精益生产之超市系统课件

精益生产之超市系统第1页，共42页。精益生产之超市系统第1页，共42页。1ObjectivesofthisModule这个模块的目标Participantswillbeableto:参与者能够Identifywheresupermarketsareneededwithinavaluestreamtosupportapullsystem识别出在价值流的哪里需要设置超市来支持拉动系统UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用PFEP数据库来正确的估算及维护超市Linksupermarketstotheoverallkanbansystemsandconveyanceroutes将超市与整个看板体系及运输路线链接起来第2页，共42页。ObjectivesofthisModule这个模块的2Topics主题WhatisaSupermarket?什么是超市？ThreeStepsofSupermarketDesign超市设计的3大步骤SupermarketLocation超市地址SupermarketSizing超市大小PFEP(PlanforEveryPart)DatabasePFEP数据库DesignDeliveryRoutes设计交付路线RunningtheSupermarket运行超市GroupExercises团队练习第3页，共42页。Topics主题WhatisaSupermarket?3JargonBuster专业术语Supermarket超市PFEP(PlanforEveryPart)单个零件方案Addresssystem地址系统Kanban看板Routes路线VMI供给商管理库存JargonBusterPFEP?Supermarket?Addresssystem?第4页，共42页。JargonBuster专业术语Supermarket超市4WhatisaSupermarket?什么是超市Operation工序20Operation工序10PULL拉动Supermarkets超市Shipping出货Rawmaterials原材料In-processstock在制品库存Finishedgoods成品第5页，共42页。WhatisaSupermarket?什么是超市Ope5WhatisaSupermarket?什么是超市？Adeliberatelydesignedmaterialstoresareawithcontrolledquantitiesofmaterials成心设定的区域储存可控数量的材料Thedownstreamprocesstakeswhatisneededandthesupermarketowner(theupstreamprocess)replenishments下游工序拿取需要的材料，超市的所有人〔上游工序〕进展补料Unliketraditionalstoresarea,noorderforms,paperworktransactions,orstockrequisitionsareneededotherthankanban不同于传统的储存区域，没有除看板以外的订单格式，纸质的交割或者物料申请第6页，共42页。WhatisaSupermarket?什么是超市？A6HeijunkaBox321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品超市143WhatisaSupermarket?什么是超市RawMaterialsSupermarket原材料超市25761KanbanPost看板架1234CellKanbanPost看板架1234Cell453PartsSupermarket零件超市234453第7页，共42页。HeijunkaBox3212343212343212347WhatisaSupermarket?什么是超市？Amaterialstoresareawhich:物料储存区：Putsmaterialclosetopointofuse将物料放置在靠近使用点Eliminatesshortages消除物料短缺现象Setsminimumandmaximumlevelsforinventory设定最大库存及最小库存量Usesfloorspaceefficiently更有效的利用空间Simplifiesorderingandmaterialhandling订购及物料搬运简单化Removesnonvalueaddedactivities:(receiving,puttingaway,kitting,counting,cycling,requisitions)消除不增值的动作：〔收货，摆料，配料，点数，循环，申请〕Improvesmaterialflowintheproductcells改善生产线的物料流程Andmakesthestatusofmaterialsvisible让物料状态可视化第8页，共42页。WhatisaSupermarket?什么是超市？A8WhatisaSupermarket?什么是超市？Simplevisualsystemsshowmaterialflow简单可视化的物料流Location,addressandquantitycontrol位置，地址及数量管理第9页，共42页。WhatisaSupermarket?什么是超市？Si9WhatisaSupermarket?什么是超市？Supermarketsandmaterialpresentation超市及物料准备Achieveexcellent6S实现卓越的6SPresentmaterialsandtheirinformationvisibly让物料及信息更加目视化Eliminatedefects消除不良Usegravityfeeds使用重力送料Reducemotionforloadingandunloading减少上料及退料的动作MaintainFIFO维护先进先出第10页，共42页。WhatisaSupermarket?什么是超市？Su10ThreeStepsofSupermarketDesign超市设计的3大步骤Setsupermarketlocation设置超市的地址Wherewillsupermarketshelpusmost?超市设置在哪里更有帮助Determinesupermarketsizing定义超市大小PFEPdatabasetodeterminequantitiesPFEP数据库来定义数量Spacerequired空间的要求Designdeliveryroutes定义送货路线Standardworkforwithdrawalanddeliveryofpartsandcontainers补料及送货及周转箱的标准作业第11页，共42页。ThreeStepsofSupermarketDes11Step1:SupermarketsLocation第一步：超市选址

Typicalsupermarketlocations典型的超市地址Attheendoftheproducerprocesswheneverpossible,asarule在有可能的情况下设置在在生产工序的尾部Atpointofuse(VMI,Citems)在使用点〔供给商管理库存，C类零件〕Atreceiving(forexternalsuppliers)在收货区〔外部供给商〕第12页，共42页。Step1:SupermarketsLocation第一12Closetothepointofuseaspossible越靠近使用点越好Directdeliverytothesupermarket直接交货到超市Minimizerepeatedhandling将重复搬运减少到最少12Step1:SupermarketsLocation第一步：超市选址第13页，共42页。Closetothepointofuseasp13Step1:SupermarketsLocation第一步：超市选址

StandardApproach标准的方法Locatesupermarketsattheendofthesupplierprocessorproductionline将超市设置在供给流程的最尾端或生产线Makeproblemsimmediatelyvisibletotheproducerprocess将问题立刻可视化的传递到生产工序Donotsacrificevisibilityforthesakeofoptimizingtheworkofmaterialhandlers不为优化物料搬运工作的缘故而牺牲可视化第14页，共42页。Step1:SupermarketsLocation第一14Step1:SupermarketsLocation第一步：超市选址

Line生产线F1Line生产线F2Line生产线F3Supermarket超市1Supermarket超市2Supermarket超市3Line生产线A1Line生产线A2Line生产线A3234第15页，共42页。Step1:SupermarketsLocation第一15Step1:SupermarketsLocation第一步：超市选址

CentralizedSupermarket集中化的超市Duetohighvolumeandormix,thefacilitylayout,thesupermarketmaynotalwaysfitattheendoftheline因为大批量或多品种，工厂格局的原因，超市也许不能总是设置在生产线的尾部。Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstreamanddownstreamprocesstominimizematerialhandling集中化的超市用于当他们设置在上游及下游工序来减少物料搬运Supermarketsforincomingpartsforassemblymaybelocatednearthereceivingdock来料零件超市可以设置在靠近收货区第16页，共42页。Step1:SupermarketsLocation第一16Step1:SupermarketsLocation第一步：超市选址

234Line生产线F1Line生产线F2Line生产线F3ConsolidatedSupermarket统一的超市Line生产线A1Line生产线A2Line生产线A3第17页，共42页。Step1:SupermarketsLocation第一17GroupExercise#1团队练习#1Goseeactivity去现场看WalkthroughthevaluestreamfromendtoendUsevaluestreammapstoassist通过现场查看整个价值流—在价值流程图的帮助下Identifylocationswithinsitevaluestreamswheresupermarketsareneeded在价值流程图中识别出哪里需要超市Documentonfuturestatemapswhereapplicable将适用的地方在未来价值流程图上表达Wherecanwe…哪里我们可以Supportkanbansystemefforts?支持看板系统？Minimizeinventorylevels?最小化库存水平？Improvevisibilityandeliminateshortages?提升可视化及消除物料短缺？第18页，共42页。GroupExercise#1团队练习#1Gose18Step2:SupermarketSizing第二步：超市大小Howmuchofeachpartwillwekeeplineside?每个零件我们需要多少在生产线旁Frequencyofconveyance运输的频率Quantityofconveyance运输的数量Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartofanoverallroute通过高频率小批量的交付来最小化生产线旁的物料第19页，共42页。Step2:SupermarketSizing第二步：19Step2:SupermarketSizing第二步：超市大小Inordertodeterminesupermarketsize,weneedtoknow…为了定义超市的大小，我们需要知道Usagevolume(quantity)用量的多少〔数量〕Whatistheschedulingmethod?什么是方案的方法？Hastheusagebeenleveled?用量被均衡化了吗？Hasthemixbeensmoothed?生产种类被稳定了吗？Isthereafrozentimewindow?有一个冻结的时间窗口吗？Deliveryfrequencyupstream上游工序的交货频率Deliveryquantity交货数量Containersize周转箱大小Locationofsignal信号的位置Weight重量Andmore等等第20页，共42页。Step2:SupermarketSizing第二步：20ThePlanforEveryPart(PFEP)answers:单个零件方案解答了：Howisthepartpurchased?零件如何进展采购？Whoproducesthispart?谁生产这个零件？Howisitpackaged?零件如何包装？Howisthepartreceived?零件如何收货？Whereisitstored?在哪里储存？Whereisitspointofuse?在哪里使用？Howisitdeliveredtopointofuse?如何交付到使用点?Step2:SupermarketSizing第二步：超市大小第21页，共42页。ThePlanforEveryPart(PFEP)21SamplePFEPData数据的案例PartNumber物料编号Thenumberusedtoidentifythematerialsatthissite在工厂内物料的识别编号Description描述Commonnameofmaterial物料的通用名称Dailyusage每天用量Averagequantityofmaterialusedperday物料每天是平均使用量PointofUse使用点Processorareawherethematerialisconsumed物料在哪个工序进行消耗PointofStorage储存点Addressorlocationwherematerialisstored物料存储的地址Orderfrequency订单频率Howoftenthematerialisorderedfromthesupplier下物料订单的频率Suppliername供应商Nameofthesupplierofmaterial零件供应商的名称Suppliercity供应商城市Citywherethesupplierofthismaterialislocated零件供应商所在城市Supplierregion供应商地区Prefecture,state,district,orprovincewheresupplierislocated零件供应商所在区域Suppliercountry供应商国家Countrywheresupplierislocated供应商所在的国家Containertype包装箱类型Typeofthecontainerusedforthismaterial物料使用的周转箱类型Containerweight包装箱重量Howmuchanemptycontainerweighs空箱的重量Weightperpart零件单重Howmuchoneunitofthismaterialweighs单个零件的重量Totalpkg.weight整箱重量Weightofafullcontainerofthismaterial物料满箱的总重PFEP(PlanforEveryPart)DatabasePFEP数据库第22页，共42页。SamplePFEPData数据的案例PartNum22Containerlength周转箱长度Lengthordepthofcontainer周转箱的长度或深度Containerwidth周转箱的宽度Widthofcontainer周转箱的宽度Containerheight周转箱高度Heightofcontainer周转箱的高度Useperassembly每个产品的用量Quantityofmaterialusedforonefinishedproduct零件在单个成品中的用量Hourlyusage每小时的使用量Maximumquantityofmaterialsconsumedperhour每小时最大是使用量Standardcontainerquantity标准的周转箱数量Quantityofmaterialinonefullcontainer满箱中的零件数量Hourlycontainerusage每小时的周转箱用量Maximumquantityofcontainersconsumedperhour每小时周转箱的最大使用量Shipmentsize送货的批量大小Standardshipmentsize(inusagedays)标准的出货大小Carrier货运公司Nameoftransportationservicecompany运输服务公司的名称Timeintransit运输时间Traveltimefromsuppliertosite(indays)从供应商处到工厂的时间（天数）Kanbanquantity看板数量Quantityofkanbancardsorpullsignalsinsystem拉动信号系统中看板卡的数量Supplierquality供应商质量Performanceratingforquality(percentage)质量的成绩（百分比）Supplierdelivery供应商交付Performanceratingfordelivery(percentage)出货的成绩（百分比）SamplePFEPData数据的案例PFEP(PlanforEveryPart)PFEP数据库第23页，共42页。Containerlength周转箱长度Lengthor23PFEPDatabasePFEP数据库PFEP(PlanforEveryPart)DatabasePFEP数据库第24页，共42页。PFEPDatabasePFEP数据库PFEP(Pla24Foreachpartnumberinthesupermarket:在超市中的每个零件编号：Whatistheaveragedailyusage?平均每天用量是多少？Whatistheincomingshipmentsize(daysusage)?来料出货的大小〔多少天的用量〕？Howmuchbufferisrequired(daysusage)?需要的缓冲库存〔多少天的用量〕？PFEP(PlanforEveryPart)DatabasePFEP数据库第25页，共42页。Foreachpartnumberinthesu25PlannedMaximumInventory方案的最大库存=Dailyusage每天用量xShipmentsizeindays’usage出货的大小〔多少天的用量〕xDays’usagepurchasedpartssafetystock〔采购件平安库存使用的天数〕Safetystock:平安库存：Howmanydaysinventorydoweneedtoguardagainst…我们需要多少天的库存来保障Supplierissues?供给商问题？Transportationissues?运输问题Internalissues?内部问题？DeterminingBufferSize定义缓冲库存的大小第26页，共42页。PlannedMaximumInventory方案的最大26MaximumContainerQuantity最大周转箱数量=PlannedMaximumInventoryLevel方案的最大库存水平/ContainerQuantity包装箱数量CalculatingContainerQuantity计算周转箱数量第27页，共42页。MaximumContainerQuantity最大周转27UpdatingthePFEP更新PFEP第28页，共42页。UpdatingthePFEP第28页，共42页。28GroupExercise#2团队练习#2Supermarketsizing超市大小CreatePFEPDatabase创立PFEP数据库Usethisinformationtosizethesupermarket使用这些信息来确定超市大小Designpilotsupermarketbasedonsizeandeaseofstorageandretrieval根据尺寸及储存的容易程度设计试产的超市的大小第29页，共42页。GroupExercise#2团队练习#2Superm29Step3:DesignDeliveryRoutes第三步：设计送货路线HeijunkaBox均衡化生产箱321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品超市1234Cell453KanbanPost看板架143RawMaterialsSupermarket原材料超市251234Cell761KanbanPost看板架PartsSupermarket零件超市234第30页，共42页。Step3:DesignDeliveryRoutes30Step3:DesignDeliveryRoutes第三步：设计送货路线

Setroutedrivetimeatnomorethan33%ofthenon-loadtimeoftheroute设置路线运输时间不超过路线空载时间的33%Onlymovematerialwhenauthorizedbythepullsignal只有在收到被授权的拉动信号后才移动物料Ensurekanbansystemrulesarefollowedandworkersremovepullsignalswhenusingthefirstpieceinacontainer确保员工按照规那么操作：在使用周转箱中第一个物料时员工发出信号Synchronizethelunchandbreaktimesofthematerialhandlerontheroutewiththoseoftheworkersintheareasbeingsupported将物料搬运员与生产线员工的午饭时间及休息时间进展同步Followspecificroutetimesandfrequenciesandinsurethatroutedeliveryisnotinterruptedforanyreason按照特定的路线时间及频率来保证运输交货不被任何原因被打断Standardizeworkonthedeliveryroutetoeliminateallwastedmotionandimprovecontinuously标准化在交货路线上的作业来消除所有的动作浪费及持续进展改进第31页，共42页。Step3:DesignDeliveryRoutes31Step3:DesignDeliveryRoutes第三步：设计送货路线Designateone-wayandtwo-wayaislesalongnaturalflowpathsinthefacility指定的单向和双向沿自然流动路径的通道设施Designallroutestoflowthroughtheplantandbacktothesupermarket设计所有的通过工厂的路线及返回到超市Designstopsanddeliverypointsalongtheroutetominimizethenonvalue-addedworkforthematerialhandler在路线上设计停顿点及交货点来最小化物料员非增值的工作Designstopsanddeliverypointsalongtheroutetominimizenonvalue-addedworkfortheoperatorwhoisbeingsupplied在路线上设计停顿点及交货点来最小化生产线员工非增值的工作Startwithone-hourdeliveryroutes,aimingfora95%efficiency(57minutes)从一小时的送货路线开场，目标到达95%的效率Setloadingtimeatthesupermarketat33%orlessofthecoupleddeliverytime在超市设置取料时间是总交货时间的33%或更少第32页，共42页。Step3:DesignDeliveryRoutes32MaterialHandlerStandardWorkExample物料员标准作业的案例Step步骤StandardWorkElements标准作业步骤ConveyanceCycleTime运输周期时间1Traveltofirstdeliverypoint到第一个送货点120seconds秒秒2Pickupwithdrawalkanbanatfirststation(deliverypoint)从第一个工位拿取补料看板卡10seconds秒3Pickupemptycontainersandloadontotrolley拿取空箱放置到物料车上20seconds秒4Delivermaterialtofirststation将物料交付到第一个工位45seconds秒5Traveltonextdeliverypoint移动到下一个送货点10seconds秒6Traveltoseconddeliverypoint移动到第二个送货点15seconds秒7Pickupwithdrawalkanbanatfirststation(deliverypoint)从第一个工位拿取补料看板卡10seconds秒8Pickupemptycontainersandloadontotrolley拿取空箱放置到物料车上20seconds秒9Delivermaterialtosecondstation将物料交付到第二个工位45seconds秒10Traveltosupermarket移动到超市120seconds秒11Sortkanbancardsforbestpickingsequence根据取料的顺序挑选看板卡10seconds秒12Dropoffemptycontainerspickedupduringroute将空箱放置到相应的位置45seconds秒13Collectcontainersneededforpickingandconveyance收集需要的周转箱及运输45seconds秒14Pickpartsandplacethemontrolley(averageof10itemsx10seconds秒perpick)取物料及将物料放置到运输车上（平均10个零件X每次10秒）100seconds秒15Placewithdrawalkanbancardsinrespectivecontainers将补料看板卡放置到相应的周转箱10seconds秒Totaltimeforroute总的路线时间625sec秒Step3:DesignDeliveryRoutes第三步：设计送货路线第33页，共42页。MaterialHandlerStandardWork33PUSH-basedMaterialHandlingRoute推动-基于物料搬运路线CCBACCBBAASupermarket超市CBABulkdelivery(E.g.4hoursupply)交货大小Requiresextraspace需要额外的空间AAABBBBACCCCC123第34页，共42页。PUSH-basedMaterialHandlingR34PULL-basedMaterialHandlingRoute拉动-基于物料搬运路线CBACBACCBBAASupermarket超市CBA1234567Time-fixeddelivery(30minutessupply)固定时间的交货Mixedloadconveyance多品种的运输第35页，共42页。PULL-basedMaterialHandlingR35Line#1Line#28:009:0010:0011:0012:0012:3013:30Shift1345234343345234552552041041761761761119321321311761321234Finishedgoodssupermarket成品超市CustomerPull客户拉动¿¡¬√√¡¬¿ABProductionLine生产线761Kanbancollected,delivered看板收集及交付LinkSupermarketwithPullSystem将超市与拉动体系进展链接Tofinishedgoodssupermarket送至成品超市Heijunkabox均衡化生产箱第36页，共42页。Line#1Line#28:009:0010:0011:36GroupExercise#3团队连续#3Designroutes路线设计Designmaterialhandlingroutesbetweensupermarketsandpointsofuse在设计物料在超市及使用点间的运输路线Practice,timeanddocumentthework练习，时间及将工作文件化Documentprovisionalstandardwork,practiceandimprove文件化暂定的标准作业，练习及提高第37页，共42页。GroupExercise#3团队连续#3Design37RunningtheSupermarket运行超市SupermarketGoldenRules超市的金科玉律Theproducingprocesstakesownershipoftheinventoryinthesupermarket(regardlessofphysicallocation)生产工序负责超市中的库存〔不管实质的地址〕Thedownstreamprocessregularlywithdraws(pulls)whattheyneedintheamounttheyneed下游工序定期的取他们所需要的物料Clearsignalsareexchangedbetweenupstreamanddownstreamprocesseswhenmaterialiswithdrawnfromthesupermarket当从超市取物料时上下游工序间的信号交换第38页，共42页。RunningtheSupermarket运行超市Sup38Setminimumandmaximuminventorylevelsforallpartsinthesupermarket在超市中设置最大及最小的库存水平Locatethepurchasedpartssupermarketclosetothereceivingdock将采购件超市设置到靠近收货区Identifythepointofuseaddressonthestoragelocationfortheitemsinthesupermarket在存储地点识别出超市内的物料的使用点Simplifyhandlingofcontainers(useflowracks,etc.)简单化的搬运周转箱Createanoverflowareainahighlyvisibleplace在目视化的区域设计过量库存区RunningtheSupermarket运行超市第39页，共42页。Setminimumandmaximuminvent39Measurementsforcontinuousimprovementofsupermarketoperation:持续改进超市操作的测量Safety:recordableincidents平安：可记录的事故Quality:zerodefects质量：零缺陷Delivery:zerolinestops交货：零停线Cash:inventoryreduction现金：库存减少Productivity:numberofmaterialhandlers生产力：物料员的数量RunningtheSupermarket运行超市第40页，共42页。Measurementsforcontinuousim40Sustainingsupermarkets可持续的超市Establishstrongvisualcontrols建立强大的目视化管理Includesupermarketauditsinleaderstandardwork在组长的标准工作中包括对超市的Checktheconditionofsupermarkets检查超市的状态Checkinventorylevels检查库存的水平Checkthattheprocessisfollowed检查流程是否遵守Verifykanbanquantityintheloop在循环中验证看板的数量RunningtheSupermarket运行超市第41页，共42页。Sustainingsupermarkets可持续的超市R41人有了知识，就会具备各种分析能力，明辨是非的能力。所以我们要勤恳读书，广泛阅读，古人说“书中自有黄金屋。”通过阅读科技书籍，我们能丰富知识，培养逻辑思维能力；通过阅读文学作品，我们能提高文学鉴赏水平，培养文学情趣；通过阅读报刊，我们能增长见识，扩大自己的知识面。有许多书籍还能培养我们的道德情操，给我们巨大的精神力量，鼓舞我们前进。第42页，共42页。人有了知识，就会具备各种分析能力，第42页，共42页。42精益生产之超市系统第1页，共42页。精益生产之超市系统第1页，共42页。43ObjectivesofthisModule这个模块的目标Participantswillbeableto:参与者能够Identifywheresupermarketsareneededwithinavaluestreamtosupportapullsystem识别出在价值流的哪里需要设置超市来支持拉动系统UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用PFEP数据库来正确的估算及维护超市Linksupermarketstotheoverallkanbansystemsandconveyanceroutes将超市与整个看板体系及运输路线链接起来第2页，共42页。ObjectivesofthisModule这个模块的44Topics主题WhatisaSupermarket?什么是超市？ThreeStepsofSupermarketDesign超市设计的3大步骤SupermarketLocation超市地址SupermarketSizing超市大小PFEP(PlanforEveryPart)DatabasePFEP数据库DesignDeliveryRoutes设计交付路线RunningtheSupermarket运行超市GroupExercises团队练习第3页，共42页。Topics主题WhatisaSupermarket?45JargonBuster专业术语Supermarket超市PFEP(PlanforEveryPart)单个零件方案Addresssystem地址系统Kanban看板Routes路线VMI供给商管理库存JargonBusterPFEP?Supermarket?Addresssystem?第4页，共42页。JargonBuster专业术语Supermarket超市46WhatisaSupermarket?什么是超市Operation工序20Operation工序10PULL拉动Supermarkets超市Shipping出货Rawmaterials原材料In-processstock在制品库存Finishedgoods成品第5页，共42页。WhatisaSupermarket?什么是超市Ope47WhatisaSupermarket?什么是超市？Adeliberatelydesignedmaterialstoresareawithcontrolledquantitiesofmaterials成心设定的区域储存可控数量的材料Thedownstreamprocesstakeswhatisneededandthesupermarketowner(theupstreamprocess)replenishments下游工序拿取需要的材料，超市的所有人〔上游工序〕进展补料Unliketraditionalstoresarea,noorderforms,paperworktransactions,orstockrequisitionsareneededotherthankanban不同于传统的储存区域，没有除看板以外的订单格式，纸质的交割或者物料申请第6页，共42页。WhatisaSupermarket?什么是超市？A48HeijunkaBox321234321234321234234234761321234761321234761321234761321234234234234234234234234234234234234FinishedGoodsSupermarket成品超市143WhatisaSupermarket?什么是超市RawMaterialsSupermarket原材料超市25761KanbanPost看板架1234CellKanbanPost看板架1234Cell453PartsSupermarket零件超市234453第7页，共42页。HeijunkaBox32123432123432123449WhatisaSupermarket?什么是超市？Amaterialstoresareawhich:物料储存区：Putsmaterialclosetopointofuse将物料放置在靠近使用点Eliminatesshortages消除物料短缺现象Setsminimumandmaximumlevelsforinventory设定最大库存及最小库存量Usesfloorspaceefficiently更有效的利用空间Simplifiesorderingandmaterialhandling订购及物料搬运简单化Removesnonvalueaddedactivities:(receiving,puttingaway,kitting,counting,cycling,requisitions)消除不增值的动作：〔收货，摆料，配料，点数，循环，申请〕Improvesmaterialflowintheproductcells改善生产线的物料流程Andmakesthestatusofmaterialsvisible让物料状态可视化第8页，共42页。WhatisaSupermarket?什么是超市？A50WhatisaSupermarket?什么是超市？Simplevisualsystemsshowmaterialflow简单可视化的物料流Location,addressandquantitycontrol位置，地址及数量管理第9页，共42页。WhatisaSupermarket?什么是超市？Si51WhatisaSupermarket?什么是超市？Supermarketsandmaterialpresentation超市及物料准备Achieveexcellent6S实现卓越的6SPresentmaterialsandtheirinformationvisibly让物料及信息更加目视化Eliminatedefects消除不良Usegravityfeeds使用重力送料Reducemotionforloadingandunloading减少上料及退料的动作MaintainFIFO维护先进先出第10页，共42页。WhatisaSupermarket?什么是超市？Su52ThreeStepsofSupermarketDesign超市设计的3大步骤Setsupermarketlocation设置超市的地址Wherewillsupermarketshelpusmost?超市设置在哪里更有帮助Determinesupermarketsizing定义超市大小PFEPdatabasetodeterminequantitiesPFEP数据库来定义数量Spacerequired空间的要求Designdeliveryroutes定义送货路线Standardworkforwithdrawalanddeliveryofpartsandcontainers补料及送货及周转箱的标准作业第11页，共42页。ThreeStepsofSupermarketDes53Step1:SupermarketsLocation第一步：超市选址

Typicalsupermarketlocations典型的超市地址Attheendoftheproducerprocesswheneverpossible,asarule在有可能的情况下设置在在生产工序的尾部Atpointofuse(VMI,Citems)在使用点〔供给商管理库存，C类零件〕Atreceiving(forexternalsuppliers)在收货区〔外部供给商〕第12页，共42页。Step1:SupermarketsLocation第一54Closetothepointofuseaspossible越靠近使用点越好Directdeliverytothesupermarket直接交货到超市Minimizerepeatedhandling将重复搬运减少到最少12Step1:SupermarketsLocation第一步：超市选址第13页，共42页。Closetothepointofuseasp55Step1:SupermarketsLocation第一步：超市选址

StandardApproach标准的方法Locatesupermarketsattheendofthesupplierprocessorproductionline将超市设置在供给流程的最尾端或生产线Makeproblemsimmediatelyvisibletotheproducerprocess将问题立刻可视化的传递到生产工序Donotsacrificevisibilityforthesakeofoptimizingtheworkofmaterialhandlers不为优化物料搬运工作的缘故而牺牲可视化第14页，共42页。Step1:SupermarketsLocation第一56Step1:SupermarketsLocation第一步：超市选址

Line生产线F1Line生产线F2Line生产线F3Supermarket超市1Supermarket超市2Supermarket超市3Line生产线A1Line生产线A2Line生产线A3234第15页，共42页。Step1:SupermarketsLocation第一57Step1:SupermarketsLocation第一步：超市选址

CentralizedSupermarket集中化的超市Duetohighvolumeandormix,thefacilitylayout,thesupermarketmaynotalwaysfitattheendoftheline因为大批量或多品种，工厂格局的原因，超市也许不能总是设置在生产线的尾部。Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstreamanddownstreamprocesstominimizematerialhandling集中化的超市用于当他们设置在上游及下游工序来减少物料搬运Supermarketsforincomingpartsforassemblymaybelocatednearthereceivingdock来料零件超市可以设置在靠近收货区第16页，共42页。Step1:SupermarketsLocation第一58Step1:SupermarketsLocation第一步：超市选址

234Line生产线F1Line生产线F2Line生产线F3ConsolidatedSupermarket统一的超市Line生产线A1Line生产线A2Line生产线A3第17页，共42页。Step1:SupermarketsLocation第一59GroupExercise#1团队练习#1Goseeactivity去现场看WalkthroughthevaluestreamfromendtoendUsevaluestreammapstoassist通过现场查看整个价值流—在价值流程图的帮助下Identifylocationswithinsitevaluestreamswheresupermarketsareneeded在价值流程图中识别出哪里需要超市Documentonfuturestatemapswhereapplicable将适用的地方在未来价值流程图上表达Wherecanwe…哪里我们可以Supportkanbansystemefforts?支持看板系统？Minimizeinventorylevels?最小化库存水平？Improvevisibilityandeliminateshortages?提升可视化及消除物料短缺？第18页，共42页。GroupExercise#1团队练习#1Gose60Step2:SupermarketSizing第二步：超市大小Howmuchofeachpartwillwekeeplineside?每个零件我们需要多少在生产线旁Frequencyofconveyance运输的频率Quantityofconveyance运输的数量Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartofanoverallroute通过高频率小批量的交付来最小化生产线旁的物料第19页，共42页。Step2:SupermarketSizing第二步：61Step2:SupermarketSizing第二步：超市大小Inordertodeterminesupermarketsize,weneedtoknow…为了定义超市的大小，我们需要知道Usagevolume(quantity)用量的多少〔数量〕Whatistheschedulingmethod?什么是方案的方法？Hastheusagebeenleveled?用量被均衡化了吗？Hasthemixbeensmoothed?生产种类被稳定了吗？Isthereafrozentimewindow?有一个冻结的时间窗口吗？Deliveryfrequencyupstream上游工序的交货频率Deliveryquantity交货数量Containersize周转箱大小Locationofsignal信号的位置Weight重量Andmore等等第20页，共42页。Step2:SupermarketSizing第二步：62ThePlanforEveryPart(PFEP)answers:单个零件方案解答了：Howisthepartpurchased?零件如何进展采购？Whoproducesthispart?谁生产这个零件？Howisitpackaged?零件如何包装？Howisthepartreceived?零件如何收货？Whereisitstored?在哪里储存？Whereisitspointofuse?在哪里使用？Howisitdeliveredtopointofuse?如何交付到使用点?Step2:SupermarketSizing第二步：超市大小第21页，共42页。ThePlanforEveryPart(PFEP)63SamplePFEPData数据的案例PartNumber物料编号Thenumberusedtoidentifythematerialsatthissite在工厂内物料的识别编号Description描述Commonnameofmaterial物料的通用名称Dailyusage每天用量Averagequantityofmaterialusedperday物料每天是平均使用量PointofUse使用点Processorareawherethematerialisconsumed物料在哪个工序进行消耗PointofStorage储存点Addressorlocationwherematerialisstored物料存储的地址Orderfrequency订单频率Howoftenthematerialisorderedfromthesupplier下物料订单的频率Suppliername供应商Nameofthesupplierofmaterial零件供应商的名称Suppliercity供应商城市Citywherethesupplierofthismaterialislocated零件供应商所在城市Supplierregion供应商地区Prefecture,state,district,orprovincewheresupplierislocated零件供应商所在区域Suppliercountry供应商国家Countrywheresupplierislocated供应商所在的国家Containertype包装箱类型Typeofthecontainerusedforthismaterial物料使用的周转箱类型Containerweight包装箱重量Howmuchanemptycontainerweighs空箱的重量Weightperpart零件单重Howmuchoneunitofthismaterialweighs单个零件的重量Totalpkg.weight整箱重量Weightofafullcontainerofthismaterial物料满箱的总重PFEP(PlanforEveryPart)DatabasePFEP数据库第22页，共42页。SamplePFEPData数据的案例PartNum64Containerlength周转箱长度Lengthordepthofcontainer周转箱的长度或深度Containerwidth周转箱的宽度Widthofcontainer周转箱的宽度Containerheight周转箱高度Heightofcontainer周转箱的高度Useperassembly每个产品的用量Quantityofmaterialusedforonefinishedproduct零件在单个成品中的用量Hourlyusage每小时的使用量Maximumquantityofmaterialsconsumedperhour每小时最大是使用量Standardcontainerquantity标准的周转箱数量Quantityofmaterialinonefullcontainer满箱中的零件数量Hourlycontainerusage每小时的周转箱用量Maximumquantityofcontainersconsumedperhour每小时周转箱的最大使用量Shipmentsize送货的批量大小Standardshipmentsize(inusagedays)标准的出货大小Carrier货运公司Nameoftransportationservicecompany运输服务公司的名称Timeintransit运输时间Traveltimefromsuppliertosite(indays)从供应商处到工厂的时间（天数）Kanbanquantity看板数量Quantityofkanbancardsorpullsignalsinsystem拉动信号系统中看板卡的数量Supplierquality供应商质量Performanceratingforquality(percentage)质量的成绩（百分比）Supplierdelivery供应商交付Performanceratingfordelivery(percentage)出货的成绩（百分比）SamplePFEPData数据的案例PFEP(PlanforEveryPart)PFEP数据库第23页，共42页。Containerlength周转箱长度Lengthor65PFEPDatabasePFEP数据库PFEP(PlanforEveryPart)DatabasePFEP数据库第24页，共42页。PFEPDatabasePFEP数据库PFEP(Pla66Foreachpartnumberinthesupermarket:在超市中的每个零件编号：Whatistheaveragedailyusage?平均每天用量是多少？Whatistheincomingshipmentsize(daysusage)?来料出货的大小〔多少天的用量〕？Howmuchbufferisrequired(daysusage)?需要的缓冲库存〔多少天的用量〕？PFEP(PlanforEveryPart)DatabasePFEP数据库第25页，共42页。Foreachpartnumberinthesu67PlannedMaximumInventory方案的最大库存=Dailyusage每天用量xShipmentsizeindays’usage出货的大小〔多少天的用量〕xDays’usagepurchasedpartssafetystock〔采购件平安库存使用的天数〕Safetystock:平安库存：Howmanydaysinventorydoweneedtoguardagainst…我们需要多少天的库存来保障Supplierissues?供给商问题？Transportationissues?运输问题Internalissues?内部问题？DeterminingBufferSize定义缓冲库存的大小第26页，共42页。PlannedMaximumInventory方案的最大68MaximumCon