美铝公司精益制造.ppt

AVIC1_ALCOA_1AddCourse IconHereAVIC1 Senior Executive SeminarSharing Strategies for SuccessOur Collective Opportunity inIntegrated Global Supply ChainsAVIC1_ALCOA_2AddCourse IconHere中航一集团高级管理人员研讨会共享成功战略共享成功战略我们在全球综合供应链中我们在全球综合供应链中共同的机会共同的机会AVIC1_ALCOA _3AgendaFocusing,Aligning and Integrating to Deliver Best Value Mary Armstrong,Boeing Commercial Airplanes Vice President and General Manager Fabrication DivisionProgram Management Theory Versus Practice:Practical TipsDon Carlisle,Boeing Commercial Airplanes Managing Director,Wichita Division,Tulsa Business UnitOur Collective Opportunity in Integrated Global Supply ChainsBob Wetherbee,Alcoa President,Alcoa Mill Products AVIC1_ALCOA _4议程议程集中、统一以及整合以交付最佳价值集中、统一以及整合以交付最佳价值 玛丽玛丽阿姆斯特朗，波音民机集团阿姆斯特朗，波音民机集团 副总裁兼制造部总经理副总裁兼制造部总经理项目管理理论与实践项目管理理论与实践:实用技巧实用技巧 唐唐卡莱尔，波音民机集团卡莱尔，波音民机集团 塔尔萨业务部，威奇托部执行总监塔尔萨业务部，威奇托部执行总监我们在全球综合供应链中共同的商机我们在全球综合供应链中共同的商机鲍勃鲍勃威瑟比，美国铝业公司（威瑟比，美国铝业公司（Alcoa）美铝轧制产品公司总裁美铝轧制产品公司总裁AVIC1_ALCOA _5Realize Best Value Across the Supply Chain For Customers and Suppliers“We work on our collective systems together to achieve the goal of making Boeing products the most competitively priced in the world.”Bob Wetherbee President,Alcoa Mill ProductsAVIC1_ALCOA _6实现供应链中客户和供应商的最佳价值实现供应链中客户和供应商的最佳价值“我们共同致力于联合的体系，以实现波音产品成为世界我们共同致力于联合的体系，以实现波音产品成为世界上最具价格竞争力产品这一目标。上最具价格竞争力产品这一目标。”鲍勃鲍勃韦瑟比韦瑟比 美铝轧制产品公司总裁美铝轧制产品公司总裁AVIC1_ALCOA _7Alcoa Moved From Vision to Best Value in Four YearsVisionCreated20002004Strategy Developed2001Phase 1Pilot withBoeing fuselage20022003Additional Resources DeployedPhase 4 Extended to new markets,customers and their suppliersContinued waste elimination and system expansionExtending the system to include our suppliers Phase 2Implemented withBoeing wingsPhase 3Extended toBoeing standard plateUnderstanding System PotentialCapturing System ValueTimeline:Alcoas Integrated Global Supply ChainAVIC1_ALCOA _8美铝在四年内从远景目标走向最佳价值美铝在四年内从远景目标走向最佳价值制定远制定远景目标景目标20002004制定战略制定战略2001第一阶段第一阶段以波音机身为试点20022003部署更多部署更多资源资源第四阶段第四阶段 扩展到新市场、客户及其供应商继续消除浪费继续消除浪费并扩展体系并扩展体系延伸体系以延伸体系以包括我们的包括我们的供应商供应商 第二阶段第二阶段从波音机翼开始实施第三阶段第三阶段扩展到波音标准板材了解体系潜能了解体系潜能获取体系价值获取体系价值时间线：时间线：美铝的全球综合供应链美铝的全球综合供应链AVIC1_ALCOA _9A Phased Approach to Change Showed Immediate ResultsPoor delivery performanceUnpredictable flow timesHigh inventory stock levels50%of orders expeditedProblems and waste were hidden within the old systemOn-time and predictable deliveryConsistent flow timesReduced inventory stock level Less than 10%of orders expedited High visibility of problems and waste improvement opportunitiesResults of Old SystemResults of Integrated SystemPhase 3:Boeing ExampleAVIC1_ALCOA _10分阶段进行变革的方法立即显示出效果分阶段进行变革的方法立即显示出效果交付绩效差交付绩效差流程时间不可预知流程时间不可预知库存量高库存量高50%的订单加急完成的订单加急完成原有系统中隐藏了问题和原有系统中隐藏了问题和浪费浪费按时、可预测的交付按时、可预测的交付流程时间稳定流程时间稳定库存量降低库存量降低 不到不到10%的订单加急完成的订单加急完成 问题和浪费的改善机会可视性高问题和浪费的改善机会可视性高原有系统的结果原有系统的结果整合后系统的结果整合后系统的结果第三阶段：第三阶段：波音举例波音举例AVIC1_ALCOA _11Dramatic Improvement Seen inOn-time Delivery Delivery Performance DataTarget:97%System start date40.0%50.0%60.0%70.0%80.0%90.0%100.0%Feb-03Mar-03Apr-03May-03Jun-03Jul-03Aug-03Sep-03Oct-03Nov-03Dec-03Jan-04Feb-04Mar-04Apr-04Phase 3:Boeing ExampleAVIC1_ALCOA _12在按时交付方面发生了重大改变在按时交付方面发生了重大改变 Delivery Performance DataTarget:97%System start date40.0%50.0%60.0%70.0%80.0%90.0%100.0%03年2月03年3月03年4月03年5月03年6月03年7月03年8月03年9月03年10月03年11月03年12月04年1月04年2月04年3月04年4月第三阶段：第三阶段：波音举例波音举例AVIC1_ALCOA _13Begin by Drawing Current System of Material FlowIngot PlantHot Line Finished SawsCustomer Receiving Pre-saw processesShipping123410-12 Week Lead Times Order EntryCustomer Service Customer Usage and OrderingAlcoa Order Fulfillment Customer Places Orders 10-16 weeks in advanceRandomOrdersMachining ProcessesHigh Inventory Level=Phase 4 Example28 Sizes28 Plates28 Plates28 Products28 PlatesAVIC1_ALCOA _14从画出当前系统的材料流开始从画出当前系统的材料流开始铝锭厂铝锭厂高温生产线高温生产线 完工后切割完工后切割客户接收客户接收切割前工艺切割前工艺运输运输123410-12 周的交货期周的交货期 接收订单接收订单客户服务客户服务 客户用途和订货客户用途和订货美铝订单完成情况美铝订单完成情况 客户提前客户提前10-16周下订单周下订单随意订单随意订单机加工艺机加工艺高库存量高库存量 =第四阶段举例第四阶段举例28 种种尺寸尺寸28 种种板材板材28 种种板材板材28 种产品种产品28 种种板材板材AVIC1_ALCOA _15Focus on Customer Usage Versus Customer Orders Customer Usage and Ordering CustomerProductionPlanningUnleveled demand to AlcoaOrders not linked to machine usagePurchase orders arrive unpredictablyHigh Inventory LevelComplex and multiple forecasting processes Frequent change orders1234ReceivingRandomOrdersMachining ProcessesAVIC1_ALCOA _16注重客户的用途，而不是客户的订单注重客户的用途，而不是客户的订单 客户使用和订购客户使用和订购 客户生产客户生产计划计划对美铝的需求不分层次对美铝的需求不分层次订单未与机加用途联系起来订单未与机加用途联系起来无法预知何时收到购买订单无法预知何时收到购买订单高库存量高库存量复杂和多重预测流程复杂和多重预测流程 频繁变更订单频繁变更订单1234接收接收随意随意订单订单机加工艺机加工艺AVIC1_ALCOA _17Old System Provided No Visibility of Actual Customer Usage Alcoa Order Fulfillment Processes not tightly connected Inventories not engineeredIngot PlantHot LineFinish SawsPre-sawPlate MillShippingOrder EntryAVIC1_ALCOA _18原有系统无法提供客户实际用途的可原有系统无法提供客户实际用途的可视性视性美铝履行订单美铝履行订单 工艺工艺并未紧密联系起来并未紧密联系起来 未设计好库存未设计好库存铝锭厂铝锭厂高温生产线高温生产线完工后切割完工后切割切割前板材铣切切割前板材铣切运输运输订单接收订单接收AVIC1_ALCOA _19New Pull System Connected Alcoa and Customer ProcessesHot LineReceivingPre-sawProcesses6 sizes3 Day Lead Time Supply Chain Management Innovations of new system:Built-in tests Help chain for problem solving Kanban boards for store replenishment Ingot PlantFinish SawsShippingDailyOrders6 Plates28 Plates1234Machining ProcessesDaily Use Data Signal28 ProductsAVIC1_ALCOA _20新型拉动式系统将美铝和客户工艺联新型拉动式系统将美铝和客户工艺联系起来系起来高温生产线高温生产线接收接收切割前工艺切割前工艺6种种尺寸尺寸三天的交货期三天的交货期供应链管理供应链管理 新系统的创新性：新系统的创新性：自测自测 解决供应链的问题解决供应链的问题 补充储存量的看板补充储存量的看板 铝锭厂铝锭厂完工后切割完工后切割运输运输每日每日订单订单6种板材种板材28种板材种板材1234机加工艺机加工艺每日使用每日使用数据信号数据信号28 种产品种产品AVIC1_ALCOA _21New System ProvidedImmediate ResultsIncreased on-time delivery from 65%to 97%Reduced customer inventory by 65%Reduced change orders from 4500 per year to less than 10 per yearIncrease visibility of problems and waste improvement opportunitiesSmoothing flow of orders for just-in-time deliveryReduced weekly variation in product demand by 67%Results of the New SystemAVIC1_ALCOA _22新系统立即显示出成效新系统立即显示出成效按时交付率从按时交付率从 65%提高至提高至 97%客户库存减少了客户库存减少了 65%变更订单从每年变更订单从每年4500份降低为每年份降低为每年不到不到10份份提高了问题的可视性，增加了改进浪提高了问题的可视性，增加了改进浪费的机会费的机会理顺了恰时、恰物、恰量交付的订货理顺了恰时、恰物、恰量交付的订货流程流程产品需求的每周变化降低了产品需求的每周变化降低了67%新系统的成效新系统的成效AVIC1_ALCOA _23New System Resulted in Reduced Costs and Improved ProfitabilityReduced Variation Product Demand New System Start Date Pieces Pulled Each WeekTime in WeeksAVIC1_ALCOA _24新系统使成本降低、盈利能力增加新系统使成本降低、盈利能力增加产品需求的变化减少产品需求的变化减少 新系统启动日新系统启动日 每周拉动的件数每周拉动的件数星期数星期数AVIC1_ALCOA _25Success Requires a New Role for the LeaderProvide clear Provide clear business case business case and vision and vision Encourage Encourage experimentation experimentation Assemble team of Assemble team of system thinkers and system thinkers and continually develop continually develop team capabilitiesteam capabilitiesEstablish Establish change agent change agent networknetworkMake Regular shop Make Regular shop floor visits to floor visits to check the systemcheck the systemThink system cost Think system cost versus purchase or versus purchase or manufacturing costsmanufacturing costsReward problem Reward problem identification identification and resolutionand resolutionEliminate Waste Eliminate Waste ContinuouslyContinuouslyEnsure executive Ensure executive sponsorship in placesponsorship in placeAVIC1_ALCOA _26成功需要领导履行新角色成功需要领导履行新角色提供明确的商业提供明确的商业提供明确的商业提供明确的商业案例和远景目标案例和远景目标案例和远景目标案例和远景目标 鼓励试验鼓励试验鼓励试验鼓励试验 组建为系统出谋划策组建为系统出谋划策组建为系统出谋划策组建为系统出谋划策的团队并不断开发团的团队并不断开发团的团队并不断开发团的团队并不断开发团队能力队能力队能力队能力建立促进变化的建立促进变化的建立促进变化的建立促进变化的网络网络网络网络定期下车间定期下车间定期下车间定期下车间检查系统检查系统检查系统检查系统考虑系统成本与购买考虑系统成本与购买考虑系统成本与购买考虑系统成本与购买或制造成本或制造成本或制造成本或制造成本鼓励发现问题和鼓励发现问题和鼓励发现问题和鼓励发现问题和解决问题解决问题解决问题解决问题不断消除浪费不断消除浪费不断消除浪费不断消除浪费确保高层领导的支持到位确保高层领导的支持到位确保高层领导的支持到位确保高层领导的支持到位AVIC1_ALCOA _27Executive Sponsorship is Critical to SuccessCreating a system vision for integrated global supply chainsChanging the traditional procurement philosophyDriving deeper alignment of all supply chain participants Increase communication between all supply chain partnersOngoing dedication to change and continuous improvement of the systemExecutive Sponsorship RequiresAVIC1_ALCOA _28高级管理人员的支持对成功至关重要高级管理人员的支持对成功至关重要制定全球综合供应链体系的远景目标制定全球综合供应链体系的远景目标改变传统的采购理念改变传统的采购理念驱使所有供应链参与者更紧密的合作驱使所有供应链参与者更紧密的合作 加强供应链所有合作伙伴之间的沟通加强供应链所有合作伙伴之间的沟通不断进行变革，不断改进体系不断进行变革，不断改进体系高级管理人员的支持需要高级管理人员的支持需要AVIC1_ALCOA _29Current Supply Chain Offers Opportunities for ImprovementSupply Chain Improvement Opportunities:Delivery Performance Lead times Quality Inventory Communication and information flowsAVIC1_ALCOA _30当前的供应链有改进机会当前的供应链有改进机会供应链的改进机会：供应链的改进机会：交付绩效交付绩效 交货期交货期 质量质量 库存库存 沟通和信息流沟通和信息流AVIC1_ALCOA _31Alcoa Aerospace Center Shanghai:Local presence Evolves into essential point in supply chain Enables more reliable performance Provides direct visibility Offers just-in-time,point-of-use delivery for cut to size servicesShanghai Becomes Key Point in Integrated Global Supply ChainsChinaXianShanghaiChengduAVIC1_ALCOA _32美铝上海宇航中心：美铝上海宇航中心：当地业务当地业务 演变为供应链的重要点演变为供应链的重要点 绩效更可靠绩效更可靠 提供直接可视性提供直接可视性 为切割到用户所需的合适尺寸提供适时配送以及配料到使用地点为切割到用户所需的合适尺寸提供适时配送以及配料到使用地点上海成为全球综合供应链的关键点上海成为全球综合供应链的关键点中国西安上海成都AVIC1_ALCOA _33Summary Integrated global supply chains deliver Best Value New system allows:Lowest cash investment in inventory-Increase visibility of customer demand and usage-Faster and smoother product launch or changeSignificant reduction in system complexity-Less opportunity for system disruption or failure-On-time delivery-Fewer transactions-Reduced administration cost-Increased problem visibility and resolutionAlignment on business goals and common system supports improved performance and mutual benefitsAVIC1_ALCOA _34小结小结 全球综合供应链交付最佳价值全球综合供应链交付最佳价值 新系统能够使：新系统能够使：库存的现金投入减至最低库存的现金投入减至最低-增加客户需求和使用的可视性增加客户需求和使用的可视性-产品启动或变化更快、更顺畅产品启动或变化更快、更顺畅系统的复杂性大大减少系统的复杂性大大减少-系统中断或失效的可能性减小系统中断或失效的可能性减小-按时交付按时交付-交易减少交易减少-管理成本降低管理成本降低-问题的可视性和解决效率提高问题的可视性和解决效率提高商业目标的统一和相同的体系对改进绩效和共同利益起到了支持商业目标的统一和相同的体系对改进绩效和共同利益起到了支持作用作用