优化生产中的物流活动

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1、Material Movement in a Lean Manufacturing Operation 优化生产中的物流活动优化生产中的物流活动Total Systems DevelopmentTotal Systems Development 全体系生产提高全体系生产提高全体系生产提高全体系生产提高JIT生产生产(准时准时,准量生产准量生产):What is meant by the term, “Just-In-Time”?JIT生产意味着什么? Does it mean JIT Supply?Does it mean JIT Supply? 准时准时, ,准量供应准量供应? ? Does

2、 it mean JIT Production?Does it mean JIT Production? 准时准时, ,准量生产准量生产? ?So, what is Just-In-Time?那么,什么是准时准量生产?The concept of producing the necessary units in the necessary quantities at the necessary time is described by the short-phrase “Just-In-Time”. JIT生产是生产是:在必需时间内生产必需数量的必需部品的概念.For example.In b

3、uilding shoes: The necessary subassemblies In building shoes: The necessary subassemblies of the proceeding process (uppers and bottoms) of the proceeding process (uppers and bottoms) should arrive at the assembly line at the time should arrive at the assembly line at the time needed in the amounts

4、needed.needed in the amounts needed.举例说明举例说明: : 在生产成品鞋的时候在生产成品鞋的时候: :制鞋所必需的部件制鞋所必需的部件( (鞋帮和鞋底鞋帮和鞋底) )要准时要准时, ,准量准量, ,准型号地到达制造车间准型号地到达制造车间. .If we achieve JIT: 如果我们做到准时,准量生产: Unnecessary inventories will be eliminated.Unnecessary inventories will be eliminated. 不必要的库存就会消除不必要的库存就会消除 Stores and warehou

5、ses will not be needed.Stores and warehouses will not be needed. 储存区和仓库也可以取消储存区和仓库也可以取消 Material carrying costs will be diminished.Material carrying costs will be diminished. 资材搬运成本降低资材搬运成本降低However.To rely solely on a central planning approach that instructs the production schedules to all processe

6、s simultaneously is not likely to result in a JIT process for all operations.但是：单纯地依赖计划生产的方法,使所有工序同步生产，并不能完全实现所有环节的准时，准量生产.TransferWasherAssemblyMachining加工加工Welding焊接焊接Assembly组装组装Shipping装船装船Weekly Schedule每周生产计划每周生产计划Typically, one control operation receives the customers Typically, one control o

7、peration receives the customers orders and disseminates schedules.orders and disseminates schedules.通常，生产控制部门接受客户定单，然后制订并传达计划通常，生产控制部门接受客户定单，然后制订并传达计划. .Production Control生产控制生产控制TransferWasherAssemblyMachining加工加工Welding焊接焊接Assembly组装组装Shipping装船装船Weekly Schedule每周生产计划每周生产计划Production Control生产控制生产

8、控制IIIIIIThe problem comes when a change is made either The problem comes when a change is made either because the order changes or equipment breaks down.because the order changes or equipment breaks down.但是当定单有变化或设备出现问题的时候，就会发生一但是当定单有变化或设备出现问题的时候，就会发生一些问题：些问题：库存库存库存库存库存库存库存库存The result is excess inv

9、entory结果是导致过多的库存within the plant as Work-In-Process在本车间工序内积压过多的库存suppliers sending in parts that are not needed上一道工序发来的并不需要的部件Additionally另外,We need extra floor space to store the material.We need extra floor space to store the material. 我们需要额外的空间来堆放材料我们需要额外的空间来堆放材料Need expeditors to satisfy the cha

10、nges in schedule.Need expeditors to satisfy the changes in schedule. 需要人力和时间投入来改变生产计划需要人力和时间投入来改变生产计划Run overtime to make up parts that we now need.Run overtime to make up parts that we now need. 用加班时间来生产现在所需部件用加班时间来生产现在所需部件Toyota rethought how to communicate schedules.丰田公司对调整生产计划做了改进:Toyota discove

11、red a different way to manage Toyota discovered a different way to manage their schedule,their schedule, 丰田使用不同的方法来制订调整生产计划丰田使用不同的方法来制订调整生产计划They stopped trying to guess what the customer They stopped trying to guess what the customer will want.will want. 他们并不去猜想客户的需求他们并不去猜想客户的需求Instead相反. Each depa

12、rtment had installed a small inventory of Each department had installed a small inventory of each product.each product. 每个车间都保持少量的库存每个车间都保持少量的库存 Downstream processes come to the supplying Downstream processes come to the supplying departments and take what it needs. departments and take what it need

13、s. 下一道工序到上一道工序去取他们所需部件下一道工序到上一道工序去取他们所需部件 This allows the processes upstream to simply This allows the processes upstream to simply replace what was taken.replace what was taken. 这样这样, ,上一工序只要补充被取走的部件即可上一工序只要补充被取走的部件即可. .The Toyota Production System TPS丰田体系. Is likely to be the most studied and disc

14、ussed operations Is likely to be the most studied and discussed operations program in the world.program in the world. 是极可能被全世界研究和讨论的体系是极可能被全世界研究和讨论的体系 Numerous books and papers have been written about TPS.Numerous books and papers have been written about TPS. 出版了很多关于出版了很多关于TPSTPS的书籍和其它资料的书籍和其它资料 Man

15、y have come to characterize TPS as “lean production” Many have come to characterize TPS as “lean production” or NOS.or NOS. 许多人认为丰田体系许多人认为丰田体系( (TPS)TPS)实际上就代表优化生产或实际上就代表优化生产或NOSNOSLean Manufacturing (NOS) NOS优化生产优化生产 Regardless of any authors opinion or rational, all agree Regardless of any authors

16、 opinion or rational, all agree that the foundation of lean manufacturing (NOS) is the that the foundation of lean manufacturing (NOS) is the continual pursuit to eliminate waste.continual pursuit to eliminate waste. 尽管大家的观点有些不一样尽管大家的观点有些不一样, ,但所有人都认为但所有人都认为NOSNOS的基础是持的基础是持续不断地减少浪费续不断地减少浪费 Waste is

17、defined as anything that consumes resources or Waste is defined as anything that consumes resources or time, but does not add value to the product.time, but does not add value to the product. 浪费是任何耗费资源或时间浪费是任何耗费资源或时间, ,但不增加产品价值的活动但不增加产品价值的活动Excess Inventory is Waste 多余的库存是一种浪费Excess inventory hides

18、problemsExcess inventory hides problems多余的库存会隐藏一些问题多余的库存会隐藏一些问题Sea of Inventory 大量库存大量库存Raw Material 原资材原资材Finished Goods 成品成品LongTransportation过长运输时间过长运输时间VendorDelivery 供应商运送供应商运送Absenteeism缺勤缺勤Commun-icationProblemPoor Scheduling计划不力计划不力MachineBreakdown设备停机设备停机QualityProblems质量问题质量问题LineImbalance

19、线内不平衡线内不平衡Long Set-Up Time过长调整时间过长调整时间Lack of House-Keeping仓储管理问题仓储管理问题沟通问题沟通问题Our goal for materials management in NOS NOS资材管理的目标 The ideal state is a smooth flow of materials throughout The ideal state is a smooth flow of materials throughout our own factoryour own factory 理想的状态是物料在整个工厂内顺畅的流动理想的状态

20、是物料在整个工厂内顺畅的流动. . We want to tie together processes that are separated by We want to tie together processes that are separated by large physical distances.large physical distances. 使那些有一定距离而相对分离的生产流程紧密结合起来使那些有一定距离而相对分离的生产流程紧密结合起来 We need to improve communication in regards to material We need to imp

21、rove communication in regards to material movement.movement. 在物流方面要加强各工序间的沟通在物流方面要加强各工序间的沟通The Push System”推动推动“生产体系生产体系In traditional manufacturing, various production schedules are released to all processes; component making and assembly. 在传统的生产中,各种生产计划被传达到各个工序,部件生产和组装部门.The Push System (cont.)”推动

22、“These part-making processes produce the parts in accordance to their schedules and transport the parts to the next process. 部件生产部门按照收到的计划生产并把成品部件运送到下一道工序.The Push System (cont.)”推动“This method makes it difficult to promptly adapt to changes. 这种方法使生产很难迅速对变化作出反应Each production schedule must be change

23、d at each process simultaneously. 每个工序的生产计划都必需同时变化以适应同步生产The Push System (cont.)”推动”The Result导致: The company must hold extra inventory among all The company must hold extra inventory among all processes.processes. 公司不得不在各个工序保持额外的库存公司不得不在各个工序保持额外的库存 This creates an imbalance of stock between This cr

24、eates an imbalance of stock between processes.processes. 各工序间的库存达不到平衡各工序间的库存达不到平衡The Pull System “拉动拉动”生产体生产体系系 In contrast, in a PULL SYSTEM, each process will In contrast, in a PULL SYSTEM, each process will withdraw the parts it needs from the proceeding withdraw the parts it needs from the proce

25、eding process. process. 相反相反, “, “拉动拉动” ”生产体系要求各个工序仅生产体系要求各个工序仅需从上一道工序提取自己所需要的部件需从上一道工序提取自己所需要的部件. .BA“production” kanban“withdrawal” kanbanProduct部件Product部件Market供应超市Supplying Process 供应工序Customer Process客户工序“生产”指示板“拒收”指示板The Pull System (cont.)”拉动”体系Since only the final-assembly process can accur

26、ately know the necessary timing and quantity of parts required, they are the only ones to receive a schedule. 因为只有制造准确地了解所需时间和部件数量,以只要制造收到生产计划即可. AssemblyStock-fit准备Stitching缝纫Assembly制造Shipping装船Weekly Schedule每周生产计划每周生产计划Final Assembly receives a schedule and pulls from the Final Assembly receives

27、 a schedule and pulls from the Market Place. Stitching and Stock-fit replenishes the Market Market Place. Stitching and Stock-fit replenishes the Market Place. Place. 制造接受生产计划制造接受生产计划, ,并借助并借助“ “供应超市供应超市” ”拉动生产拉动生产. .缝缝纫和准备向纫和准备向“ “供应超市供应超市” ”补充部件补充部件. .Production Control生产控制生产控制The Pull System (con

28、t.)”拉动”体系With the schedule, the final-assembly goes to the supplying departments and withdraws what parts are needed.根据生产计划,制造到供应车间去提取所需部件.The Pull System (cont.)”拉动“生产The preceding operation then produces the replacements of The preceding operation then produces the replacements of the parts withdr

29、awn by the subsequent process. the parts withdrawn by the subsequent process. 这样这样, ,前一前一道工序开始生产被下一道工序提走的部件以补充所需道工序开始生产被下一道工序提走的部件以补充所需. .BAssembly制造Stitching缝纫A“production” kanban“withdrawal” kanbanProduct部件Product部件Market供应超市“生产”指示板“拒收”指示板Markets “供应超市” Markets are the storage locations for all th

30、e parts prior to Markets are the storage locations for all the parts prior to going to the next operation.going to the next operation. “ “供应超市供应超市” ”是为下一道工序储存所需各种部件的区域是为下一道工序储存所需各种部件的区域. . Markets simply are organized collections of purchased Markets simply are organized collections of purchased par

31、ts and work-in-process.parts and work-in-process. 组建组建“ “供应超市供应超市” ”只是为了搜集购买的部件和线上的库存只是为了搜集购买的部件和线上的库存. . If parts are already stored in your plant, then you can If parts are already stored in your plant, then you can construct markets.construct markets. 如果工厂内有储存部件如果工厂内有储存部件, ,那就可以设置此体系那就可以设置此体系. .C

32、autions about Markets关于“超市体系”的警告:Dont get caught up in other peoples philosophy.Dont get caught up in other peoples philosophy.不要受别的观点的影响不要受别的观点的影响: : Markets do not have to be located next to the receiving Markets do not have to be located next to the receiving docks. docks. 超市不一定要靠近部件接受区超市不一定要靠近部件

33、接受区 Markets do not have to be large in size.Markets do not have to be large in size. 规模不一定很大规模不一定很大 You can have several mini-markets if space is difficult You can have several mini-markets if space is difficult to get. to get. 若空间不够若空间不够, ,可设多个分散的小超市可设多个分散的小超市. .Use your own common senseUse your ow

34、n common sense运用自己的常识来解决问题运用自己的常识来解决问题! !Rules for developing Markets设立“超市”的规则:Have a storage location for every part.Have a storage location for every part. 为每一部件设立储存区为每一部件设立储存区Determine the maximum of any one part that will Determine the maximum of any one part that will be stored. be stored. 为任一需

35、储存部件设立最大库存标准为任一需储存部件设立最大库存标准Provide adequate storage space.Provide adequate storage space. 提供合适的储存区域提供合适的储存区域Safety is a priority.Safety is a priority. 要优先考虑安全因素要优先考虑安全因素. .Lessons Learned about Markets设立超市需注意的几点: Have an overflow spot and a means to monitor.Have an overflow spot and a means to moni

36、tor. 设立库存限制和监控方法设立库存限制和监控方法 Try to reserve spaces for future parts.Try to reserve spaces for future parts. 提前考虑，为以后的部件留出储存空间提前考虑，为以后的部件留出储存空间 Preferably, do not store the same part in more than one Preferably, do not store the same part in more than one location. location. 同一部件最好储存在一个区域同一部件最好储存在一个区域

37、 Make sure aisle ways can accommodate forklifts.Make sure aisle ways can accommodate forklifts. 保证过道可容纳或通行搬运工具保证过道可容纳或通行搬运工具. .Determine customer demand确定客户需求Takt time is a reference number that gives you a Takt time is a reference number that gives you a sense for the pace at which each process nee

38、ds sense for the pace at which each process needs to be producing.to be producing. TAKT TAKT 节拍时间为了解并调整各个工序的生产速度节拍时间为了解并调整各个工序的生产速度提供参考依据提供参考依据To calculate takt time, divide the available time To calculate takt time, divide the available time by the customer demand.by the customer demand. 用可利用的生产时间除

39、以客户需求量，用可利用的生产时间除以客户需求量， 即为节拍时间即为节拍时间. .For our plant对我们公司来说: One shift is nine hoursOne shift is nine hours there is one 60-minute lunchthere is one 60-minute lunch9 9小时一个班次小时一个班次, ,其中有其中有1 1个小时的就餐休息时间个小时的就餐休息时间 Work-time Work-time 工作时间工作时间 8Hrs. X 60min/hr = 480 minutes8Hrs. X 60min/hr = 480 minut

40、es 8 8小时小时 X 60 = 480X 60 = 480分钟分钟 480 minutes per shift480 minutes per shift There is 28,800 seconds per shiftThere is 28,800 seconds per shift480480分钟每个班次分钟每个班次, ,即即28,80028,800秒每个班次秒每个班次Customer demand客户需求The customer needs 2,000 pairs each day.The customer needs 2,000 pairs each day.客户每天需要客户每天需

41、要2,0002,000足鞋足鞋We work one shift each day in Assembly, 6 days per week.We work one shift each day in Assembly, 6 days per week.制造车间每天一个班次制造车间每天一个班次, ,每周工作每周工作6 6天天Customer demand is Customer demand is 客户的需求是客户的需求是: : 2,000 Pairs / 28,800 sec 2,000 Pairs / 28,800 sec 2,000 2,000足足 / 28,800 / 28,800秒秒

42、 or 1 PAIR every 14.4 secondsor 1 PAIR every 14.4 seconds Market setups and locations供应超市准备和位置选定 Locate space within the plant that can be used as a Locate space within the plant that can be used as a market(s).market(s). 选定公司可作为超市的位置选定公司可作为超市的位置 Minimize the number of markets.Minimize the number of

43、 markets. If may be necessary to start with several small ones, If may be necessary to start with several small ones, later to combine into one.later to combine into one. 尽量减少超市的数量尽量减少超市的数量, ,若有必要可先设立几个小的超市若有必要可先设立几个小的超市, ,以后再合并成大的超市以后再合并成大的超市. .Manpower and equipment needed人员和设备要求Parts are delivere

44、d to the line by Material Handlers using Parts are delivered to the line by Material Handlers using hand-carts.hand-carts.搬运人员用手推车将部件运到生产线搬运人员用手推车将部件运到生产线The Material Handler has a designated route that covers all The Material Handler has a designated route that covers all the stations he (or she) i

45、s responsible for.the stations he (or she) is responsible for.搬运人员按照指定的运输路线负责自己的工作区域搬运人员按照指定的运输路线负责自己的工作区域He delivers all parts needed on that delivery cycle, retrieves He delivers all parts needed on that delivery cycle, retrieves all empty containersall empty containers搬运人员必须循环搬运所需部件搬运人员必须循环搬运所需部件

46、, ,并取回空的部件箱并取回空的部件箱Training 培训The people who are affected by the new system need to The people who are affected by the new system need to understand why the company has implemented the understand why the company has implemented the program.program.新体系所涉及到的人员需要懂得为什么公司实施此体系新体系所涉及到的人员需要懂得为什么公司实施此体系Thos

47、e who are to support it must understand how it works.Those who are to support it must understand how it works.支持新体系的人员需懂得体系是怎样运作的支持新体系的人员需懂得体系是怎样运作的All people must receive adequate training in order for the All people must receive adequate training in order for the system to be both robust and succe

48、ssful.system to be both robust and successful.所有相关人员需接受培训以保证新体系的运作效率和成功。所有相关人员需接受培训以保证新体系的运作效率和成功。Training (continued) 培训Remember who the audience is:Remember who the audience is:Production workers have little regard for how Production workers have little regard for how many turns the inventory make

49、smany turns the inventory makesMaterial handlers will not see inventory reduction Material handlers will not see inventory reduction as a benefit.as a benefit.记住谁是培训对象：记住谁是培训对象： 那些对库存的影响不太关心的生产者那些对库存的影响不太关心的生产者 看不到减少库存会带来收益的资材管理者看不到减少库存会带来收益的资材管理者Training (continued) 培训Design your training program(s

50、) using the knowledge youDesign your training program(s) using the knowledge youwill gain in the systems development.will gain in the systems development.运用你在实施运用你在实施NOSNOS的过程中得到的经验来设计培训内容，的过程中得到的经验来设计培训内容，Keep it simple.Keep it simple.使培训内容简洁易懂，使培训内容简洁易懂，Give yourself enough time to handle the toug

51、h questions.Give yourself enough time to handle the tough questions.Respect the peoples concerns.Respect the peoples concerns.用足够的时间来解决比较棘手的问题，尊重别人的意见。用足够的时间来解决比较棘手的问题，尊重别人的意见。Results of a Pull System生产拉动体系的结果In operations where the implementation has been successful, both the management and workforce believe the work environment to be “enhanced”在拉动体系取得成功的那些环节,无论是管理层还是工人都会认为他们的工作环境正在改善。Results of a Pull System生产拉动体系的结果Where there has been little effort to make the system work, the plant typically has shortages and misses delivery windows.若工厂没有努力去实现拉动生产，就会出现部件投入不足和不能按照生产需要来搬运部件。