个1-箱系统是2-箱系统的例外.1-箱零件不象2-箱那样被存储，因为:高库存成本空间需要货架/仓储成本在线旁的地点库存短少时，1-箱被补充。库存短少的影响应该是微弱的，因为:零件/供应品是非常少的使用者。当线旁的存货短缺发生时，零件/供应品也同样在使用点.零件/供应品被存放在库房附近容易补充.33Stock Room or Vendor11FullBin/CardMove 1 to 2 when 2 is pulled,Send TriggerUseComponentsEmptyBin/CardPoint-Of-Use (POU) Locations or Work-In-Proc

38、ess (WIP) 1-Bin Replenishment (Typically from “Line-Side”)Reduces part/supply shortages increasing productivityFacilitates WIP reductionWill result in significant productivity improvements in stock/supply roomReduces/eliminates stockroom impact on lot sizesMay simplify inventory/cycle count processe

39、sLine-SideStorageLTOF134库房或供应商111-箱补充(特别是从“线旁”)LTOF1添满的箱/卡空的箱/卡当 2 被拉动时，移动 1 到 2 ，发送触发信号使用点位置 (POU) 或工作库存 (WIP) 减少零件/供应品库存，增加生产效率促进 WIP的降低将导致在库房里的显著的生产力提高降低/消除库房在批数量上的影响可以简单化存货/周转的计算流程线旁库存SS/2OF),LTmax(箱数量+*=使用的部件DMD35Stockroomor Vendor1 Line POU1-Bin Replenishment Transactions1-Bin System inventory

40、 transactions mirror those of the 2-Bin systemFrontflush for reducing transactions but reduce overall inventory accuracyBackflush for increasing inventory accuracy (slightly) but increase number of system transactions11-bin Card Part XYZTriggerReplenishment1-bin Card Part XYZ36库房或供应商1 线 POU1-箱补充事务处理

41、1-箱系统库存交接与2-箱系统相似前端堆积 减少交接过程但降低总体库存量的准确性后端堆积 增加了库存准确性（幅度轻微）但增加了系统处理的事务量11-箱卡零件 XYZ触发补充1-箱卡零件 XYZ37TakeawaysKnow the the various types of Bin Replenishment systemsBe able to describe the benefits of a Bin systemHow to size (calculate) all the parameters for a Bin system38总结知道箱补充系统的不同类型能够描述一个箱系统的利益能够去

42、计算一个箱系统的所有参数39APPENDIX2-Bin Replenishment Pull附录2-箱补充拉系统Instructions for Typical Card Triggered 2-Bin ReplenishmentThis process uses green and red cards to trigger replenishment; “bins” are actually the box/container the part/supply is shipped in.1. Employee removes a bin and drops its green 2-bin c

43、ard into the mailbox:Pull parts from “bin” with green card before using any with the 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 cal

44、culated “bin” quantity).4. Inventory transactions are performed (depending on issue 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.When stock/supply room replaces the material, ensure that

45、 the red card is placed on the full bin.Always leaves you a full red bin remaining when green bin runs out.If 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!42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

46、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，将绿色的2-箱卡放入邮箱: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.当库房补充材料时，确保红色卡被放在添满的箱上.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.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

47、快采取行动。43Maintaining a Card Triggered 2-Bin ProcessCheck periodically for lost cards and replace.Best time is right after replenishment; any cards not replaced or in the mailbox are lost.Police the proper use of cards:Supervisor/Lead drop green cards when green bin is empty.Supervisor/Lead drop red c

48、ards on stock out investigate!Supervisor/Lead ensure cards are replaced when parts are restocked.Green bins are completely used before red bins.Resize bins when demand changes.Add cards for new parts, delete cards for obsolete parts.44保持卡触发2-箱系统的过程定期检查卡片是否丢失并更换.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维持卡片的合理使用

49、:当绿卡箱用完变空时，主管/组长投放绿卡.当存货用完时，主管/组长投放红卡 调查!当零件重新补充时，主管/组长确保卡片被更换.在用红卡箱前，确保绿卡箱已经被用完.当需求改变时需要重新调整箱的数量.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.45Bin 1Bin 2Example Card Triggered Line-Side 2-Bin RackBin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bi

50、n 1Bin 12-Bin MailboxOrder Cards1.Always pull material from bin with GREEN card if it is there.2.Store/supply room replaces material and switches RED card to material just replaced.3.The cards are attached to magnetic strip labels (for ease of movement for resizing).Bin 1Bin 1Bin 246Bin 1Bin 2举例：由卡触

51、发的线旁2-箱货架Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 2Bin 1Bin 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 1Bin 1Bin 247Example Card Triggered Line-Side 2-Bin System48举例：由卡触发的线旁2-箱系统4

52、9Example Card Triggered Line-Side 2-Bin System2-Bin Cards are Green and Red, per the process. Cards are placed into plastic sheaths to protect them from getting knocked off the racking.Clear plastic sheaths are attached to metal racking via sticky magnetic strip make resizing easier.Bin labels are w

53、hite sticky backed and placed inside of plastic sheath for protection.A clear plastic sheath over a white label indicates that the bin is being replenished.50举例：由卡触发的线旁2-箱系统根据流程的需要，2-箱卡是绿卡和红卡. 卡片可装入塑料套中以防止摩擦磕碰.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.料箱标签为白色的，贴在塑料套内背面加以保护.塑料套显示出白色时表明料箱正在补充.51If a clear plastic s

54、heath/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.Weatherstrip40130W/STRIP .270HT.187BK FS WStandard Pack: box Units per Pack:6000STOCKOUT4 Box(es) Have Been OrderedLocation = A25Physic

55、al = S-1000 2-Bin R1 - L3 - S3Common NamePart NumberPart DescriptionIndicates Part is on OrderIndicates Quantity on OrderLine-Side LocationRack and Space LocationSample Bin/Rack Label52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40130W/STRIP .270HT.187BK FS W标准包装: 盒 每包件数：6000用完4 箱已订货地点 = A

56、25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53Weatherstrip40130W/STRIP .270HT.187BK FS WStandard Pack: box Units per Pack:6000Order: 4 Box(es) When No box(es) Are LeftLocation = A252-Bin Space = S-1000 2-Bin R2 - A - 4Common NamePart NumberPart DescriptionIndicates Q

57、uantity on OrderLine-Side LocationRack and Bin LocationCards are typically colored light red or light green and laminated for protection.Sample 2-Bin Card54挡风胶条40130W/STRIP .270HT.187BK FS W标准包: 盒子 每包数量:6000订货: 当无剩余时，需要 4 箱订货地点 = A252-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

58、述显示订货数量线旁场所货架和空间位置55Sample Rack Layout FrontRack 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 from the othe

59、r.”56货架排布的样板 前面货架布置一般可用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”。57Sample Rack Layout BackIf 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 si

60、de to avoid confusion.58货架排布的样板 前面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.59Measurement of 2-Bin Effectiveness2-Bin Effectiveness is measured by:Stockouts when material was in the stock/supply room Number of parts per day/week/month/yearIndicates that the bin is not sized correct