WIP的危害原因消除及案例详细展开.ppt

* 计算盒数时考虑不够一个看板（例中为一盒）时的处理-以整盒计（四舍五入法） * 例中台面只是一种承载方式，可有其它选择，适用就行； 可以的话，装警报装置-在中间两盒下设一微动开关，外接蜂鸣器，当中间最后一盒取走即刻鸣叫，提醒前工段需补给货物了 * 新设工厂或扩大经营，应最大程度上采用“流线化生产”布局方式；相对于“并行式”排拉方式 * * * * 平衡前面讲过，可稍加回顾！ * 滑槽等辅助方式，只是当工站间存在传递困难时才采用，不需要辅助工具能实现传递则最佳！ * 理解WIP削减是如何地增加流动资金、减少利息支出？ 企业资金来源有二：自存积金和借贷筹资。库存是要用资金来购买的，动用借贷就意味着需付出利息 * 降低库存何以使问题“浮现”？ * 降低库存的过程本身就是全员挑战整个物料管控的过程 * * Change to Before: Straight line with huge WIP and lower flow. Use trays to transfer parts. After: Split line to 6 cells with same function. Transfer parts one by one. Metrics Before Update Improving % WIP (pcs) 3600 420 88% Lead Time (minutes) 12.8 1.2 90% PPH 120 150 25% Remark: A- Tape part B- Install LED C- Apply glue D- Install light pipe A A A A A A B B B B B B C C C C C C D D D D D D In Out A B C D In Out A B C D In Out A B C D In Out A B C D In Out A B C D In Out A B C D In Out Metrics Before Update Improving % WIP (pcs) 3760 840 77% PPH 94 120 27% * Before: Straight line with huge WIP and extra motions. After: Reduce WIP and increase efficiency through performing one-piece flow. Change to Use slide way to make one-piece flow happen * Metrics Before Update Improving % WIP (pc) 124 30 75% PPH 200 250 25% Before： Use a fixture soldering module, one fixture holds 4 modules. Fixture with 4 modules can’t be transferred to next step until each operator finishes soldering 4 modules. Next step Change to Fixture Module Next step After： Arrange 4 operators as a group. The first operator only solders the first module, then transfers the fixture to the second person who solders the second module … Part flows faster * 焗炉 Change to Metrics Before Update Improving % Efficiency 96% 114% 18% Lead Time (minutes) 15.3 11 28% Conveyor Belt (set) 1 0 A set of conveyor belt saved. Before： Straight line with extra motion of loading unloading parts. Part flows slowly. Operators need to frequently turn about their bodies. Conveyor Belt Slide Way After： Adopt slide way instead of conveyor be