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1、KAIZEN ROADMAP,TAKT/Customer Demand,Capacity/TOC Analysis,Load /Line Balance Analysis,Value Stream Mapping,Spaghetti Map,Cell Design/Develop New Layout,Develop Continuous Flow,On-going Continuous Improvement,(As-is ,B、To keep OTD it should arrange overwork time 62H for machine B(Load/capacity adjust
2、ment),KAIZEN ROADMAP,EXAMPLE,3. Load/Line balance,KAIZEN ROADMAP,Line balance(%)=(C.T/29.2*n ) 100%=89.5% Line balance loss (%)=1-Line balance(%)=10.5%,EXAMPLE,Line balance(%)=(Capability 5.4*n/capability ) 100%=52.7% Line balance loss (%)=1-Line balance(%)=47.3% Production loss=Average capability-c
3、urrent capability= 8.3- 5.4=2.9,3. Load/Line balance,7.0,9.7,Bottleneck,EOLR,KAIZEN ROADMAP,EXAMPLE,Capacity calculation-EOLR 产能计算,KAIZEN ROADMAP,EXAMPLE,EXAMPLE,Production Control,Daily Ship Schedule,Weekly Schedule,Daily Order,Weekly FAX,Forecast (2 months),Cutting,sewing,Forming,FINISHED GOODS,RA
4、W MATERIAL,Customer,Supplier,VSM-Current,C/T=?(TCT1) People: ? Uptime=? C/O=?min Batch size=? FTY=? Shift:1 (8H)?,Monthly demand:11000pr? Daily demand: 500 pr?,Packing,10days?,80sec?,3days?,1day?,58sec?,2days?,10days?,30sec?,140sec?,DTD=26 day? MCT=308sec(25 person?) Pcs C/T=? sec,DTD=26days? VA=308
5、 sec? VAR%=VA/DTD*100%=?,EOLR?,EOLR?,EOLR?,EOLR?,C/T=?(TCT2) People:? Uptime=? C/O=?min Batch size=? FTY=? Shift:1(8H)?,C/T=?(TCT3) People: ? Uptime=? C/O=? Batch size=? FTY=? Shift:1(8H)?,C/T=?(TCT4) People: ? Uptime=? C/O=? Batch size=? FTY=? Shift:1(8H)?,WIP?,Distance?,Distance?,Distance?,Distanc
6、e?,WIP?,WIP?,WIP?,?,KAIZEN ROADMAP,4. Value Steam Mapping,Non-Flow VS. Flow,Different factory comparison,KAIZEN ROADMAP,5. Spaghetti Map,Traditional Layout,Material Flow in a Process-Orientated Layout 以工序为导向的物料流程,Machines grouped together according to their function 按照机器的功能将一样的机器放在一起,KAIZEN ROADMAP,
7、5. Spaghetti Map,Workshop Layout,Drill Area,Mill Area,Tumble,Bench Area,Broach,FPI,Shot/Glass Peen,Heat Treat,Inspection,Cast Clean,1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17,EXAMPLE,KAIZEN ROADMAP,5. Cell Design,Cell Design,KAIZEN ROADMAP,Layout Improvement,Before,After,Grinder 6,Grinder 5,Grinder 7,Grinder 4,Mill 2,Lathe 1,Roll 8,Lathe 3,Lathe 1,From RM pile,To WIP room,Lathe 3,Mill 2,Lathe 1,Lathe 2,Grinder 4,Grinder 5,Grinder 6,Grinder 6,Grinder 6,RM house,Semi-FP/FP house,KAIZEN ROADMAP,
