及时化生产系统.ppt
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1、及時化生產系統,1,及時化(just in time,JIT)概述,提出者:豐田汽車副社長,大野耐一(Taiichi Ohno)。意義將需要的物品在必須的時間供應必須的品質與數量到需要的地點。目的消除混亂使系統彈性化降低籌置與前置時間存量最小化消除浪費,及時化生產系統,2,JIT目標和建築架構的歸納,及時化生產系統,3,常見的資源浪費1,超額生產(overproduction)等候時間(waiting time)不必要的運送(unnecessary transporting)存貨(inventory)加工浪費(processing waste)不必要的生產步驟產出瑕疵品,及時化生產系統,4,常
2、見的資源浪費2,無效的工作方法(inefficient work method)不佳的佈置和物料搬運模式,增加在製品存貨產品不良再製成本消費者不滿意造成銷售損失,及時化生產系統,5,Waste in Operations,及時化生產系統,6,Waste in Operations,及時化生產系統,7,Waste in Operations,及時化生產系統,8,消除浪費之改善哲學1,視浪費為敵人,消除浪費是首要之務。改善需逐步且持續地進行,而非間歇性地進行大規模改善。每個人都必須參與。改善原則在於利用經濟的策略即可達成,不需花費昂貴的技術或顧問。改善的方法可以應用於各種地方。,及時化生產系統,9
3、,消除浪費之改善哲學2,藉由目視系統達成:作業程序和製程等皆透明化,使得問題與浪費清晰易見。專注於創造價值之處。以流程為導向。主要的改善努力著重於新的想法和新的工作方式。組織學習的本質即為做中學。,及時化生產系統,10,Basic Elements of JIT1,標準的零件(產品設計)模組化設計(產品設計)高產能的系統(產品設計)可同時生產(產品設計),將員工視為資產(人員/組織的要素)訓練員工,使其變成多能工(人員/組織的要素)持續改善(人員/組織的要素)成本會計(人員/組織的要素)領導與專案管理(人員/組織的要素),及時化生產系統,11,Basic Elements of JIT2,Ce
4、llular layouts(製程設計Pull production system(製造規劃與控制)Flexible resources(製程設計)Kanban production control(製造規劃與控制)Small-lot production(製程設計),Quick setups(製程設計)Uniform production levels(製造規劃與控制)Quality at the source(製程設計)Total productive maintenance(製造規劃與控制)Supplier networks(製造規劃與控制),及時化生產系統,12,Flexible Re
5、sources,Multifunctional workers(多能工)Perform more than one jobGeneral purpose machines(通用設備)Perform several basic functionsStudy operators&improve operations,及時化生產系統,13,Cellular Layouts,Group dissimilar machines in manufacturing cell to produce family of partsWork flows in one direction through cellC
6、ycle time adjusted by changing worker paths,及時化生產系統,14,Manufacturing Cell with Worker Routes,及時化生產系統,15,Worker Routes Lengthened as Volume Decreases,及時化生產系統,16,推式與拉式系統,推式系統(push system)(例如,MPR)當工作在某工作站完成時,產出就被推往下一站。拉式系統(pull system)(例如,JIT)工作移動的控制落於下一站;每一工作站從前一站拉拔所需產出。,及時化生產系統,17,Kanban Production C
7、ontrol System(看板生產管制系統),Kanban card indicates standard quantity of productionDerived from two-bin inventory system(雙倉制)Kanban maintains discipline of pull productionProduction kanban(生產看板)authorizes productionWithdrawal kanban(提領看板)authorizes movement of goods,及時化生產系統,18,A Sample of Kanban,及時化生產系統,1
8、9,The Origin of Kanban,及時化生產系統,20,Single-Card Kanban System,及時化生產系統,21,Storage area,Empty containers,Full containers,Single-Card Kanban System,Receiving post,Kanban card for product 1,Kanban card for product 2,及時化生產系統,22,Storage area,Empty containers,Full containers,Single-Card Kanban System,Receivi
9、ng post,Kanban card for product 1,Kanban card for product 2,及時化生產系統,23,Storage area,Empty containers,Full containers,Single-Card Kanban System,Receiving post,Kanban card for product 1,Kanban card for product 2,及時化生產系統,24,Storage area,Empty containers,Full containers,Single-Card Kanban System,Receivi
10、ng post,Kanban card for product 1,Kanban card for product 2,及時化生產系統,25,Storage area,Empty containers,Full containers,Single-Card Kanban System,Receiving post,Kanban card for product 1,Kanban card for product 2,及時化生產系統,26,Storage area,Empty containers,Full containers,Single-Card Kanban System,Receivi
11、ng post,Kanban card for product 1,Kanban card for product 2,Fabrication cell,O1,O2,O3,O2,及時化生產系統,27,看板系統 single kanban,及時化生產系統,28,Types of Kanbans Dual kanbans,及時化生產系統,29,Dual kanban vs.single kanban,Dual kanbanIs used when material is not necessarily moving between two consecutive processes,or when
12、 there is more than one input to a process and the inputs are dispersed throughout the facility.Single kanbanIs used when the processes are tightly linked.,及時化生產系統,30,Types of Kanbans,Kanban SquareMarked area designed to hold itemsSignal KanbanTriangular kanban used to signal production at the previ
13、ous workstationMaterial KanbanUsed to order material in advance of a processSupplier KanbansRotate between the factory and suppliers,及時化生產系統,31,Types of Kanbans kanban square and kanban racks,及時化生產系統,32,Types of Kanbans signal kanbans,及時化生產系統,33,看板管理系統之規則,不要把不良品交給後製程。由後製程到前製程來領取零件。前製程僅生產將被後製程領用去的數量。
14、生產必須平衡。看板只做為微調整的手段,其張數必須減到最少。製程必須安定化、合理化。,及時化生產系統,34,Single-Card Kanban System,KANBAN,Part Number:1234567ZLocation:Aisle 5Bin 47Lot Quantity:6Supplier:WS 83Customer:WS 116,Each container must have a cardAssembly always withdraws from fabrication(pull system)Containers cannot be moved without a kanba
15、nContainers should contain the same number of partsOnly good parts are passed alongProduction should not exceed authorization,及時化生產系統,35,看板(容器)數量之決定1,K=容器數量。d=工作中心之計劃使用率(預期每日需求)。p=每箱容器零件之平均加工時間。W=在生產過程中之平均等候時間,加上每箱物料的搬運時間。C=標準容器之零件容量。X=政策變數。反應生產系統的效率(10%以內),及時化生產系統,36,看板(容器)數量之決定2,及時化生產系統,37,看板(容器)數
16、量之決定3,whereN=number of kanbans or containersd=average demand over some time periodL=lead time to replenish an orderS=safety stockC=container size,及時化生產系統,38,容器數量決定範例,某汽車零件公司生產4輪傳動車的方向盤及暫停系統中的搖桿手臂組合。一般1箱零件在製造週期中需要0.02天的加工及0.08天的物料處理和等候時間。零件每日的需求為2000個單位。管理部門認為搖桿手臂組合的需求不確定,所以其安全庫存為需求量的10%。若每箱內各有22個零件,
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