《Toyota Kata Process Analysis.丰田招式-流程分析》.ppt

Toyota Kata – Process Analysis. 2. Category 2. Compensating. Not true improvement.2 类- 补偿,不是真实的改善 Add a small standard work-in-progress buffer up- and downstream of the machine, to isolate its “personality” from the rest of the 1X1 flow. This only works IF the total machine time is at or below the planned cycle time. 在下游设备前增加标准的小批量的在制品缓冲区(将其从单件流中独立出来),但需要总的设备时间是小于或等于计划加工周期. Move work to other processes, which slows down the takt time and planned cycle time for this process.将一部分工作移到其它工序,这样可以将该工序的节拍时间和计划加工周期延长. Toyota Kata – Process Analysis. 3. Category 3. Buy more capacity – This should be the last resort. 3类-增加更多的产能(增加设备-最后的选择) At Toyota the saying is quote “ If we are resourceful and creative we can almost always find ways to get more capacity out of a machine”.在丰田有句话叫做”如果我们发挥策略和创造力,我们将找到不通过增加设备而提高产能的方法” Toyota Kata – Process Analysis. Machine capacity chart can help you see the natural capacity level of a process. 设备产能图帮助我们看到流程的真实产能 Below chart depicts a problem with two machines. If total machine cycle reduced can meet Pc/t.有2台设备的产能有问题. With Creativity can increase capacity. Even can add more products. Takt Pc/t 90% of Pc/t 25 20 15 10 5 Line A is not yet at its natural capacity limit. A线还没有达到真实的产能,(其它设备产能富裕) 35 30 Line A Toyota Kata – Process Analysis. Two machines still cannot meet Pc/t. However most of the machines are at or nearing their capacity.有两台设备仍旧不能满足计划加工周期的时间(大于). Takt Pc/t 90% of Pc/t 25 20 15 10 5 Line B is close to its natural capacity limit. B线非常接近当前的产能. 35 30 Line B Toyota Kata – Process Analysis. How many Shifts? 多少班 In conjunction with Checking machine capacity, number of shifts should be considered. 和检查设备的产能,我们需要考虑开多少个班 Clearest way to gauge which option, the below table can be prepared.可以通过如下表格来帮助计算 15 sec 11 Sec. 10 sec. 1 Number of shifts 班数 2 30 sec. 22 sec. 19 sec. 3 45 sec. 33 sec. 28 sec. TT Pc/t Max Mc/t Maximum machine cycle time. (Max Mc/t = Pc/t X 90% 最大设备加工周期时间=计划加工周期*90% Longest allowable total machine cycle time for a