精益生产-Generic_Pull_System(中英文对照)

MeasureAnalyzeControlImproveLeanSixSigmaGenericPullSystemDefinitionofGenericPullBestPracticeCaseExamplesHowtoDetermineGenericPullLevelsExerciseAntennaSimulationRD010402MeasureAnalyzeControlImproveLeanSixSigma普通拉系统定义普通拉系统的最佳实践案例举例如何去决定普通拉水准练习天线模拟RD010402ImproveGenericPullSystem3LeanSixSigmaImprovementProcessRoadMapAnalyzeControlImproveDefine•IdentifyProblem•DevelopListofCustomers•DevelopListofCTQ’sfromVoiceoftheCustomer•FinalizeProjectFocusandKeyMetrics•CompletePDFMeasure•MapBusinessProcess•MapValueStream•DevelopDataCollectionPlan•ConductMeasurementSystemAnalysis•CollectData•ConductProcessCapabilityAnalysisAnalyze•ProposeCriticalX’s•PrioritizeCriticalX’s•VerifyCriticalX’s•EstimatetheImpactofEachXonY•QuantifytheOpportunity•PrioritizeRootCauses•ConductRootCauseAnalysisonCriticalX’sImprove•CriticalX’sConfirmed•DevelopPotentialSolutions•SelectSolution•OptimizeSolution•PilotSolutionControl•ImplementProcessChangesandControls•WriteControlPlan•CalculateFinalFinancial/•ProcessMetrics•TransitionProjecttoFutureOwners•IdentifyProject•TranslationOpportunitiesMeasureDefine•ProjectIDTools•ProjectDefinitionForm•NetPresentValueAnalysis•InternalRateofReturnAnalysis•DiscountedCashFlowAnalysis•PIPManagementProcess•RACI•QuadCharts•ProcessMapping•ValueAnalysis•Brainstorming•Multi-VotingTechniques•ParetoCharts•C&E/FishboneDiagrams•FMEA•CheckSheets•RunCharts•ControlCharts•GageR&R•Cp&Cpk•SupplyChainAcceleratorAnalysis•Multi-Vari•BoxPlots•InteractionPlots•Regression•ANOVA•C&EMatrices•FMEA•Brainstorming•PullSystems•SetupReduction•TPM•ProcessFlow•Benchmarking•Affinity•DOE•HypothesisTesting•ForceField•TreeDiagrams•GanttCharts•CheckSheets•RunCharts•Histograms•ScatterDiagrams•ControlCharts•ParetoCharts•InteractiveReviews•Poka-YokeRevised1-12-02ImproveGenericPullSystem4LearningObjectivesUnderstandthebestpracticedefinitionHowtoapplythisbestpracticeinvariousenvironmentsAbletodeterminethelevelsofinventoryusingthefivestepsDemonstratethisbestpracticethroughexercisesandsimulationImproveGenericPullSystem5课程目的理解最佳实践的定义如何在多变的环境中应用这个最佳实践能够去决定库存的水平用5个步骤通过练习和模拟来示范这一最佳实践ImproveGenericPullSystem6What’sinItforMe?UnderstandthereasonforthistoolindifferentenvironmentsHowtousethistoolforpotentialblackbeltprojectsImproveGenericPullSystem7我学到了什么?理解在不同环境中使用这个工具的原因对于黑带潜在项目如何去使用这个工具ImproveGenericPullSystem8GenericPullSystemsGenericPullSystemslimittheamountofWork-In-Processinventoryinordertocontrolcycletime.ImproveGenericPullSystem9普通拉系统普通拉系统为了控制周转时间限制了制程库存的数量（Work-In-Process）.ImproveGenericPullSystem10WIPCapExitsStartsTriggerGenericPullSystemDefinedDefinition:AGenericPullSystemestablishesaWIPcapontheamountofinventorywithinapredefinedphysicalworkarea(setofworkstations)orprocess.TomaintaintheWIPcap,exitsfromtheprocesstriggerstartsintotheprocess.EstablishingWIPcapisthekeytocycletimereduction!!ImproveGenericPullSystem11WIPCapExitsStartsTrigger普通拉系统的定义定义:一个普通拉系统是在一个预先确定的物理工作区域（工作站）或流程中，在存货金额上建立了一个WIPcap.来维护WIPcap,从流程中的“出口”（exits）来触发进入流程的“出发”（Starts).建立WIPcap是降低周转时间的关键ImproveGenericPullSystem12WhentoUseGenericPullAlwaysGenericPullsystemscanbeusedinanyofthefollowingmanufacturing/transactionalenvironments:Repetitiveprocess/repetitiveproductSimilarproducts/partsrunwithinsameprocessflowExample:Automotiveassemblyline,customerorderprocessingRepetitiveprocess/non-repetitiveproductDissimilarproducts/partsrunwithinsameprocessflowExample:Buildtoorderprintedcircuitboardmanufacturer,customercomplaintprocessingNon-repetitiveprocess/non-repetitiveproductDissimilarproducts/partsrunwithinadissimilarprocessflowExample:Machinemodel/prototypeshop,NPIprocessesGenericPullsystemsshouldalwaysbeusedwhenareplenishmentpullsystemisimplementedImproveGenericPullSystem13何时使用普通拉系统永远普通拉系统可以被使用在下列任何制造/事务处理的环境中:重复的流程/重复的产品类似的产品/零件在同一个流程中运行例如:汽车的组装线,客户定单流程重复的流程/不重复的产品不同的产品/零件在同一个流程中运行例如:根据定单定制的电路板制造商,客户投诉流程不重复的流程/不重复的产品不重复的产品/零件在不同的流程里运行例如:机器模型/原型制作车间,NPI流程当补充拉系统被实施时，普通拉系统将永远被使用ImproveGenericPullSystem14WhenflyingfromDFWtoO’Hare,weoftenwindupwaitingonthegrounddueto“flowcontrol.”SinceO’Hareisoverloaded,airtrafficcontrolkeepsusinDallasuntilthecongestionoverO’Hareclears,versusgettingthereandcirclingChicago.Eitherway,weenduplate.However,usingthe“flowcontrol”(fixedWIP)method,weuselessfuelandreducetheriskofanaccident.Inaddition,wekeepouroptionsopen(suchasre-routingiftheweatherbecomestoobad).Inapullsystem,maintaininga“fixedWIP”keepsworkordersinpaperformaslongaspossible.Thisprovidesthegreatestflexibilitytoschedule/engineeringchanges.Inaddition,lowWIPmeansafastercycletime,whichincreasestheprobabilityreleasesarebasedonactualcustomerordersversusforecast.“FixedWIP”ImprovesFlexibilityImproveGenericPullSystem15当航班从DFW到O’Hare,我们通常由于“流控制”而在地面上紧张的等待。因为O’Hare机场超负荷了,空中交通控制要求我们在达拉斯等待，直到O’Hare的堵塞清除掉；与在芝加哥上空盘旋相比，任何一条路都注定会让我们晚点。可是，使用“流控制”(固定WIP)方式,我们用的燃油更少且降低了事故的风险.此外,我们仍然享有我们的选择权(例如重新选择路线如果天气变的更糟的话).在一个拉系统中，维护一个“固定WIP”可以使工作指令尽可能的在计划阶段。这样为制定计划/工艺变更提供了最大的弹性。此外，底WIP意味着更快的周转时间，这样可以增加基于客户的订单而不是根据预测“固定的WIP”改善弹性ImproveGenericPullSystem16ThePowerofaWIPCapWIPCap–Cycletimeisreducedan