MeasureMeasureAnalyzeAnalyzeControlControlImproveImproveLean Six SigmaLean Six SigmaGeneric Pull SystemuDefinition of Generic Pull Best Practiceu Case ExamplesuHow to Determine Generic Pull LevelsuExercise uAntenna SimulationRD010402MeasureMeasureAnalyzeAnalyzeControlControlImproveImproveLean Six SigmaLean Six Sigma普通拉系统u定义普通拉系统的最佳实践u 案例举例u如何去决定普通拉水准u练习u天线模拟RD010402ImproveImproveLean Six Sigma Improvement Process Road MapAnalyzeAnalyzeControlControlImproveImproveDefineIdentify ProblemDevelop List of CustomersDevelop List of CTQs from Voice of the CustomerFinalize Project Focus and Key MetricsComplete PDFMeasureMap Business ProcessMap Value StreamDevelop DataCollection PlanConduct MeasurementSystem AnalysisCollect DataConduct Process Capability AnalysisAnalyzePropose Critical XsPrioritize Critical XsVerify Critical XsEstimate the Impact of Each X on YQuantify the OpportunityPrioritize Root CausesConduct Root Cause Analysis on Critical XsImproveCritical Xs ConfirmedDevelop Potential SolutionsSelect SolutionOptimize SolutionPilot SolutionControlImplement Process Changes and Controls Write Control PlanCalculate Final Financial/Process MetricsTransition Project to Future OwnersIdentify Project Translation OpportunitiesMeasureMeasureDefineDefineProject ID ToolsProject Definition FormNet Present Value Analysis Internal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management ProcessRACIQuad ChartsProcess MappingValue AnalysisBrainstormingMulti-Voting TechniquesPareto ChartsC&E/Fishbone DiagramsFMEACheck SheetsRun ChartsControl ChartsGage R&RCp&CpkSupplyChainAccelerator AnalysisMulti-VariBox PlotsInteraction PlotsRegressionANOVAC&E MatricesFMEABrainstormingPull SystemsSetup ReductionTPMProcess FlowBenchmarkingAffinityDOE Hypothesis TestingForce FieldTree DiagramsGantt ChartsCheck SheetsRun ChartsHistogramsScatter DiagramsControl ChartsPareto ChartsInteractive ReviewsPoka-YokeRevised 1-12-023Generic Pull SystemImproveImproveLearning ObjectivesuUnderstand the best practice definitionuHow to apply this best practice in various environmentsuAble to determine the levels of inventory using the five stepsuDemonstrate this best practice through exercises and simulation4Generic Pull SystemImproveImprove课程目的u理解最佳实践的定义u如何在多变的环境中应用这个最佳实践u能够去决定库存的水平用5个步骤u通过练习和模拟来示范这一最佳实践5Generic Pull SystemImproveImproveWhats in It for Me?uUnderstand the reason for this tool in different environmentsuHow to use this tool for potential black belt projects6Generic Pull SystemImproveImprove我学到了什么?u理解在不同环境中使用这个工具的原因u对于黑带潜在项目如何去使用这个工具7Generic Pull SystemImproveImproveGeneric Pull SystemsuGeneric Pull Systems limit the amount of Work-In-Process inventory in order to control cycle time.8Generic Pull SystemImproveImprove普通拉系统u普通拉系统为了控制周转时间限制了制程库存的数量（Work-In-Process）.9Generic Pull SystemImproveImproveWIP CapExitsStartsTriggerGeneric Pull System DefinedDefinition:uA Generic Pull System establishes a WIP cap on the amount of inventory within a predefined physical work area(set of workstations)or process.uTo maintain the WIP cap,exits from the process trigger starts into the process.Establishing WIP cap is the key to cycle time reduction!10Generic Pull SystemImproveImproveWIP CapExitsStartsTrigger普通拉系统的定义定义定义:u一个普通拉系统是在一个预先确定的物理工作区域（工作站）或流程中，在存货金额上建立了一个WIP cap.u来维护 WIP cap,从流程中的“出口”（exits）来触发进入流程的“出发”（Starts).建立WIP cap 是降低周转时间的关键11Generic Pull SystemImproveImproveWhen to Use Generic PulluAlwaysuGeneric Pull systems can be used in any of the following manufacturing/transactional environments:nRepetitive process/repetitive productlSimilar products/parts run within same process flowuExample:Automotive assembly line,customer order processingnRepetitive process/non-repetitive productlDissimilar products/parts run within same process flowuExample:Build to order printed circuit board manufacturer,customer complaint processingnNon-repetitive process/non-repetitive productlDissimilar products/parts run within a dissimilar process flowuExample:Machine model/prototype shop,NPI processesuGeneric Pull systems should always be used when a replenishment pull system is implemented 12Generic Pull SystemImproveImprove何时使用普通拉系统u永远u普通拉系统可以被使用在下列任何制造/事务处理的环境中:n重复的流程/重复的产品l类似的产品/零件在同一个流程中运行u例如:汽车的组装线,客户定单流程n重复的流程/不重复的产品l不同的产品/零件在同一个流程中运行u例如:根据定单定制的电路板制造商,客户投诉流程n不重复的流程/不重复的产品l不重复的产品/零件在不同的流程里运行u例如:机器模型/原型制作车间,NPI流程u当补充拉系统被实施时，普通拉系统将永远被使用13Generic Pull SystemImproveImproveWhen flying from DFW to OHare,we often wind up waiting on the ground due to“flow control.”Since OHare is overloaded,air traffic control keeps us in Dallas until the congestion over OHare clears,versus getting there and circling Chicago.Either way,we end up late.However,using the“flow control”(fixed WIP)method,we use less fuel and reduce the risk of an accident.In addition,we keep our options open(such as re-routing if the weather becomes too bad).In a pull system,maintaining a“fixed WIP”keeps work orders in paper form as long as possible.This provides the greatest flexibility to schedule/engineering 。
