流程标准化相关培训资料.pptx

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1、 1-1-1 1 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML流流流流程标准化程标准化程标准化程标准化Routing StandardizationRouting Standardization 1-1-2 2 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML议议议议程程程程

2、 AgendaAgenda目的目的/结果结果 Purpose/results与与流线生产有关的问题流线生产有关的问题 Issues relating to flow流流程标准化六步骤程标准化六步骤 6 steps to routing standardization 1-1-3 3 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML学习学习学习学习内容内容内容内容 What Youll LearnWhat Youll Learn根据根据相

3、似流程，将成品相似流程，将成品(零件零件)分类分类How to group products(parts)into families according to common routings如何如何简化零件流程简化零件流程How to simplify part routings根据根据零件系列，将流线生产单元文件化，并予零件系列，将流线生产单元文件化，并予以实施以实施How to implement and document flow production cells around part family groups 1-1-4 4 2005TBM Consulting Group,Inc

4、.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML及及及及时生产原理时生产原理时生产原理时生产原理 JIT PrinciplesJIT Principles跟上跟上“节拍节拍”时间时间Pace to“takt”time 达成流线生产达成流线生产Create flow production 结合结合“拉动拉动”系统系统Incorporate“pull”system 1-1-5 5 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM C

5、onsulting Group,Inc.All Rights Reserved.SMLSML流流流流程标准化的目的程标准化的目的程标准化的目的程标准化的目的Purpose of Routing StandardizationPurpose of Routing Standardization减少减少独特流程的数量独特流程的数量Reduce the number of unique routings简简化个别零件的流程化个别零件的流程Simplify individual part routings制定制定标准化工作标准化工作Develop standard work 1-1-6 6 2005T

6、BM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML贵贵贵贵司的流程象哪个？司的流程象哪个？司的流程象哪个？司的流程象哪个？Which Is Your Process?Which Is Your Process?流线型流线型非流线型非流线型零件零件零件零件零件零件零件零件零件零件零件零件零件零件零件零件 1-1-7 7 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consultin

7、g Group,Inc.All Rights Reserved.SMLSML不良流线的原因不良流线的原因不良流线的原因不良流线的原因 Causes of Poor FlowCauses of Poor Flow演化式增长演化式增长 Evolutionary growth人员人员安排变化安排变化 Staffing changes标准标准成本会计成本会计 Standard cost accounting产产能高峰能高峰 Capacity peaks共共用设备用设备 Shared equipment数量数量变化变化 Quantity variations流流程技术程技术 Process techno

8、logy流流程变化程变化 Routing variations外部外部交接点交接点 External handoffs回环工序回环工序 Loopbacks换换模时间太长模时间太长 Setups too long不同不同零件的数量零件的数量 Number of different parts超超级机器级机器 Super machine大大批量批量 Large batches流流程思维程思维 Process thinking必要必要的操作的操作(修理修理)As-required operations(repair)1-1-8 8 2005TBM Consulting Group,Inc.All R

9、ights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML变化变化变化变化的种类的种类的种类的种类 Types of VariationTypes of Variation数量数量变化变化 Quantity variation产品产品变化变化 Product variation 1-1-9 9 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML变化变化变化变

10、化的程度的程度的程度的程度 Degree Of VariationDegree Of Variation产量比例产量比例 零件数量比例零件数量比例特征特征种类很少种类很少制造业里最常见，种类非常多制造业里最常见，种类非常多种类极多，变化极大种类极多，变化极大(很罕见很罕见)1-1-1010 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML流流流流程标准化六步骤程标准化六步骤程标准化六步骤程标准化六步骤6 Steps To Routing

11、 Standardization6 Steps To Routing Standardization1.进行进行零件零件-数量数量(P-Q)分析分析2.Prepare part-quantity(P-Q)analysis3.2.进行进行流程分析流程分析4.Prepare process route analysis5.3.根据根据相似流程，对零件进行分类相似流程，对零件进行分类6.Group parts by routing similarity7.4.定义定义设备可用性设备可用性8.Define equipment availability9.5.简简化零件流程化零件流程10.Simplif

12、y part routings11.6.实施新的流程系列，并将其文件化实施新的流程系列，并将其文件化12.Implement and document new process family groups 1-1-1111 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML零件零件零件零件-数量数量数量数量 (P-Q)(P-Q)分析分析分析分析Part-Quantity(P-Q)AnalysisPart-Quantity(P-Q)Analy

13、sis*由于圆整问题，各个比例之和并不等于由于圆整问题，各个比例之和并不等于100%Individual percentages dont equal 100%due to rounding零件代号零件代号Part Number数量数量Quantity数量比例数量比例%of Quantity累计数量比例累计数量比例Cumulative Quantity(%)ABCD5684152524%24%2316848022%46%2351536017%63%9851228513%76%756511457%83%216981306%89%189961055%94%456 46804%98%15695653

14、%100%*1-1-1212 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML零件零件零件零件-数量数量数量数量 (P-Q)(P-Q)关系图关系图关系图关系图 Part-Quantity(P-Q)ChartPart-Quantity(P-Q)Chart数量数量零件代号零件代号累计数量比例累计数量比例 1-1-1313 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Con

15、sulting Group,Inc.All Rights Reserved.SMLSML流流流流程分析程分析程分析程分析 Process Route AnalysisProcess Route Analysis工作中心工作中心 Work Center零件零件 Part#数量数量 Quantity车削车削Lathe镗镗Bore机加工机加工Mach焊焊 Weld磨磨Grind机加工机加工Mach铣铣Mill检验检验Insp56841525231684802351536098512285756511452169813018996105456 46801569565111111111234222222

16、2333333334454444442 1-1-1414 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML零零零零件系列件系列件系列件系列 (1)(1)Part Family Group(1)Part Family Group(1)工作中心工作中心 Work Center零件零件 Part#数量数量 Quantity车削车削Lathe镗镗Bore机加工机加工Mach焊焊Weld磨磨Grind机加工机加工Mach铣铣Mill平衡平衡Bal

17、检验检验Insp56811506510100423390321080453350123457643215746899832156987123457689987653421 1-1-1515 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML零零零零件系列件系列件系列件系列 (2)(2)Part Family Group(2)Part Family Group(2)=外部工序外部工序 Outside process工作中心工作中心 Work

18、 Center零件零件Part#数量数量Quantity车削车削Lathe磨磨Grind热处理热处理HT Treat滚光滚光Tumble喷涂喷涂Coating内圆磨内圆磨ID Grind机加工机加工Mach检验检验Insp1289175765110064447516585111122223333444455556666777788889999 1-1-1616 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SMLSML定义定义定义定义设备可用性设

19、备可用性设备可用性设备可用性 Define Equipment AvailabilityDefine Equipment Availability识别识别现有设备现有设备Identify existing available equipment分配分配设备予各个流程组别设备予各个流程组别Allocate equipment to process groups识别识别潜在瓶颈问题潜在瓶颈问题Identify potential bottlenecks 1-1-1717 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consult

20、ing Group,Inc.All Rights Reserved.SMLSML简简简简化零件流程化零件流程化零件流程化零件流程 Simplify Part RoutingsSimplify Part Routings简简化操作顺序化操作顺序Simplify the sequence of operations同同一系列的所有零件都制定标准化流程一系列的所有零件都制定标准化流程Develop a standard route for all parts in a family减少减少工序数量工序数量Reduce the number of operations消除消除单元外的交接点单元外的交接

21、点Eliminate out-of-cell handoffs避免避免回环工序回环工序Eliminate loop-backs避免避免共用装卸中心共用装卸中心Eliminate shared load centers考虑考虑使用标准化流程模块使用标准化流程模块Consider using standard routing templates消除消除替换流程替换流程Eliminate alternative routings 1-1-1818 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc

22、.All Rights Reserved.SMLSML将新的系列文件化，并予以实施将新的系列文件化，并予以实施将新的系列文件化，并予以实施将新的系列文件化，并予以实施Implement&Document New Family GroupsImplement&Document New Family Groups制定制定工场布置图工场布置图 Establish a layout更改更改所有文件所有文件 Change all documentation立即立即开始开始 Start immediately定定下确实的完成日期下确实的完成日期 Establish a firm completion date