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1、Lean Hand Book 精益生产手册,1,Defect : X 1/10 缺陷降低90% Inventory : X 库存减半 Productivity : X 2 生产效率翻倍 Lead Time : X 生产周期减半 Scrap : X 1/10 报废降低90% Space : X 面积减半,Goal : Add Value 制程设计治具同时放置 4 块PCB板，则制程的节拍时间是 48 秒/治具。如果同时有 2 条生产线生产，制程的节拍时间则为 96 秒。,Scenario 2: If Top and Bottom product running on same line at t
2、he same time, Takt time shall be half = 48sec 情节2：如果正反面产品同时在一条生产线生产，节拍时间则为一半，48秒。,As such the Process Takt Time Calculation as following: 制程节拍时间计算如下： = Takt Time X Product Up x Process Up X Number of Line = 2 sec X 6 products per panel X 4 Panel per pallet X 2 Lines = 96 sec,8,What is Standard WIP什么
3、是标准WIP,Various types of WIP in our manufacturing process 生产过程中存在各种类型的WIP Standard WIP 标准WIP Process WIP制程WIP Process To Process WIP制程与制程间WIP Station To Station WIP工位与工位间WIP,9,What is Standard WIP什么是标准WIP,WIP means INVENTORY. INVENTORY is Basically bad. WIP就是库存。库存从根本上说是“不好”的。 Standard WIP is the Idea
4、l or Should be conditions for WIP 标准WIP是理想WIP或者是WIP的应有状态。 However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and bottle neck 然而，在完全达到标准WIP数量前，你需要经过不同的阶段了解制程中的浪费和瓶颈。 Key Note from Sensei: 老师的重要提示： To understand the abo
5、ve WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解WIP定义，你需要去到现场在工作中实践正确的WIP数量。这是让你理解这个定义的唯一方法。,10,What is Standard WIP什么是标准WIP,The purpose of Standard WIP is:标准WIP的目的： Separation bet
6、ween machine job and man job 区分机器作业和手动作业 Ensures quality requirements确保质量要求 Ensures smooth flow based on Takt time确保基于节拍时间的连续流 Example 1: 例子1 WIP in the reflow oven for curing with process time 6 min and Takt time 30 sec. 在回流焊炉中固化的WIP，制程时间 6 min，节拍时间 30 sec. Standard WIP in the curing oven = Process
7、 Time / Takt Time 回流焊炉的标准WIP = 6 min / 30 sec = 12 Pcs,11,What is Standard WIP什么是标准WIP,Example 2: 例子2 WIP in the tester at backend assembly with process time 60 sec and Takt Time 30 sec. 后段组装线测试机的WIP，制程时间 60 sec，节拍时间 30 sec. Standard WIP in the Test station = 60 sec/ 30 sec 测试工位的标准WIP = 2 pcs In oth
8、er words, Standard WIP in order to fulfill the above 1), 2), 3) functions, It is the compulsory WIP in the machine / process before establish standard work for the process. 换句话说，标准WIP能够确保上述1),2),3)达成，在建立标准作业前，标准WIP是机器和制程强制的WIP。,12,What is Standard WIP什么是标准WIP,Process WIP 制程WIP WIP within same proces
9、s with low variation of cycle time 同一个制程中的WIP，周期时间CT变化很小 It is all that WIP in the same process, not categorized as Standard WIP or PTP WIP. 所有在同一个制程中的WIP，不是标准WIP或制程间WIP. Example:- 例如 Before Kaizen, Manual Insert (MI) Line Process WIP =9 pcs. After Kaizen MI Process WIP is 3. Standard WIP for each s
10、tation is 1pc. 改善前，插件拉的制程WIP=9 pcs。改善后插件拉制程WIP=3pcs。每个工位的标准WIP为1pcs.,variance,After,Before,Process WIP = 3, Standard WIP = 1,Process WIP = 9, No standard WIP,13,What is Standard WIP什么是标准WIP,Process To Process WIP (PTP WIP) 制程间WIP WIP between 2 different processes with big gap cycle time两个周期时间相差很大的不同
11、制程间的WIP. PTP WIP Is needed due to changeover in upstream line. 上游制程需要转拉，则需设定制程间WIP.,Not All line need PTP WIP.不是所有产线都需要制程间WIP. If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期时间小于下游制程的周期时间 Example 1:- SMT Cycle time (30 sec) Less then Manual Insertion (60 sec) 例1：SMT周期时间(
12、30 sec)小于MI插件周期时间 (60 sec) CT (Upstream process) Need PTP WIP 需要制程间WIP If Cycle time Upstream process is Equal or greater then Down stream process, No PTP WIP required. 如果上游制程的周期时间大于或等于下游制程的周期时间，不需要制程间WIP.,14,What is Standard WIP什么是标准WIPProcess To Process WIP制程间WIP,Example 2:- Process A cycle time 1
13、5 sec. It is faster then Process B cycle time 25sec. Process A is running 2 product models as capacity requirement. In order to Keep Process line running, process to process WIP is required between Process A and B. The calculation as below:- 例2：制程A周期时间是15sec，比制程周期时间25sec快。制程A根据生产能力需求，需要生产2种产品。为了保证产线
14、正常运作，需要在制程A和制程B之间设定制程间WIP。计算如下：,Takt Time = 30sec Changeover Time = 5 min,30sec,Process A,Process B,15,Takt Time 节拍时间,Cycle time Takt time ( 1 Station Process ) C/TTakt Time (1个工位）,Cycle time than takt for single process (2 same stations needed) C/TTakt (需要2个相同工位),TAKT Time = 20s,Note注: CT TT : Addi
15、tional Machine/Man needed 需要额外的机器/人员,It can be used to calculate 节拍时间可以计算 Total Operators needed员工需求数量 Total machines needed机器需求数量 Standard WIP needed & Etc标准WIP需求数量，等,16,Is the Takt time visible (with counter and triggering point)? 节拍时间可以直观地看出来吗？有没有借助工具(计数器和触发机制) 。 2) Is the Takt board defined (on
16、the board)? 节拍时间确定了吗？(把节拍时间写在白板上) 3) Are the Standard WIP defined? 标准WIP有定义吗? 4) Do you know how to separate manual (persons) from auto (the machines) work? 你知道如何区分手动作业和自动作业吗? 5) Is the Work load leveling defined for man，machine and C/O? 人工,机器以及换线使用工作负荷均衡表分析了吗？ 6) Is the H/C calculated based on Takt time? 人力的多少是根据节拍时间计算出来的吗? 7) Is the Std work (front page) SWCS (back page) posted in front of each operator? 每个工站前都有标准作业(前页)和标准作业合并表SWCS(背页)吗?,Op
