精益生产之2箱补充拉系统2BinReplenishmentPull中课件

03十二月2022精益生产之2箱补充拉系统2BinReplenishmentPull(中01十二月2022精益生产之2箱补充拉系统2BinRep12-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RD0112022-Bin

补充拉系统2-箱补充拉系统的介绍RD011202LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-023LeanSixSigma

ImprovementPr3LearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentouseabinSystemBeabletosize(calculate)alltheparametersforabinsystem4LearningObjectivesUnderstand4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5课程目的理解箱补充系统的不同类型55What’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystem6What’sinItforMe?Beableto6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7我学到了什么?能够在黑带项目中应用这个工具772-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofastandardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedpartsPurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartreplenishmentis“triggered”basedonconsumption82-BinReplenishmentPullIntro82-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92-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9WhatIsa2-BinReplenishment?Formanypartsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedperiodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe“1st”isbeingrefilled/replenished.Therearetwoprimaryreplenishmentlocations:Line-SideandPointofUse10WhatIsa2-BinReplenishment?102-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112-箱补充拉系统是什么?对于在流程中的众多零件而言，一个2-11Benefitsof2-BinReplenishmentOrganizedandoverallcleanerappearanceofstoredmaterialsReducedfrequencyoforderssubmittedtothestockroom/vendorReducednumberoftripsforre-supplyBettermanagementofinventoryontheshopfloorMorepredictableinventorycostsImproveemployeeproductivityby:Eliminatingpart/supplyshortagesatthepoint-of-useReducetimewastedbypersonnel/supervisionretrievingsupplies/inventoryfromthestockroomand/orvendorsEliminatelostormisplacedmaterial2-BinReplenishmentcanbeusedforoffice/safetysupplies,productioninventory,productionsupplies–evenathome!12Benefitsof2-BinReplenishmen122-箱补充拉系统的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!132-箱补充拉系统的好处存储的材料外观非常清洁和有条理1313WhentoUse2-BinReplenishmentPullRepetitiveproductoffering/processRelativelyconsistentdemand/volume(lowvariability)Part/supplyshortagesareaconsistent/costlyproblemPart/supplyinventorycostsare“outofcontrol”dueto:Lostormisplacedparts/suppliesLackofissue/dispersaldisciplineorcontrol14WhentoUse2-BinReplenishmen14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15何时使用2-箱补充拉系统重复的产品供应/流程1515WhatIsaBin?Doesn’tnecessarilylooklikea“bin”Canbeastandardplasticbin(Acro-bin)Canalsobethebox/containerthepart/supplyisshippedin(alsocalleda“standardpack”–purchasingdefinition)Whenthebox/containermethodisused,a“bin”canbeonestandardpackorseveralstandardpacks.Examples:1boxofscrews2boxesofscrews1drumofoil30bagsofconnectors1rolloflabels4tubesofsealant16WhatIsaBin?Doesn’tnecessar16一箱是什么?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17一箱是什么?这并不是说一定要看上去像个“箱子”17172-BinReplenishmentDataParameters/NeedsDemand/Usage(DMD)TypicallyexpressedintermsofAverageDailyUsage(ADU)inunitsLeadTime(LT)ThetimeittakesfromwhenatriggerissenttowhenreplenishmentarrivesInthiscase,canalsobethoughtofas“RestockingTime”OrderFrequency(OF)Iforders/triggersaresentatscheduledtimes(i.e.,noteveryday,suchasonceperweek)Typical2-BinsystemsdonotuseanOrderFrequency,asreplenishmentcanoccureveryday/shift(ormore)Box/ContainerQuantityIfstock/supplyroomorvendordoesnotbreakdownshippingquantity,thenthebinquantitymaybesetequaltosomemultipleofthebox/containerquantity(standardpack)thatthepart/supplyisshippedinSafetyStockTypically1/2themax(LT,OF)*DMD,maybesetotherwisedependentonindividualconditions182-BinReplenishmentDataParam182-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）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1/2max(LT,OF)*DMD,否则根据独立的情况来看192-箱补充系统数据

参数/要求需求/使用(DMD)1919StockRoomorVendor12FullBin/CardMove1to2when2ispulled,Send

TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)2-BinReplenishment

(“Line-Side”Stocking)Reducespart/supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresultinsignificantproductivityimprovementsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF220StockRoomorVendor12FullMove20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

+*=21库房或12添满的当2被拉动时，移动1到使用的空的使21FullBin/CardPullfrom1untilempty,sendtriggerandpullfrom2untilempty,sendtrigger,etc.UseComponentsEmptyBin/Card2-BinReplenishment

(“Point-ofUse”Stocking)LTOF12-BinPOUstockingisusedwhenre-stockingisnotanissue.StockRoomorVendorPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)222FullPullfrom1untilempty,U22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+*=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)23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232-BinReplenishmentCalculationsBinQuantity=Max(LT,OF)+SS/2Ifreplenishinginstandardpacks,BinQuantityisroundeduptotheneareststandardpackmultipleExample:CalculatetheBinQuantityforthefollowing(standardpackreplenishment):PartNumber: 40567Description: RubberGlovesDemand/Usage: 25pairs/dayLeadTime: 2days(trigger-stock/supplyroom-replenishment)OrderFrequency: N/ABoxQuantity: 50pairsBinQuantity=[Max(2days,N/A)*25pairs/day]+.5*[Max(2days,N/A)*25pairs/day]/2=63pairsButwehavetorounduptotheneareststandardpack,so:BinQuantity=100pairs=2boxes242-BinReplenishmentCalculatio242-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近似标准箱的数量，所以:箱数量=100对=2箱252-箱补充的计算箱数量=Max(LT,OF)+SS25Exercise#1:

2-BinReplenishmentCalculatetheBinQuantityforthefollowingsupplyitemina2-BinLine-SideReplenishmentprocessdirectlylinkedtothesupplier:PartNumber: 80886Description: PrinterPaperDemand/Usage: 22reams/dayLeadTime: 4days(trigger-purchasing-supplier-receiving-replenishment)OrderFrequency: 5daysBoxQuantity: 10reamsBinQuantity=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.Butwehavetorounduptotheneareststandardpack,so:BinQuantity=

=

.26Exercise#1:

2-BinReplenishme26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–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=

=

.27练习#1:

2-箱补充如下供应品的2-箱线旁补充流程直接连27Exercise#2:

2-BinReplenishmentCalculatetheBinQuantityforthefollowingassemblyitemina2-BinLine-SideReplenishmentprocesslinkedtothewarehouse:PartNumber: A44B2Description: 4"Dia.SteelExtrusionDemand/Usage: 225ft/dayLeadTime: 1day(trigger-warehouse-replenishment)OrderFrequency: N/AExtrusionLength: 30ftBinQuantity=[Max(

,

)*

]+.5*[Max(

,

)*

]/2=

.Butwehavetorounduptotheneareststandardpack,so:BinQuantity=

=

.28Exercise#2:

2-BinReplenishme28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: A44B2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=

=

.29练习#2:

2-箱补充如下组装线2-箱线旁补充流程直接连接2912-BinReplenishment

BinLabelingandInformationEachBin/StorageLocationshouldhaveabarcodelabelortag.Makesurenottouseapermanentlabelappliedtoarack/bin,becauseyouwilleventuallywanttoresizeandmayhavetomakenewlabels!LabelsforLineSideBins/TagsforResupplyBinsPartNumber,Description,andLocationarePrinted.BinQuantityshouldnotbeprinted(requirestoomanylabelchangeswhenresizing–triggermechanismorsystemwillhaveBinQuantity)EachBinLocationshouldbeuniquetoavoidconfusionwhenrestocking.ExamplesareintheAppendix.LocationPartNumberDescription2LocationPartNumberDescription3012-BinReplenishment

BinLabe3012-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3112-箱补充

箱标贴和信息每个箱/库存地点都应该有一个条31Notesona1-BinSystemAonebinsystemisanexceptiontothe2-binforveryslowmovingparts/supplies.1-binpartsarenotstoredin2-binsbecauseof:HighinventorycostSpacerequirementsRacking/storagecost1-binsarereplenisheduponstockoutattheLine-Sidelocation.Stockoutimpactshouldbelowbecause:Parts/suppliesareverylowusers.Parts/suppliesarealsoatpointofusewhenLine-Sidestockoutoccurs.Parts/suppliesarestockedinnearbystock/supplyroom–easytoreplace.32Notesona1-BinSystemAoneb321-箱系统的注意对于流动非常缓慢的零件/供应品来说，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.331-箱系统的注意对于流动非常缓慢的零件/供应品来说，一个1-33StockRoomorVendor11FullBin/CardMove1to2when2ispulled,Send

TriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)1-BinReplenishment

(Typicallyfrom“Line-Side”)Reducespart/supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresultinsignificantproductivityimprovementsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF134StockRoomorVendor11FullMove34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DMD35库房或111-箱补充

(特别是从“线旁”)LT1添满的空的当35StockroomorVendor1LinePOU1-BinReplenishmentTransactions1-BinSysteminventorytransactionsmirrorthoseofthe2-BinsystemFrontflushforreducingtransactionsbutreduceoverallinventoryaccuracyBackflushforincreasinginventoryaccuracy(slightly)butincreasenumberofsystemtransactions11-binCardPartXYZTriggerReplenishment1-binCardPartXYZ36Stockroom1LinePOU1-BinReple36库房或供应商1线POU1-箱补充事务处理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XYZ37库房或1线POU1-箱补充事务处理1-箱系统库存交接与237TakeawaysKnowthethevarioustypesofBinReplenishmentsystemsBeabletodescribethebenefitsofaBinsystemHowtosize(calculate)alltheparametersforaBinsystem38TakeawaysKnowthethevarious38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计算一个箱系统的所有参数39总结知道箱补充系统的不同类型3939APPENDIX

2-BinReplenishmentPullAPPENDIX

2-BinReplenishmentP40附录

2-箱补充拉系统附录

2-箱补充拉系统41InstructionsforTypicalCard

Triggered2-BinReplenishmentThisprocessusesgreenandredcardstotriggerreplenishment;“bins”areactuallythebox/containerthepart/supplyisshippedin.1. Employeeremovesabinanddropsitsgreen2-bincardintothemailbox:Pullpartsfrom“bin”withgreencardbeforeusinganywiththeredcard.2. Atsametime(s)eachday,thecardsarepickedupfromthemailboxandreturnedtothestock/supplyroom.3. Thestock/supplyroompullsproperamountofparts/material(notedoncard,setequaltothecalculated“bin”quantity).4. Inventorytransactionsareperformed(dependingonissuemethod),andthematerialsandcardsaredeliveredtothestoragelocation.5. Employeestocksmaterialinstoragelocationandreturnscardtoitsproperplace.Whenstock/supplyroomreplacesthematerial,ensurethattheredcardisplacedonthefullbin.Alwaysleavesyouafullredbinremainingwhengreenbinrunsout.Ifnot,youcouldrundownbothbinsandstockoutbeforeeitherisreplaced;ifaredcardisinthereplenishmentprocess,apartshortageisimminent–actfast!42InstructionsforTypicalCard42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—尽快采取行动。43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43MaintainingaCardTriggered2-BinProcessCheckperiodicallyforlostcardsandreplace.Besttimeisrightafterreplenishment;anycardsnotreplacedorinthemailboxarelost.Policetheproperuseofcards:Supervisor/Leaddropgreencardswhengreenbinisempty.Supervisor/Leaddropredcardsonstockout–investigate!Supervisor/Leadensurecardsarereplacedwhenpartsarerestocked.Greenbinsarecompletelyusedbeforeredbins.Resizebinswhendemandchanges.Addcardsfornewparts,deletecardsforobsoleteparts.44MaintainingaCardTriggered244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: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.45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.4545Bin1Bin2ExampleCardTriggered

Line-Side2-BinRackBin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-Bin

MailboxOrderCards1. AlwayspullmaterialfrombinwithGREEN

cardifitisthere.2. Store/supplyroomreplacesmaterialandswitchesREDcardtomaterialjustreplaced.3. Thecardsareattachedtomagneticstriplabels(foreaseofmovementforresizing).Bin1Bin1Bin246Bin1Bin2ExampleCardTrigger46Bin1Bin2举例：

由卡触发的线旁2-箱货架Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-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).Bin1Bin1Bin247Bin1Bin2举例：

由卡触发的线旁2-箱货架Bin47ExampleCardTriggered

Line-Side2-BinSystem48ExampleCardTriggered

Line-S48举例：

由卡触发的线旁2-箱系统49举例：

由卡触发的线旁2-箱系统4949ExampleCardTriggered

Line-Side2-BinSystem2-BinCardsareGreenandRed,pertheprocess.Cardsareplacedintoplasticsheathstoprotectthemfromgettingknockedofftheracking.Clearplasticsheathsareattachedtometalrackingviastickymagneticstripmakeresizingeasier.Binlabelsarewhitestickybackedandplacedinsideofplasticsheathforprotection.Aclearplasticsheathoverawhitelabelindicatesthatthebinisbeingreplenished.50ExampleCardTriggered

Line-S50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.51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51Ifaclearplasticsheath/pouchisusedtohousethelabelandthecard,thenaclearpouchovertheracklabelindicatesthatthepartisonorder–aneasywaytoPoka-Yoketheprocess.Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:box UnitsperPack: 6000STOCKOUT4Box(es)HaveBeenOrderedLocation=A25Physical=S-10002-BinR1-L3-S3CommonNamePartNumberPartDescriptionIndicatesPartisonOrderIndicatesQuantityonOrderLine-SideLocationRackandSpaceLocationSampleBin/RackLabel52Ifaclearplasticsheath/pouc52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.187BKFSW标准包装:盒 每包件数： 6000用完4箱已订货地点=A25物理位置=S-10002-BinR1-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53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53Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:box UnitsperPack: 6000Order:4Box(es)WhenNobox(es)AreLeftLocation=A252-BinSpace=S-10002-BinR2-A-4CommonNamePartNumberPartDescriptionIndicatesQuantityonOrderLine-SideLocationRackandBinLocationCardsaretypicallycoloredlightredor

lightgreenandlaminatedforprotection.Sample2-BinCard54WeatherstripCommonNamePartNu54挡风胶条40130W/STRIP.270HT.187BKFSW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-10002-BinR2-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数量线旁场所货架和空间位置55挡风胶条卡片一般是亮红或亮绿颜色，2-箱卡样55SampleRackLayout–FrontRacklayoutsdrawninExcel/othermakeexcellentimplementationandupkeepmapstoguidestocking/restockingefforts.Manytimesitisgoodtohaveparts/suppliesononlyonesideofarack–thatwayyoucan“pullfromoneside”and“replenishfromtheother.”56SampleRackLayout–FrontRack56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”。57货架排布的样板–前面货架布置一般可用EXCEL或其他工具57SampleRackLayout–BackIfarackhasafrontandabackside,makesuretolabelboth.Also,ifapart/supplystandardpackcanbeseenfrombothsidesoftherack(largebox/container),labelONLYonesidetoavoidconfusion.58SampleRackLayout–BackIfa58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.59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59Measurementof2-BinEffectiveness2-BinEffectivenessismeasuredby:Stockoutswhenmaterialwasinthestock/supplyroomNumberofpartsperday/week/month/yearIndicatesthatthebinisnotsizedcorrectly,ORthereplenishmentleadtimeisincorrect,oralackofdisciplineintheprocessArepartsorganized?Yes/NoTypicallyavisualcheckoftheprocesswillsuffice,BUTtheprocessmustbeauditedatperiodicintervals(once/month)Areunscheduledreplenishmentsbeingmade?Howmanyperday/week/month?Consistentunscheduledreplenishmentsmayindicatethatdemandhasincreasedandthebinneedstoberesized.60Measurementof2-BinEffective602-箱效果的量测2-箱效果可以由下列方法量测:当材料在库房时的物料短缺每天/周/月/年的零件数量指出箱数量不正确，或补充交货时间不正确，或过程缺乏组织性零件是否有组织的?是/否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）是否有计划外补充现象?每天/周/月有多少次?持续的计划外补充表明需求增加，箱数量需调整。612-箱效果的量测2-箱效果可以由下列方法量测:6161StockroomorVendor2-BinLine-SideReplenishment

BackflushingInventory1. PartsarepulledfromlinePOUlocation,backflushingrelievesconsumedinventoryfromline-sidelocation.2. Binispulledfromline-sidestoragetore-supplyPOUlocation.3. Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4. Binisrefilledwithappropriatequantity.5. Inventoryistransferredfromstockroomtoline-sidelocation.6. Fullbinwithtriggerreturnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryTransferOccursHere1Line-SideStorage2InventoryBackflush(Charge-Off)OccursHereLinePOU262Stockroom2-BinLine-SideReple62库房/供应商2-箱线旁补充

后端堆积库存1. 零件从线使用点（POU）的位置被拉动,后端堆积减轻了从线旁消耗的库存.2. 箱被拉动着从线旁库存到使用点（POU）补充位置.3. 触发信号(卡,箱,等.)被返回到库房或供应商.4. 箱被重新添满到适合的数量.5. 库存被转移从库房到线旁位置.6. 满箱将回到线旁.2-箱卡零件XYZ触发补充2-箱卡零件XYZ库存转移发生在这里1线旁库存2库存后端积压(Charge-Off)发生在这里线POU263库房/供应商2-箱线旁补充

后端堆积库存1. 零件从线使用点63StockroomorVendor2-BinLine-SideReplenishment

FrontflushingInventory1. PartsarepulledfromlinePOUlocation.2. Binispulledfromline-sidestoragetore-supplyPOUlocation.3. Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4. Binisrefilledwithappropriatequantity.5. Inventoryisfront-flushedoutofstockroomtoWIPorexpenseaccount.6. Fullbinwithtriggerreturnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryFrontflush(Charge-Off)OccursHere1Line-SideStorage2LinePOU264Stockroom2-BinLine-SideReple6403十二月2022精益生产之2箱补充拉系统2BinReplenishmentPull(中01十二月2022精益生产之2箱补充拉系统2BinRep652-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RD0112022-Bin

补充拉系统2-箱补充拉系统的介绍RD0112066LeanSixSigma

ImprovementProcessRoadMapAnalyzeControlImproveDefineIdentifyProblemDevelopListofCustomersDevelopListofCTQ’sfromVoiceoftheCustomerFinalizeProjectFocus

andKeyMetricsCompletePDFMeasureMapBusinessProcessMapValueStreamDevelopData

CollectionPlanConductMeasurement

SystemAnalysisCollectDataConductProcess

CapabilityAnalysisAnalyzeProposeCriticalX’sPrioritizeCriticalX’sVerifyCriticalX’sEstimatetheImpactofEachXonYQuantifytheOpportunityPrioritizeRootCausesConductRootCause

AnalysisonCriticalX’sImproveCriticalX’sConfirmedDevelopPotentialSolutionsSelectSolutionOptimizeSolutionPilotSolutionControlImplementProcess

ChangesandControlsWriteControlPlanCalculateFinalFinancial/ProcessMetricsTransitionProjecttoFutureOwnersIdentifyProjectTranslationOpportunitiesMeasureDefineProjectIDToolsProjectDefinitionFormNetPresentValueAnalysisInternalRateofReturnAnalysisDiscountedCashFlowAnalysisPIPManagementProcessRACIQuadChartsProcessMappingValueAnalysisBrainstormingMulti-VotingTechniquesParetoChartsC&E/FishboneDiagramsFMEACheckSheetsRunChartsControlChartsGageR&RCp&CpkSupplyChainAcceleratorAnalysisMulti-VariBoxPlotsInteractionPlotsRegressionANOVAC&EMatricesFMEABrainstormingPullSystemsSetupReductionTPMProcessFlowBenchmarkingAffinityDOEHypothesisTestingForceFieldTreeDiagramsGanttChartsCheckSheetsRunChartsHistogramsScatterDiagramsControlChartsParetoChartsInteractiveReviewsPoka-YokeRevised1-12-0267LeanSixSigma

ImprovementPr67LearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentouseabinSystemBeabletosize(calculate)alltheparametersforabinsystem68LearningObjectivesUnderstand68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69课程目的理解箱补充系统的不同类型569What’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystem70What’sinItforMe?Beableto70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71我学到了什么?能够在黑带项目中应用这个工具7712-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofastandardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedpartsPurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartreplenishmentis“triggered”basedonconsumption722-BinReplenishmentPullIntro722-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732-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73WhatIsa2-BinReplenishment?Formanypartsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedperiodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe“1st”isbeingrefilled/replenished.Therearetwoprimaryreplenishmentlocations:Line-SideandPointofUse74WhatIsa2-BinReplenishment?742-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