精益生产基础课件.ppt

* * * * * * * * * * * * * * * * * * * * * * * * 4 2 In Out Example of Supermarket 超市范例 * Set break bulk area for Supermarket 为超市设置卸货区 Right Size of Supermarket 设置超市的合适尺寸 Supermarket physical set-up should meet “Supermarket Evaluation Checklist”(Refer to page 64) and the score should be 100% 必须100%达到超市评估表要求(如64页) Start with “Right size of bin” which is based on consumption rate and condition required by customer (production line) 基于消耗量和客户需求计算”料盒合适尺寸” Min-Max and Re Order Point (ROP) shall be clearly defined and visually trigger最小-最大和叫料点必须清楚定义和能够可视化 Replenishment should be based on consumption pull 补料基于消耗拉动 Right Size of Inventory 合适库存 Utilize the “Inventory Tracking Sheet” (refer page 68) 运用库存追踪表(68页) Calculate right size of Inventory – Ideal Inventory (Min-Max / RoP) 计算合适库存大小-理想库存(最小-最大/叫料点) Isolate and Visualize excess inventory 隔离放置多余库存，并标示 Right Purchase Method 正确的采购方式 Use Kanban as delivery control 利用看板作运送控制 Trigger PO and delivery signal to supplier only if kanban issued 只有看板发出之后才能下PO和运送 Steps to Set-up Supermarket 建立超市的步骤 * Height Requirements 高度要求: Rack height is limited to human height or reachable with eliminated motion climbing, searching and sorting 高度控制在人伸手可触的高度，减少爬高，寻找和捡料的动作 Address 位置: Location, Part Number, ROP (Min/Max) 位置，料号，叫料点(最小/最大) FIFO 先进先出: Demonstrate an auto gravity pull gradient design FIFO mechanism利用货架斜角和物料自重保证先进先出 Pull Material 拉动: Shop floor providing Sequential pull systems. Supermarket issuing only what is requested to replenish Production Material usage 连续拉动系统，超市只有在物料使用后才能发料 Visual Management 可视化: Enable material order personal react to inventory level 叫料人员根据库存水准反应。 No Waiting Transaction 没有等待: All activities between raw material receiving and build on board have been evaluated; eliminate non-value-creating waste such as waiting 评估所有原材料收货和上架的动作，保证中间没有不增加价值的浪费，如等待。 Return Flow 退料流程: Material return to supermarket flow as pre-define processes, Excess material return to warehouse is under standard work control. An Integrated fl