精益生产衡量指标

精益生产的衡量指标Leanmanufacturingmeasuring*进料仓库道出货仓库时间------DTDDocktoDock*首次合格率------FTTFirsttimethrough*依排成生产------BTSBuildtoschedule*总何设备效率------OEEOverallequipmenteffectiveness进料到出货时间DocktoDockTimeDTDDocktoDockTime(DTD)*Definition定义.从原物料下货到完成成品出货之间的过去时间theelapsedtimebetweentheunloadingofrawmaterialsandthereleaseoffinishedgoodsforshipment.总DTD时间为产品耗费时间如原物料，制程作业，与在厂完成品出货前在品的时间thetotaldocktodocktimeforaproductincludesthetimethataproductspendsasrawmaterial,work-inprocessandasafinishedproductinplant,priortobeingrelaesed.出貨進料進料倉庫成品倉庫進料倉庫到出貨倉庫時間(DTD)製造週期時間(MCT)生產製造過程衡量指標(DTD)衡量指标-DTDDTD–從进料仓库到出貨仓库間时间指原料進廠製成完成品準備出貨的時間包含製造週期時間DTD-是衡量（时数）物料通过工厂的速度，不是程序的速度DTDismeasure(inhours)ofthespeedofmaterialthroughtheplant,notthespeedoftheprocess.衡量指标DTD*Benefits利益.DTD时间改善以减少库存由较少的物料管理与库存结果较少几率损坏部品改善FTTdocktodocktimeisimprovedbydecreasinginventorieswhichleadstolessmaterialhandingandstorage.thisresultinfeweropportunitiestodamageparts.Therebyimprovingfirsttimethrough..改善DTD时间可增进能力支援OTD目标improveddocktodocktimeleadstoimprovedabilitytosupporttheordertodelivery(OTD)target..减少物料管理，废弃，及库存搬运成本，全部可以改善总成本数lowermaterialhanding.Obsolescence.Andinventorycarryingcostsallleadtoimprovedtotalcostnumbers.衡量指标DTD*为什么Why:.工廠必須消除浪費與改變到顧客拉式系統PLANTSMUSTELIMINATEWASTEANDMOVETOWARDSCUSTOMER“PULL”SYSTEMS..設置巨大緩衝區生產過多零件(增快製程速度)但是降低了物料速度Bybuildinglargebuffersyouproducemoreparts(increaseThespeedofyourprocess)butslowdownthespeedofmaterials..減少庫存可以減少物料管理及儲存,結果減少損壞零件的機會.decreasinginventoriesleadstolessmaterialhandingandstorage,whichresultsinfeweropportunitiestodamageparts.衡量指标DTD*为什么Why:.衡量生产库存週转的时间管理.DTD日程越短则週转越快.有效管理库存资金,降低生产成本.快速对应顾客需求衡量指标DTD*为什么Why：.DTD附加价值（实质）作业（valueaddedoperation）仅量少分.DTD绝大部分时间是无附加价值.等待（wait）.停滞（stagnation）.缓行（buffer）.存储（storage）.搬运（Transfer）.检查（Inspection）.返工（Rework）衡量指标DTD*何处where:1.原物料-购买的零件（管制部品）接收进入工厂开始计数.运委托制件.因为已经产品構成.rawmaterial-purchasepart(controlpart)–begincountingwhenitisreceivedintheplant.Evenonconsignment.Becauseitisalreadyinitsproductfromalreadyinitsproductform..原物料变更成为产品构成Rawmaterialthatischangeditsproductform衡量指标DTD*何处where：2.制程工作，包括物料在修理返工区域及全部缓衝区Work-in-process(WIP),includingmaterialinrepairreworkareas,andallbuffers.完成产品-所有完成品包含管制部品并入DTD计算直到被从马头交运Finishedgoodsenditemproducts–allfinishedgoodsontainingthecontrolpartareincludedintheDTDcalculationuntiltheyphysicallyshippedformthedock衡量指标DTD*何时when:数据收集时必须在作业型態表现优良的产品线上進行Datashouldbecollectedatthesametimewhichbestrepresentstheoperatingpatternofaproductline衡量指标DTD*如何做.降低原材料库存.降低安全库存量.提高进料频度衡量指标--DTD*如何做.降低成品库存.降低安全库存.提高交货频度衡量指标DTD*如何做.减少在制品/制程高效率化.目视化以及防误措施.一个流小批量.作业依排程生产.推展全员生产性保养.缩短转换时间衡量指标-DTD*降低总DTD时间.制程工程分析改善物流效率.消除停滞减少搬运.制程作业分析改善.降低周期时间.消除不良.提高首次合格率.排除稼动损失.提高总合设备效率.善用价值流图析衡量指标-DTD*降低总DTD时间.DTD-从价值流图析能作用明确有效展现.应用工业工程分析改善效率並进行时间缩短改善（时间）-是各企业公司同样拥有之唯一等量资源衡量指标-DTD单作业DTD=复合作业DTD=总管制数线末速率DTD作业1+DTD作业2+DTD作业3线末速率TotalDockToDockCalculation(SingleOperation)DTD=(MultipleOperation)DTD=TotalUnitsofControlPartEndofLineRateDTD(Operation1)+DTD(Operation2)+DTD(Operation)EndofLineRate首次合格率－FTTFirstTimeThrough衡量指标—FTT定义Definition1.FTT是为在一完整制程生产中，第一次既符合品质要求的产品件数的百分比率不含被報廢，返工，重试验，線外修理，返回件数FirstTimeThroughisthepercentageofunitsthatcompleteaprocessandqualityguidelinesthefirsttimewithoutbeingscrapped,return,retested,repaired,orreturned衡量指标—FTT定义Definition2.FTT是衡量生产制程的品质itisameasureofthequalityofthemanufacturingprocess.可应用FPS程序工具改善FTT(防误措施，幕式化工厂，快速转换)wecanimproveourFTTbyapplyingourFPSprocessandtools(errorproofing,visualfactory&quickchangeover).衡量指标—FTTFTT首次合格率投入制程总件数-（报废+返工+重试+线外修理+退回件数）Unitsenteringprocess–(Scrap+returns+retests+repairedoff-line+returns)投入制程总件数Unitsenteringprocess衡量指标-FTT利益Benefits1.提升制程/品质不良減少，库存降低,改善DTD时间Increasedprocess/outqualityreducestheneedforextraproductioninventory,improvementDTDtime..改善及维护顺序通过制程以改进BTSimprovesandmaintainssequencethroughouttheprocess,improvingBuildtoschedule(BTS).衡量指标-FTT利益Benefits2.确保接收良品提高品质水准与降低浪费产生並全面提升OEEIncreasedqualitybeforetheconstraintensuresthatitonlyreceives“goodparts”whichpromotesahigherqualityrateandreduceswastedoutattheconstraint,whichallimprovetheOEE.以降低索赔（保证），報费，与修理成本改善总成本Totalcostisimprovedthroughlowerwarranty,scrapandrepaircosts衡量指标-FTT为什麼Why:1改善FTT成果将improvementsinFirstThroughwillresultin:.提升产能increasedcapacity.改善产品品质对内部及外部客户Improvedproductqualitytointernalandexternalcustomers.降低大量生产库存结果，改善了DTD时间ReducedneedforexcessproductioninventoryresultinginimprovedDocktoDocktime衡量指标-FTT为什么Why:2.改善了能力以维护顺序通过制程改善了BTSimprovedabilitytomaintainsequencethroughouttheprocessresultinginimprovedBuildSchedule.提升品质加入作业要求改善OEEincreasedqualityinputtoconstraintoperationsresultinginimprovedOverallEquipmentEffectiveness.消除因报废，修理，与过多库存浪费的结果,以改善总成本Eliminationofwastesduetoscrap,repair,andexcessinventoryresultinginimprovedTotalCost衡量指标-FTT何处Where:.FTT数据收集必须在最终制程實施FTTDatashouldbecollectedattheendofprocesses.延伸目标：100percent(100%)FTT能力=零制造不良与交送StretchObjective:Onehundredpercent(100%)FFTcapability=Zerodefectsmadeorpassedon衡量指标-FTT何时When:.首次合格率数據必须收集并使用.最少以班别（出勤）.数据必须应用带动日常实践行动.FirstTimeThroughdatashoul