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1、精益生产的衡量指标 Lean manufacturing measuring,*进料仓库道出货仓库时间- DTD Dock to Dock *首次合格率 - FTT First time through *依排成生产 - BTS Build to schedule *总何设备效率 - OEE Overall equipment effectiveness,进料到出货时间 Dock to Dock Time DTD,Dock to Dock Time (DTD),*Definition 定义 .从原物料下货到完成成品出货之间的过去时间 the elapsed time between the u
2、nloading of raw materials and the release of finished goods for shipment .总DTD时间为产品耗费时间如原物料，制程作业，与 在厂完成品出货前在品的时间 the total dock to dock time for a product includes the time that a product spends as raw material, work-in process and as a finished product in plant, prior to being relaesed.,進料倉庫,成品倉庫,進
3、料倉庫到出貨倉庫時間 (DTD),製造週期時間(MCT),生產製造過程,衡量指標(DTD),衡量指标-DTD,DTD 從进料仓库到出貨仓库間时间 指原料進廠製成完成品準備出貨的時間 包含製造週期時間 DTD - 是衡量（时数）物料通过工厂的 速度，不是程序的速度 DTD is measure (in hours) of the speed of material through the plant, not the speed of the process.,衡量指标 DTD,*Benefits 利益 .DTD时间改善以减少库存由较少的物料管理与库存结果较少几率 损坏部品改善FTT dock
4、to dock time is improved by decreasing inventories which leads to less material handing and storage .this result in fewer opportunities to damage parts. There by improving first time through. .改善DTD时间可增进能力支援OTD目标 improved dock to dock time leads to improved ability to support the order to delivery (
5、OTD) target. .减少物料管理，废弃，及库存搬运成本，全部可以改善总成本数 lower material handing. Obsolescence. And inventory carrying costs all lead to improved total cost numbers.,衡量指标 DTD,*为什么 Why: .工廠必須消除浪費與改變到顧客拉式系統 PLANTS MUST ELIMINATE WASTE AND MOVE TOWARDS CUSTOMER “PULL”SYSTEMS. .設置巨大緩衝區生產過多零件(增快製程速度)但是降低了物料速度 By buildi
6、ng large buffers you produce more parts (increase The speed of your process ) but slow down the speed of materials. .減少庫存可以減少物料管理及儲存,結果減少損壞零件的機會. decreasing inventories leads to less material handing and storage, which results in fewer opportunities to damage parts.,衡量指标 DTD,*为什么 Why: .衡量生产库存週转的时间管理
7、 .DTD日程越短则週转越快 .有效管理库存资金,降低生产成本 .快速对应顾客需求,衡量指标 DTD,*为什么 Why： .DTD附加价值（实质）作业（value added operation）仅量少分 .DTD 绝大部分时间是 无附加价值 .等待 （wait） .停滞（stagnation） .缓行 （buffer） .存储 （ storage） .搬 运 （Transfer） .检查 （Inspection） .返工（Rework）,衡量指标 DTD,*何处 where :1 .原物料 - 购买的零件（管制部品）接收进入工厂开始计数.运委托制件.因为已经产品構成. raw materia
8、l-purchase part (control part) begin counting when it is received in the plant .Even on consignment. Because it is already in its product from already in its product form. .原物料变更成为产品构成 Raw material that is changed its product form,衡量指标 DTD,*何处 where ：2 .制程工作，包括物料在修理返工区域及全部缓衝区 Work-in-process (WIP),
9、including material in repair rework areas, and all buffers .完成产品-所有完成品包含管制部品并入DTD计算直 到被从马头交运 Finished goods end item products all finished goods ontaining the control part are included in the DTD calculation until they physically shipped form the dock,衡量指标 DTD,*何时 when: 数据收集时必须在作业型態表现优良的产品线上進行 Data
10、should be collected at the same time which best represents the operating pattern of a product line,衡量指标 DTD,*如何做 .降低原材料库存 .降低安全库存量 .提高进料频度,衡量指标 -DTD,*如何做 . 降低成品库存 .降低安全库存 .提高交货频度,衡量指标 DTD,*如何做 .减少在制品/制程高效率化 .目视化以及 防误措施 .一个流 小批量 .作业依排程生产 .推展全员生产性保养 .缩短转换时间,衡量指标-DTD,*降低总 DTD 时间 . 制程工程分析改善物流效率. 消除停滞减少搬
11、运 . 制程作业分析改善. 降低周期时间 .消除不良. 提高首次合格率 .排除稼动损失. 提高总合设备效率 .善用价值流图析,衡量指标-DTD,*降低总 DTD 时间 .DTD-从价值流图析能作用明确有效展现 .应用工业工程分析改善效率 並进行时间缩短改善 （ 时间）- 是各企业公司同样拥有之唯一 等量资源,衡量指标-DTD,单作业 DTD= 复合作业 DTD=,总管制数,线末速率,DTD作业1+DTD作业2+DTD作业3,线末速率,Total Dock To Dock Calculation,(Single Operation ) DTD = (Multiple Operation) DTD
12、=,Total Units of Control Part,End of Line Rate,DTD(Operation1)+DTD(Operation2)+DTD(Operation),End of Line Rate,首次合格率FTT First Time Through,衡量指标FTT,定义Definition 1 .FTT是为在一完整制程生产中，第一次既符合品质要求的产品件数的百分比率 不含被報廢，返工，重试验，線外修理，返回件数 First Time Through is the percentage of units that complete a process and qual
13、ity guidelines the first time without being scrapped, return, retested, repaired, or returned,衡量指标FTT,定义Definition 2 .FTT是衡量生产制程的品质 it is a measure of the quality of the manufacturing process .可应用FPS程序工具改善FTT (防误措施，幕式化工厂，快速转换) we can improve our FTT by applying our FPS process and tools (error proof
14、ing, visual factory & quick changeover).,衡量指标FTT,FTT首次合格率 投入制程总件数-（报废+返工+重试+线外修理+退回件数） Units entering process (Scrap + returns + retests + repaired off-line +returns),投入制程总件数,Units entering process,衡量指标-FTT,利益 Benefits 1 .提升制程/品质不良減少，库存降低,改善DTD时间 Increased process/out quality reduces the need for ex
15、tra production inventory, improvement DTD time. .改善及维护顺序通过制程 以改进BTS improves and maintains sequence throughout the process, improving Build to schedule (BTS).,衡量指标-FTT,利益 Benefits 2 .确保接收良品提高品质水准与降低浪费产生並全面提升OEE Increased quality before the constraint ensures that it only receives “good parts” which
16、promotes a higher quality rate and reduces wasted out at the constraint ,which all improve the OEE .以降低索赔（保证），報费，与修理成本改善总成本 Total cost is improved through lower warranty, scrap and repair costs,衡量指标-FTT,为什麼 Why:1 改善FTT成果将 improvements in First Through will result in: .提升产能 increased capacity .改善产品品质对内部及外部客户 Improved product quality to internal and e
