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1、Short Lead Time缩短制造周期CCI员工参与标准化制造质量缩短制造周期持续改进32 GMSContinuous ImprovementBuilt-InQualityShort LeadTimePeopleInvolvementStandardizationShort Lead Time 缩短制造周期缩短制造周期Health andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessControlledExternal TransportationManufacturi
2、ngProcess ValidationProductQualityStandardsQualitySystemManagementScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementValuesVision/MissionShop FloorManagementInternal Pull /DeliveryAndonConceptProblemSolvingSimpleProcessFlowIn-ProcessControl &VerificationStandardizedWorkSmal
3、l LotPackagingTemporaryMaterialStorageQualityFeedback/Feed-forwardVisualManagementManagementby TAKT TimeWork-placeOrganizationEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintena
4、nce Fixed Period Ordering System/ Order PartsShortLeadTime缩短制造周期学完缩短制造周期内容，将会：明白缩短制造周期对客户响应及减少成本的重要性u了解缩短制造周期的相关概念u了解控制物料进入及在工厂内流动的精益物料管理系统纯粹的精益物流系统是从供应商最后的增殖产品到客户的开始使用期间，没有等待、储存量、双重处理、多余库存。Short Lead Time Strategy缩缩短制造周期短制造周期策略策略Supplier(供应商供应商)Plant(工厂工厂) Point of Use 开始使用开始使用 Receive Customer Ord
5、erReceive Customer Order 接收定单接收定单接收定单接收定单 Produce Vehicle Produce Vehicle 生产手机生产手机生产手机生产手机 Deliver Vehicle Deliver Vehicle 交付产品交付产品交付产品交付产品 Receive Payment Receive Payment 收到收到收到收到付款付款付款付款The movement of material in the right quantity, at the right time, to the right location, with the right equipme
6、nt, using the shortest lead time and lowest possible cost for both supplier and customer. 在最短的时间内，供应商与客户双方最少的成本损耗条件下，物料在适当的时间里把合适的数量用恰当的工具运送到一定的地点的流动。LeanMaterialFlowDefinition精益物流定义1) Parts Ordering 定购零件定购零件2) Suppliers 供应商供应商3) Packaging 包装包装4) Transport 运输运输5) Receiving 接收接收6) Temp. Stores 临时仓库临时
7、仓库7) Material Pull System物料拉动系统物料拉动系统8) Assembly Line 生产线生产线LeanMaterialsManagement精益物料管理FullFullFullFullEmptyEmptyOperator(操作工操作工)Part Presentation(零件摆设零件摆设)Conveyance(运输运输)Staging(分段运输分段运输)Receive/Unload(接收接收/卸货卸货)Transportation(运输运输)Suppliers(供应商供应商)LOWEST TOTAL COST 最低成本REDUCE LEAD TIMEPLAN FOR
8、EVERY PARTLeanMaterialFlow:GuidingPrinciples精益物流：指导原则SAFE(安全)Highvalueadded(高增殖生产)uCompression（压）uPartPresentation （介（介绍）uSmall Lot uBulk uSequenced/ Repack（计、序列）、序列）uErgonomic uSpace (空间空间)uOrganization (组织组织)uFIFO (先进先出先进先出)uMethod （方式）方式）uFrequency (频率频率)uCommunicatin (交流交流)uWindow Receiving (窗口接
9、收窗口接收)uEquipment (装置装置)uFrequency (频率频率) uDirect Ship (直接运输）直接运输）u100% Tracked (100% 跟踪跟踪)uResponsive (响应响应)uOn Time (及及时时)uRight Quantity (数量数量)uTo Specifications (合适规格合适规格)1.VehicleSchedules制造计划生产计划应均衡各个阶段的生产需求。百分百地在交付日期交货。整个生产部门都应该了解制造状态。支持减少手机交付时间和各种生产限制。Customer Order 客户定单：客户定单：When can I get m
10、y mobile phone?(什么时候可以交付什么时候可以交付?)143256ProductionPlan2.PartsOrdering:IndividualParts订购：个件Partorderbaseduponaprojectedvehiclebuildschedule零件订购要以设定的生产计划为基础Order=(PartsNeeded)-(PartsHave)订单 = (需要零件) - (现有零件)Pick Up Document 订购文件Delivery quantity and timing instructions per shipment每次运输的数量及时限CCI PlantD
11、eliverySupplierPick Up DocumentPick Up DocumentPlantLine side Operation3.SupplyBase(供应基地)在CCI工厂附近为对制造周期有特殊要求的零件设立的基地（通常是些定序的分装件）(按先后需求排序是合格供应商的职责):-在送到生产线之前供应商拥有库存供应数量最低化: 零件或分装件的单一供应点总供应基地的最小化（供应商数量）基于总材料传送成本决定货源4-1.TransportationandReceiving运输与接收每天运送频率预警：货车司机在供应商处检查货物货物不符时协商Suppliers(供应商供应商)MON. -
12、 8:00 amTUE. - 8:00 amWED. - 8:00 amTHU. - 8:00 amFRI. - 8:00 amCBA4-1.TransportationandReceiving运输与接收LeadLogisticsProvider(LLP):On-sitesinglepointofcontactforplant.(现场单一联系)Routeplanningandscheduling.(路线计划与安排)Visualroute/dockboard.(目视化路线/接收板)PlantReceiving:工厂接收Visualboard(目视化栏板) - Canlookatboardands
13、eewhatishappening(看栏板就可以知道情况)Scheduled， daily/weekly日/周计划-Whenmaterialwillarriveatplant(什么时候零件能到达工厂)Levelunloadplan(平衡卸货计划)PlantLLPTransportation Route Boardxx# 1# 2# 3# 4RouteTime定义：不直接把材料从供应商处运送到线旁，而是暂时将其集中存放的区域。目的：组织控制不直接由供应商送到生产线的材料库存量、产量和 物流4-2. Central Material Area( (集中材料区域集中材料区域) )4-2. 4-2.
14、Central Material Area (Central Material Area (集中材料区域集中材料区域) )KeyConcepts(主要概念):uOrganizebybulk/cartontoseparateequipment&minimizespacerequirements(用大箱或纸箱装零件来隔离设备，减少空间需求)u1 locationperpartnumber(一个零件一个存放点)uMinimizespace(空间最小化)uMinimizedeliverylead-time(运送时间最小化)4-2. 4-2. Central Material Area (Central
15、 Material Area (集中材料区域集中材料区域) )Key Benefits (主要益处):uOptimize space, manpower & equipment (优化空间、人员及设备优化空间、人员及设备)uMin. impact of production pull fluctuations (减少生产拉动波动的影响减少生产拉动波动的影响)uSupport F.I.F.O. (支持先进先出支持先进先出)Definition (定义定义):A method of material replenishment based on consumption, authorized by
16、 the user, who sends a signal to manufacture, ship, or delivery a product at a specific time, place, and quantity. (使用者认可的，通过向生产、运输部门发出信号，要求在一定时间内在具体地方运送定量产品的一种补充消耗物料的方法。)A flexible tool that enables Just-in-Time. (一个能确保JIT 的灵活工具)Connects operations to material supply. (连接生产与材料供给.) 5. Internal Pull/
17、Delivery (内部拉动内部拉动/运送运送)5-1. Types of Internal Pull Systems (内部物流的拉动系统的种类)EmptyContainerPullProcess(空箱拉动系统空箱拉动系统)PullCardProcess(卡片拉动系统卡片拉动系统)ElectronicPull System(EPS) (电子拉动系统电子拉动系统)“Nothing moves without a pull signal (无信号无拉动无信号无拉动).”Pull Card Process (卡片拉动系统卡片拉动系统):Description (定义定义): A material
18、pull system that uses cards to communicate replenishment requirements (使用卡片来传递供货信息的物流拉动系统使用卡片来传递供货信息的物流拉动系统)(投递卡片)(扫描卡片)(运送材料）EPS Process (EPS 系统系统):(材料需求材料需求)(电子识别电子识别)(材料提取，分运）材料提取，分运）(材料运送材料运送)(交货结束交货结束)Empty Container Pull Process (空箱拉动系统空箱拉动系统)Using LocationReplenishProductionTeam Member生产人员生产人
19、员Push OutPush InEMPTYFULLuSimple design (简单设计简单设计)uDesign to enable multiple part numbers per delivery (能够每次多零件运送的设计能够每次多零件运送的设计)uStandardize equipment and components throughout the plant (number of types, hitches, chassis) (整个工厂设备及零件标准化（种类、栓、底盘的数目）整个工厂设备及零件标准化（种类、栓、底盘的数目）)uDesign for manual manipul
20、ation (push and pull). (人工操作（推或拉）的设计人工操作（推或拉）的设计)6. MobileEquipment(运输设备):NOYES Example(实例): Line side Delivery (线旁运送)DollyExamples(手推车实例)Bulk container dolly base (Standard)(大箱手推车基座大箱手推车基座)(标准标准)Swivel Turntable Base(旋转转盘基座旋转转盘基座)7.PartPresentation(零件展示）Returnable containers (回收空箱回收空箱)One or two ho
21、urs usage per container (每个箱一到两小时的用量每个箱一到两小时的用量)Hand-carried or hand-manageable (dolly) (手提或手推手提或手推)Easy part pick (容易提取容易提取)Proper parts labeling (合适的标签合适的标签)Stackable (层叠层叠)Simple design (设计简单设计简单)Part Presentation (零件摆设):Within Workstation (在工位内)Within arms reach at point of installation (安装点在手臂可
22、及处)Less than 5 feet in height (line of sight) (高度低于5英尺)Hand Manageable (人工操作人工操作)5 feetPart ASmall Lot Container (小装箱小装箱) Bring the parts to the operator (零件运送到操作工身旁零件运送到操作工身旁)零件展示实例能够人力或自动移动能够人力或自动移动装螺丝螺栓的围兜装螺丝螺栓的围兜减少运动浪费减少运动浪费小件包装小件包装Lean Material Flow ( (精益物流精益物流) )Weak Material Flow (欠缺物流欠缺物流)Id
23、eal Material Flow (理想物流理想物流) Lack of Visual Management Techniques (缺乏目视化管理缺乏目视化管理) Single Part/Container Delivery Per Trip (每次单一零件每次单一零件/单箱配送单箱配送)Material Pushed to Subsequent Location (零件推动到其他地点零件推动到其他地点) Material Dictates Length of Production Operators Foot Print (材料指示生产材料指示生产) Empty Material Loca
24、tions (空箱回收地点空箱回收地点) Idle Material Operators (闲置的材料员闲置的材料员) Visual Management (目视化管理目视化管理)Multiple Deliveries per Part Number (每次同一零件的多箱配送每次同一零件的多箱配送) Established Inventory Levels (确定的库存量确定的库存量)Parts Scheduled via Pull Signal (Kanban,Broadcast) (拉动信号对应相应零件看板、广播）拉动信号对应相应零件看板、广播）) Reduced Leadtime (Supplier Co-location) (减少制造周期（供应商共同地点减少制造周期（供应商共同地点) Driver Checks at Supplier Dock (司机在供应商处验货司机在供应商处验货) Low Cost, Flexible Equipment (低成本，灵活的设备低成本，灵活的设备)
