2.2NewContinuousFlow单件流第一课时讲义

2.2NewContinuousFlow单件流第一课时讲义JITProductionCharacteristics(准时化生产的特性）WorkStatementAnalysis（工作状况分析）Equipmentinorderofprocesses（设备按工艺排列）Smallandinexpensiveequipment（用小而经济的设备）One-pieceflowproduction（单件流生产)ProductioninProductCell(orFishbone“Rib”)(再独立单元内生产）Multi-process-handlingworkers（掌握多种技能的工人）Standingoperations,movingwhileworking(站立工作，随着工作移动）Ergonomically-correctoperations（符合人体工程学-正确的操作）Productionpacedtotakttime(按照节拍时间进行生产）BalanceOperationsinthecell,“Standardoperations”definedandimplemented（在独立单元内平衡作业且“标准作业方式”被定义和实施）LevelProduction（均衡生产）(UsuallydonebyIndustrialEngineeringwithFactoryManagement)（通常由工业工程师完成）Category160%ofproduction.（类别160%的生产）Category2next25%ofproduction.（类别2随后的25%的生产）Category3last15%ofproduction（类别3最后的15%的生产）PartNumberG15G29H15Y17Y18H21Qty25,15016,22912,15511,21411,101150CumulativeQuantity25,15041,37953,53464,74875,84990,120%27.918.013.512.412.30.2Cum%27.945.959.471.884.1100.01XXX2XX3XPQAnalysisPreparedby:D.SmithPeriod:7/1-9/30PartType...............Exle（例如）:Product/Quantity(PQ)Analysis（产品/数量分析）WorkStatementAnalysis（工作状况分析）ContinuousFlow(连续流动）3

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547ProcessRoutingChartPreparedby:D.SmithDate:10/12OperationMachinePartNumber0118,19,2002710416,1705HT2075108521123454ProcessRouteAnalysis(工艺路线分析）Basedonusage:Determinestandardroutings.（决定标准路线）Grouppartnumberswithsimilarroutings.（将相识路线的产品号归类）Determinepossiblecellsforpartnumbergroupings.（由产品号归类决定可能的独立生产单元）Evaluatecapacity,bottlenecks,andequipmentwhichmustbeshared.（评估产能，瓶颈和必须共享的设备）WorkStatementAnalysis（工作状况分析）ContinuousFlow(连续流动）1316,1717__5866658SawDeburrHeatTreatFinishingNibblerPressPressPressMillDrill1LatheLatheLathe345672LatheSawSawSawGrinderGrinderGrinderMillDeburrLatheSawHeatTreatLathePressFinishingLocateEquipmentinOrderofProcesses（按照工艺次序放置设备）Targetaspecificstatementofworkand选取一个具体的工作内容setupaproductorprocesscelltoproducethatstatementofwork.为此项工作建立独立工作区Relatecellstopartswithsimilarprocessandroutings.（将有相似工艺和加工路线的独立工作区相连）ContinuousFlow(连续流动）Thingstoconsider:（需考虑的事情）Choosesmall,dedicatedmachines.（选择小而专用的机器）Installcastersonequipmentforflexibility(abilitytochangelayoutdailyifneeded).（为了灵活，为设备装上轮脚）Minimizedistancebetweenoperations.（减少工序间的距离）Avoidlarge,fastequipmentinacell(onlyfastenough).（尽量避免在使用大而快的设备）Storematerials,supplies,andtoolingatpointofuse.（将材料，供应和工装放在要使用的地方）Small&InexpensiveEquipment（用小而经济的设备）ContinuousFlow(连续流动）$100,000Cyclesevery1.2seconds周转时间1.2秒$1,500Cyclesevery60seconds周转时间60秒Takttime=75sec节拍时间=75秒ÄÅÃRMFGÀÁ3Identifyandeliminatewastesandconstraintswhichlimitone-pieceflow.（识别并消除影响单件流生产的浪费和限制）“One-less-at-a-time”drivesyoutoone-pieceflow.（以每次减少一件的方式来推动单件流）StrivetoProduceandMoveOnePieceataTime（争取做到单件流生产）ContinuousFlow(连续流动）Productrequiresthreeprocessesthattakeoneminuteeach（产品需经过三个工序，每个工序需用一分钟）Processingfirstbatchinbatchesof10requires30minutes（如以10个为一批生产用时30分钟）Processingfirst“batch”one-at-a-timerequiresonly12minutes（如以单件流进行生产仅需12分钟）TraditionalBatchProcessing（传统的成批加工）10minutes10minutes10minutesTotalBatchAprocessingtime:30minutes（所有A批次的加工时间为30分钟）ContinuousFlowProcessing（连续流动的加工方法）TotalBatchAprocessingtime:12minutes

（所有A批次的加工时间为12分钟）Only3minutesfor1stpart（仅3分钟一个）1234567891011123ContinuousFlow(连续流动）StrivetoProduceandMoveOnePieceataTime（争取做到单件流生产）Out（出）In（进）One-PieceFlow（单件流）One-PieceFlow（单件流）BatchProcess成批加工(RequiresaLotSizeof120)批量为120BatchConveyance（批量运输）MaximumTotalInventoryof120atthislocation（此处的最大库存量为120）ReadyProcessedDealingWithMonuments（针对超大装备）ContinuousFlow(连续流动）Enablepeopletoleavemachineandmovetonextprocess.使人能离开机器并移动到下一个工序）Applyautonomation(automationwithahumantouch).（应用自动化）Installdevicestostopmachinewhenfinishedorproblemoccurs(Jidoka).（安装当加工完成或出现问题时能停止的装置）Installmistake-proofingdevices.（安装防错装置）Eliminatewatchingmachinesandwaiting.（消除看管机器和等待的时间)Performanothervalue-addingtaskwhilemachineisworking.(机器工作时做另一项有价值的工作）Before（从前）After（现在）Uh-oh,

there’saproblem.I’dbetterstopandsignalsomeonetocomehere.（有问题，我应该找人来看一下。）MoveWhileWorking:SeparatePeoplefromMachines（工作时移动：将人从机器中解放出来）ContinuousFlow(连续流动）Whatskillsareneededtooperatethecell?（操作独立工作区所需的技能？）Whoperformswhattasks?（谁来完成任务？）Howwillweworktogetherinthecell?（在独立工作区，我们如何协同工作？）Designformutualassistanceandusedefined“passingzones.”（以互助的方式设计）Multi-Process-HandlingWorkers（掌握多种技能的工人）ContinuousFlow(连续流动）JohnMaryFrank333323353363

34333133ProcessSkills（工序所需技能）People（人）1234567PassingZone7333Ask:“Howfastshouldweproduce?”（问：“我们生产需多快？”）Planproductionrateandmaterialflowstomatchrealconsumptionbythecustomer(mayincludesomeplannedstockoffinishedgoods).（生产速率和材料的流动应与顾客的实际需求相匹配（可以包含一些计划内的成品库存））Matchproductionratesandspeedstoconsumptionoffinishedgoods.（使生产速率与成品消耗相一致）RequiredproductionrateistheTakttime.（所需要的生产速率即节拍）PlanCustomerConsumption（顾客消费）AParts400BParts800CParts600DParts200ProducePacedtoTaktTime(按照节拍时间进行生产）ContinuousFlow(连续流动akttime=10ABCDEFGH12345OperatorProblem!Operatorcan’tmakeTakttime.BalanceOperationsContinuousFlow(连续流动）HGFEDakttime=10BC12345Operator（操作人员）Onesolution:Redistributethework.（一种方案：重新分配工作）WASTEofTime(peoplewaiting)浪费：等待时间LineBalance（平衡生产线）ContinuousFlow(连续流动）BHFGE1Dakttime=10C12345OperatorE2Anothersolution:IfwecansplitupE,wecanfreeupanoperatorandeliminatealotofwaste.（另一种方案：如可能拆分E,我们可以解放出一个操作人员并消除很多浪费）OPT=operatorcycletime/takttimeLineBalance（平衡生产线）ContinuousFlow(连续流动）JITProductionCharacteristicsWorkStatementAnalysis（工作状况分析）Equipmentinorderofprocesses（设备按工艺排列）Smallandinexpensiveequipment（用小而经济的设备）One-pieceflowproduction（单件流生产)“U”-shapedworkflow,counterclockwise（“U”型逆时针布置工作流）Multi-process-handlingworkers（掌握多种技能的工人）Standingoperations,movingwhileworking(站立工作，随着工作移动）Ergonomically-correctoperations（符合人体工程学-正确的操作）Productionpacedtotakttime(按照节拍时间进行生产）BalanceOperati