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1、2-Bin Replenishment Pull,Introduction to 2-Bin Replenishment Pull Line-side versus Point-of-Use Stocking 2-Bin Data Needs and Calculations Inventory Disposition Options Card Triggered 2-Bin Process 1-Bin Systems Appendix,RD011202,2-Bin 补充拉系统,2-箱补充拉系统的介绍 线旁VS使用点库存 2-箱数据的要求和计算 库存部署选择 卡触发2-箱流程 1-箱系统 附录
2、,RD011202,Lean Six Sigma Improvement Process Road Map,Analyze,Control,Improve,Define Identify Problem Develop List of Customers Develop List of CTQs from Voice of the Customer Finalize Project Focus and Key Metrics Complete PDF,Measure Map Business Process Map Value Stream Develop DataCollection Pla
3、n Conduct MeasurementSystem Analysis Collect Data Conduct Process Capability Analysis,Analyze Propose Critical Xs Prioritize Critical Xs Verify Critical Xs Estimate the Impact of Each X on Y Quantify the Opportunity Prioritize Root Causes Conduct Root Cause Analysis on Critical Xs,Improve Critical X
4、s Confirmed Develop Potential Solutions Select Solution Optimize Solution Pilot Solution,Control Implement Process Changes and Controls Write Control Plan Calculate Final Financial/ Process Metrics Transition Project to Future Owners Identify Project Translation Opportunities,Measure,Define,Project
5、ID Tools Project Definition Form Net Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management Process RACI Quad Charts,Process Mapping Value Analysis Brainstorming Multi-Voting Techniques Pareto Charts C “bins” are actually the box/container the part/suppl
6、y is shipped in. 1. Employee removes a bin and drops its green 2-bin card into the mailbox: Pull parts from “bin” with green card before using any with the red card. 2.At same time(s) each day, the cards are picked up from the mailbox and returned to the stock/supply room. 3. The stock/supply room p
7、ulls proper amount of parts/material (noted on card, set equal to the calculated “bin” quantity). 4. Inventory transactions are performed (depending on issue method), and the materials and cards are delivered to the storage location. 5.Employee stocks material in storage location and returns card to
8、 its proper place. When stock/supply room replaces the material, ensure that the red card is placed on the full bin. Always leaves you a full red bin remaining when green bin runs out. If not, you could run down both bins and stock out before either is replaced; if a red card is in the replenishment
9、 process, a part shortage is imminent act fast!,42,2-Bin Replenishment Pull,典型的卡触发2-箱补充的介绍,这个流程用绿色和红色卡来触发补充；“箱”是实际用来发货零件/供应品的盒子/容器. 1. 员工清掉一个箱后，将绿色的2-箱卡放入邮箱: 在使用有红色卡的零件前，先从有绿卡的箱中拉零件 2.每天的同一时候, 邮箱卡片被收集并返回到库房中. 3. 库房拉动零件/材料的适合数量 (在卡上注明，将之设定为计算出的“箱”数量). 4. 库存处理被执行了(根据发放的方式), 然后材料和卡被传送到仓储地点. 5.员工将物料放在仓储
10、地点然后将卡返回到适合的地方. 当库房补充材料时，确保红色卡被放在添满的箱上. 当绿箱被放出去使用时，始终保持红卡箱中的零件已经被填满. 如果不是这样，在任一箱补充前你将用尽每个箱存货；如果红卡在补充过程中，零件短缺现象即将出现尽快采取行动。,43,2-Bin Replenishment Pull,Maintaining a Card Triggered 2-Bin Process,Check periodically for lost cards and replace. Best time is right after replenishment; any cards not replac
11、ed or in the mailbox are lost. Police the proper use of cards: Supervisor/Lead drop green cards when green bin is empty. Supervisor/Lead drop red cards on stock out investigate! Supervisor/Lead ensure cards are replaced when parts are restocked. Green bins are completely used before red bins. Resize
12、 bins when demand changes. Add cards for new parts, delete cards for obsolete parts.,44,2-Bin Replenishment Pull,保持卡触发2-箱系统的过程,定期检查卡片是否丢失并更换. 最佳时间是在补充之后，如果卡片未被更换或未在邮箱都视为丢失 维持卡片的合理使用: 当绿卡箱用完变空时，主管/组长投放绿卡. 当存货用完时，主管/组长投放红卡 调查! 当零件重新补充时，主管/组长确保卡片被更换. 在用红卡箱前，确保绿卡箱已经被用完. 当需求改变时需要重新调整箱的数量. 新增的零件要增加不同的卡，过期
13、的死库存零件要将卡片毁尸灭迹.,45,2-Bin Replenishment Pull,Example Card Triggered Line-Side 2-Bin Rack,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 1,Bin 2,Bin 1,Bin 2,Bin 2,Bin 1,Bin 2,Bin 1,Bin 1,2-Bin Mailbox,Order Cards,1.Always pull material from bin with GREEN card if it is there. 2.Store/supply room replac
14、es material and switches RED card to material just replaced. 3.The cards are attached to magnetic strip labels (for ease of movement for resizing).,Bin 1,Bin 1,Bin 2,46,2-Bin Replenishment Pull,举例：由卡触发的线旁2-箱货架,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 2,Bin 1,Bin 1,Bin 2,Bin 1,Bin 2,Bin 2,Bin 1,Bin 2,Bin 1,
15、Bin 1,2-箱邮箱,订单卡片,1.如果这里有绿卡箱，那么必须要从绿卡箱里拉材料. 2.库房补充材料并将红卡换到刚补充的材料里. 3.卡片最好是有磁性的 ( 这样在调整数量时可以方便移动).,Bin 1,Bin 1,Bin 2,47,2-Bin Replenishment Pull,Example Card Triggered Line-Side 2-Bin System,48,2-Bin Replenishment Pull,举例：由卡触发的线旁2-箱系统,49,2-Bin Replenishment Pull,Example Card Triggered Line-Side 2-Bin
16、System,2-Bin Cards are Green and Red, per the process. Cards are placed into plastic sheaths to protect them from getting knocked off the racking. Clear plastic sheaths are attached to metal racking via sticky magnetic strip make resizing easier. Bin labels are white sticky backed and placed inside of plastic sheath for protection. A clear plastic sheath over a white label indicates that the bin is being replenished.,50,2-Bin Replenishment Pull,举例：由卡触发的线旁2-箱系统,根据流程的需要
