精益生产之箱补充拉系统BinReplenishmentPull中.pptx

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to Edit Master Title Style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Improve,Click to Edit Master Title Style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Improve,2-,Bin Replenishment Pull,Introduction to 2-Bin Replenishment Pull,Line-side versus Point-of-Use Stocking,2-Bin Data Needs and Calculations,Inventory Disposition Options,Card Triggered 2-Bin Process,1-Bin Systems,Appendix,RD011202,第1页,2-,Bin,补充拉系统,2-,箱补充拉系统介绍,线旁,VS,使用点库存,2-,箱数据要求和计算,库存布署选择,卡触发2-箱流程,1-,箱系统,附录,RD011202,第2页,Lean Six Sigma Improvement Process Road Map,Analyze,Control,Improve,Define,Identify Problem,Develop List of Customers,Develop List of CTQs from Voice of the Customer,Finalize Project Focus and Key Metrics,Complete PDF,Measure,Map Business Process,Map Value Stream,Develop DataCollection Plan,Conduct MeasurementSystem Analysis,Collect Data,Conduct Process Capability Analysis,Analyze,Propose Critical Xs,Prioritize Critical Xs,Verify Critical Xs,Estimate the Impact of Each X on Y,Quantify the Opportunity,Prioritize Root Causes,Conduct Root Cause Analysis on Critical Xs,Improve,Critical Xs Confirmed,Develop Potential Solutions,Select Solution,Optimize Solution,Pilot Solution,Control,Implement Process Changes and Controls,Write Control Plan,Calculate Final Financial/,Process Metrics,Transition Project to Future Owners,Identify Project,Translation Opportunities,Measure,Define,Project ID Tools,Project Definition Form,Net Present Value Analysis,Internal Rate of Return Analysis,Discounted Cash Flow Analysis,PIP Management Process,RACI,Quad Charts,Process Mapping,Value Analysis,Brainstorming,Multi-Voting Techniques,Pareto Charts,C&E/Fishbone Diagrams,FMEA,Check Sheets,Run Charts,Control Charts,Gage R&R,C,p,&C,pk,SupplyChainAccelerator Analysis,Multi-Vari,Box Plots,Interaction Plots,Regression,ANOVA,C&E Matrices,FMEA,Brainstorming,Pull Systems,Setup Reduction,TPM,Process Flow,Benchmarking,Affinity,DOE,Hypothesis Testing,Force Field,Tree Diagrams,Gantt Charts,Check Sheets,Run Charts,Histograms,Scatter Diagrams,Control Charts,Pareto Charts,Interactive Reviews,Poka-Yoke,Revised 1-12-02,3,2-Bin Replenishment Pull,第3页,Learning Objectives,Understand the various types of bin replenishment systems,Know the benefits of a bin system,Understand when to use a bin System,Be able to size(calculate)all the parameters for a bin system,4,2-Bin Replenishment Pull,第4页,课程目,了解箱补充系统不一样类型,知道一个箱系统好处,了解何时使用一个箱系统,能够去计算一个箱系统全部参数,5,2-Bin Replenishment Pull,第5页,Whats in It for Me?,Be able to apply this tool to a Black Belt project,Able to implement a Bin system,6,2-Bin Replenishment Pull,第6页,我学到了什么?,能够在黑带项目中应用这个工具,能够实施一个箱系统,7,2-Bin Replenishment Pull,第7页,2-,Bin Replenishment Pull Introduction,A 2-Bin Replenishment Pull System is a simplified version of a standard replenishment pull system and maintains the benefits:,Establishes strategically located buffers of parts within a process,Raw material,Manufactured parts,Purchased parts,Finished goods,De-couples the supplying process from the consuming process via the buffer inventory,Part replenishment is“triggered”based on consumption,8,2-Bin Replenishment Pull,第8页,2-箱补充拉系统介绍,2-,箱补充拉系统是一个标准补充拉系统简化版本，其好处是：,在一个流程中建立战略性零件缓冲区,原材料,制造零件,采购零件,成品,经过缓冲库存将供给过程和消耗过程联络起来,零件补充是基于消耗而触发,9,2-Bin Replenishment Pull,第9页,What Is a 2-Bin Replenishment?,For many parts in a process,a 2-Bin system can be used to replenish the parts versus a synchronous supply:,A bin has enough parts/supplies to cover a calculated period of usage at the point-of-use.,When the bin runs out,a 2nd bin is there to take its place while the“1st”is being refilled/replenished.,There are two primary replenishment locations:Line-Side and Point of Use,10,2-Bin Replenishment Pull,第10页,2-,箱补充拉系统是什么?,对于在流程中众多零件而言，一个2-箱系统能够被用来补充零件相对于同时供给,:,一箱有足够零件/供给品以满足在使用点上已计算出用量周期,。,当第一箱用完了后，在补充/重新装料时，第二箱取代第一箱位置继续满足使用。,有两个主要补充地点：线旁和使用点,11,2-Bin Replenishment Pull,第11页,Benefits of 2-Bin Replenishment,Organized and overall cleaner appearance of stored materials,Reduced frequency of orders submitted to the stockroom/vendor,Reduced number of trips for re-supply,Better management of inventory on the shop floor,More predictable inventory costs,Improve employee productivity by:,Eliminating part/supply shortages at the point-of-use,Reduce time wasted by personnel/supervision retrieving supplies/inventory from the stockroom and/or vendors,Eliminate lost or misplaced material,2-Bin Replenishment can be used for office/safety supplies,production inventory,production supplies even at home!,12,2-Bin Replenishment Pull,第12页,2-,箱补充拉系统好处,存放材料外观非常清洁和有条理,提交给库房/供给商频率降低,重复供给差错数量降低了,现场库存管理更加好,库存成本更含有预测性,提升员工生产率,:,排除在使用点零件/供给短缺,降低因为人员/管理等，从库房和/或供给商重新找回供给/库存时间浪费,排除材料丢失或放错地方,2-,箱补充能够被使用在办公室，安全供给，生产库存，生产供给甚至在家里,!,13,2-Bin Replenishment Pull,第13页,When to Use 2-Bin Replenishment Pull,Repetitive product offering/process,Relatively consistent demand/volume(low variability),Part/supply shortages are a consistent/costly problem,Part/supply inventory costs are“out of control”due to:,Lost or misplaced parts/supplies,Lack of issue/dispersal discipline or control,14,2-Bin Replenishment Pull,第14页,何时使用2-箱补充拉系统,重复产品供给/流程,重复稳定需求,(,底变异,),零件,/,供给短缺是常事，且是一个代价很大问题,零件/供给库存成本是失控，因为：,零件/供给品丢失或放错地方,缺乏投料/分发一致性或控制,15,2-Bin Replenishment Pull,第15页,What Is a Bin?,Doesnt necessarily look like a“bin”,Can be a standard plastic bin(Acro-bin),Can,also,be the box/container the part/supply is shipped in(also called a“standard pack”purchasing definition),When the box/container method is used,a“bin”can be one standard pack or several standard packs.Examples:,1 box of screws,2 boxes of screws,1 drum of oil,30 bags of connectors,1 roll of labels,4 tubes of sealant,16,2-Bin Replenishment Pull,第16页,一箱是什么?,这并不是说一定要看上去像个“箱子”,它能够是一个标准塑料箱,它也能够是用于零件运输一个盒子或容器,(,也能够用采购定义被称为一个“标准包,”),当盒子/容器方式使用了后,一个“箱”能够是一个标准包或几个标准包。比如：,1,盒螺钉,2,盒螺钉,1,打油,30,包连接器,1,卷标贴,4,管子密封剂,17,2-Bin Replenishment Pull,第17页,2-,Bin Replenishment Data Parameters/Needs,Demand/Usage(DMD),Typically expressed in terms of Average Daily Usage(ADU)in units,Lead Time(LT),The time it takes from when a trigger is sent to when replenishment arrives,In this case,can also be thought of as“Restocking Time”,Order Frequency(OF),If orders/triggers are sent at scheduled times(i.e.,not every day,such as once per week),Typical 2-Bin systems do not use an Order Frequency,as replenishment can occur every day/shift(or more),Box/Container Quantity,If stock/supply room or vendor does not break down shipping quantity,then the bin quantity may be set equal to some multiple of the box/container quantity(standard pack)that the part/supply is shipped in,Safety Stock,Typically 1/2 the max(LT,OF)*DMD,may be set otherwise dependent on individual conditions,18,2-Bin Replenishment Pull,第18页,2-箱补充系统数据参数/要求,需求/使用(,DMD),普通来说用平均天天用量（,ADU）,来表示,交货期(,LT),从补充需求触发到补充品抵达时间。,在这里，也能够被认为是“再进货时间”。,订单频率(,OF),假如订单/触发信号发放是按预定时间（如：并不是天天，而是每七天一次）,2-,箱系统是不需要用订单频率。补充能够发生在天天、每班（或更多）,盒子/容器数量,假如库房或供给商没有列出运输数量明细分类，那么箱数量能够设定为等于运输零件/供给品若干盒子/容器数量,安全库存,普通来说设定为,1/2 max(LT,OF)*DMD,不然依据独立情况来看,19,2-Bin Replenishment Pull,第19页,Stock Room or Vendor,1,2,Full,Bin/Card,Move 1 to,2 when 2,is pulled,Send Trigger,Use,Components,Empty,Bin/Card,Point-Of-Use(POU)Locations,or Work-In-Process(WIP),2-,Bin Replenishment(“Line-Side”Stocking),Reduces part/supply shortages increasing productivity,Facilitates WIP reduction,Will result in significant productivity improvements in stock/supply room,Reduces/eliminates stockroom impact on lot sizes,May simplify inventory/cycle count processes,Line-Side,Storage,LT,OF,2,20,2-Bin Replenishment Pull,第20页,库房或,供给商,1,2,添满,箱/卡,当 2 被拉动时，移动,1,到,2，,发送触发信号,使用,部件,空,箱/卡,使用点位置,(POU),或工作库存,(WIP),2-箱补充(“线旁”库存),降低零件/供给品库存，增加生产效率,促进,WIP,降低,将造成在库房里显著生产力提升,降低/消除库房在批数量上影响,能够简单化存货/周转计算流程,线旁库存,LT,OF,2,SS/2,DMD,OF),LT,max(,箱数量,+,*,=,21,2-Bin Replenishment Pull,第21页,Full,Bin/Card,Pull from 1 until empty,send trigger and pull from 2 until empty,send trigger,etc.,Use,Components,Empty,Bin/Card,2-,Bin Replenishment(“Point-of Use”Stocking),LT,OF,1,2-,Bin POU stocking is used when re-stocking is not an issue.,Stock Room or Vendor,Point-Of-Use(POU)Locations,or Work-In-Process(WIP),2,22,2-Bin Replenishment Pull,第22页,拉动从1开始直到用完为止,发送触发信号，然后拉动从2开始直到用完为止，发送触发信号,等等,.,使用,部件,2-箱补充(“使用点”库存,),LT,OF,1,SS/2,DMD,OF),LT,max(,箱数量,+,*,=,当重新备库存不是一个问题时，使用2-箱,POU,库存,库房或,供给商,2,添满,箱/卡,空,箱/卡,使用点位置,(POU),或工作库存,(WIP),23,2-Bin Replenishment Pull,第23页,2-,Bin Replenishment Calculations,Bin Quantity=Max(LT,OF)+SS/2,If replenishing in standard packs,Bin Quantity is rounded up to the nearest standard pack multiple,Example:,Calculate the Bin Quantity for the following(standard pack replenishment):,Part Number:40567,Description:Rubber Gloves,Demand/Usage:25 pairs/day,Lead Time:2 days(trigger-stock/supply room-replenishment),Order Frequency:N/A,Box Quantity:50 pairs,Bin Quantity,=Max(2 days,N/A)*25 pairs/day+.5*Max(2 days,N/A)*25 pairs/day/2,=63 pairs,But,we have to round up to the nearest standard pack,so:,Bin Quantity=100 pairs=2 boxes,24,2-Bin Replenishment Pull,第24页,2-箱补充计算,箱数量=,Max(LT,OF)+SS/2,假如是标准包补充，箱数量应该是近似于标准包倍数,举例:,计算以下数据箱数量,(,标准包补充,):,零件号码:40567,描述:橡胶手套,需求/用量:25 双/天,交货时间:2 天,(,触发,库房,补充,),订单频率:不适用,箱数量:50 双,箱数量,=Max(2,天,N/A)*25,双/天,+.5*Max(2,天,N/A)*25,双,/,天/2,=63,双,不过,我们要取一个近似标准箱数量，所以,:,箱数量=100 对,=2,箱,25,2-Bin Replenishment Pull,第25页,Exercise#1:,2-Bin Replenishment,Calculate the Bin Quantity for the following supply item in a 2-Bin Line-Side Replenishment process directly linked to the supplier:,Part Number:80886,Description:Printer Paper,Demand/Usage:22 reams/day,Lead Time:4 days(trigger-purchasing-supplier-receiving-replenishment),Order Frequency:5 days,Box Quantity:10 reams,Bin Quantity,=Max(,)*,+.5*Max(,)*,/2,=,.,But,we have to round up to the nearest standard pack,so:,Bin Quantity=,=,.,26,2-Bin Replenishment Pull,第26页,练习#1:,2-箱补充,以下供给品2-箱线旁补充流程直接连接着供给商，计算箱数量,:,零件号码:80886,描述:打印纸,需求/用量:22 令/天,交货时间:4 天,(,触发,采购,运输,收货,补充,),订单频率:5 天,箱数量:10 令,箱数量,=Max(,)*,+.5*Max(,)*,/2,=,.,不过,我们要取一个近似标准包数量，所以,:,箱数量=,=,.,27,2-Bin Replenishment Pull,第27页,Exercise#2:,2-Bin Replenishment,Calculate the Bin Quantity for the following assembly item in a 2-Bin Line-Side Replenishment process linked to the warehouse:,Part Number:A44B2,Description:4 Dia.Steel Extrusion,Demand/Usage:225 ft/day,Lead Time:1 day(trigger-warehouse-replenishment),Order Frequency:N/A,Extrusion Length:30 ft,Bin Quantity,=Max(,)*,+.5*Max(,)*,/2,=,.,But we have to round up to the nearest standard pack,so:,Bin Quantity=,=,.,28,2-Bin Replenishment Pull,第28页,练习#2:,2-箱补充,以下组装线2-箱线旁补充流程直接连接着供给商，计算箱数量,:,零件号码:,A44B2,描述:直径4“钢铁拉丝,需求/用量:225 英尺,/,天,交货时间:1 天,(,触发 仓库,补充,),订单频率:不适用,拉丝长度:30 英尺,箱数量,=Max(,)*,+.5*Max(,)*,/2,=,.,不过,我们要取一个近似标准包数量，所以,:,箱数量=,=,.,29,2-Bin Replenishment Pull,第29页,1,2-,Bin ReplenishmentBin Labeling and Information,Each Bin/Storage Location should have a barcode label or tag.,Make sure not to use a permanent label applied to a rack/bin,because you will eventually want to resize and may have to make new labels!,Labels for Line Side Bins/Tags for Resupply Bins,Part Number,Description,and Location are Printed.,Bin Quantity should not be printed(requires too many label changes when resizing trigger mechanism or system will have Bin Quantity),Each Bin Location should be unique to avoid confusion when restocking.,Examples are in the Appendix.,Location,Part Number,Description,2,Location,Part Number,Description,30,2-Bin Replenishment Pull,第30页,1,2-箱补充箱标贴和信息,每个箱/库存 地点都应该有一个条码标贴或标签,确保不要用永久标签贴在一个货架/箱。因为你将会调整大小，且贴上一个新标贴！,在线旁需要重新补充箱上标贴,被打印零件号码,描述,地点等,箱数量不应该被打印出来,(,当调整大小时需要太多标签改变,触发机制或系统将有箱数量,),每个箱地点必须是独一无二以防止在重新补充库存时混同,举例在附件里,.,地点,零件号码,描述,2,地点,零件号码,描述,31,2-Bin Replenishment Pull,第31页,Notes on a 1-Bin System,A one bin system is an exception to the 2-bin for very slow moving parts/supplies.,1-bin parts are not stored in 2-bins because of:,High inventory cost,Space requirements,Racking/storage cost,1-bins are replenished upon stock out at the Line-Side location.,Stock out impact should be low because:,Parts/supplies are very low users.,Parts/supplies are also at point of use when Line-Side stock out occurs.,Parts/supplies are stocked in nearby stock/supply room easy to replace.,32,2-Bin Replenishment Pull,第32页,1-,箱系统注意,对于流动非常迟缓零件/供给品来说，一个1-箱系统是2-箱系统例外,.,1-,箱零件不象2-箱那样被存放，因为,:,高库存成本,空间需要,货架/仓储成本,在线旁地点库存短少时，1-箱被补充。,库存短少影响应该是微弱，因为,:,零件/供给品是非常少使用者。,当线旁存货短缺发生时，零件/供给品也一样在使用点,.,零件/供给品被存放在库房附近轻易补充,.,33,2-Bin Replenishment Pull,第33页,Stock Room or Vendor,1,1,Full,Bin/Card,Move 1 to,2 when 2,is pulled,Send Trigger,Use,Components,Empty,Bin/Card,Point-Of-Use(POU)Locations,or Work-In-Process(WIP),1-,Bin Replenishment(Typically from“Line-Side”),Reduces part/supply shortages increasing productivity,Facilitates WIP reduction,Will result in significant productivity improvements in stock/supply room,Reduces/eliminates stockroom impact on lot sizes,May simplify inventory/cycle count processes,Line-Side,Storage,LT,OF,1,34,2-Bin Replenishment Pull,第34页,库房或,供给商,1,1,1-箱补充(尤其是从,“,线旁,”),LT,OF,1,添满,箱/卡,空,箱/卡,当 2 被拉动时，移动,1,到,2，,发送触发信号,使用点位置,(POU),或工作库存,(WIP),降低零件/供给品库存，增加生产效率,促进,WIP,降低,将造成在库房里显著生产力提升,降低/消除库房在批数量上影响,能够简单化存货/周转计算流程,线旁库存,SS/2,OF),LT,max(,箱数量,+,*,=,使用,部件,DMD,35,2-Bin Replenishment Pull,第35页,Stockroom,or Vendor,1,Line POU,1-,Bin Replenishment Transactions,1-,Bin System inventory transactions mirror those of the 2-Bin system,Frontflush,for reducing transactions but reduce overall inventory accuracy,Backflush,for increasing inventory accuracy(slightly)but increase number of system transactions,1,1-,bin Card Part XYZ,Trigger,Replenishment,1-,bin Card Part XYZ,36,2-Bin Replenishment Pull,第36页,库房或,供给商,1,线,POU,1-箱补充事务处理,1-箱系统库存交接与2-箱系统相同,前端堆积,降低交接过程但降低总体库存量准确性,后端堆积,增加了库存准确性（幅度轻微）但增加了系统处理事务量,1,1-箱卡零件,XYZ,触发,补充,1-箱卡零件,XYZ,37,2-Bin Replenishment Pull,第37页,Takeaways,Know the the various types of Bin Replenishment systems,Be able to describe the benefits of a Bin system,How to size(calculate)all the parameters for a Bin system,38,2-Bin Replenishment Pull,第38页,总结,知道箱补充系统不一样类型,能够描述一个箱系统利益,能够去计算一个箱系统全部参数,39,2-Bin Replenishment Pull,第39页,APPENDIX,2-Bin Replenishment Pull,第40页,附录,2-箱补充拉系统,第41页,Instructions for Typical Card Triggered 2-Bin Replenishment,This process uses green and red cards to trigger replenishment;“bins”are actually,the box/container the part/supply is shipped in.,1.Employee removes a bin and drops its green 2-bin card into the mailbox:,Pull parts from“bin”with green card before using any with the red card.,2.At same time(s)each day,the cards are picked up from the mailbox and returned to the stock/supply room.,3.The stock/supply room pulls proper amount of parts/material(noted on card,set equal to the calculated“bin”quantity).,4.Inventory transactions are performed(depending on issue method),and the materials and cards are delivered to the storage location.,5.Employee stocks material in storage location and returns card to its proper place.,When stock/supply room rep