SONY的生产管理及厂房设置(1)

Sony’sImplementationofProductionInnovationEquipmentandManufacturingSystemSolutions1Introduction1.1Shiftinproductionneeds1.2Importanceofdemandorientedproduction1.3Productioninnovation’s3maintypesofloss1.4CellproductionmethodChapter1ShiftinProductionNeedsDiversificationofNeedsSevereEconomicalEnvironmentNetworkAgeGlobalizationFallofProductPricesProtectionoftheEnvironmentDigitalizationMassproductionManytypes,smallqtyVarioustypes,variousquantitiesDemandOrientedProductionSpecializationMulti-functionalWell-soldproductschangequicklySurplusofinventoryduetothefallofproductpricesDrasticMarketChangeLessEnergyLessResources,RecyclingLSIMechanicalSoftwareNoBordersGlobalStandardsTelecommunicationRevolutElectronicCommerceWorstpost-wareconomicslumDeclineofConsumptionImportanceofDemandOrientedProductionProductswhichcannotbesoldChange-overlossWIPlossLeadtimeHandlinglossReductionLargemoduletypeproductionlineBatch-typeproductionlineVariousdemand-orientedcellproductionlinesDemandDemandDemandLinechange-over,modelchangeLead-time,Inventory,etc.cdebafSellwhatisproducedProduceaccordingtodemandTheUltimateProductionSystemCostInvestmentLeadtimeInventorySpaceChange-overlossRejectedproductsBreakdownMinimizationZeroOnlymaketherequiredproductsattherequiredtimeImplementationofProductionInnovationProductionInnovation’s3maintypesofloss1.Handlingloss2.Transportationloss3.StagnationlossMinimizationofnon-valueaddedresourcesProgressbyProductionInnovation(1)ProductionbasedonforecastProductionstyleLargeqtyproductionInnovationSmallLotProductionTarget:ZeroInventoryCustomer’sRequiredproductsRequiredtimeRequiredqtyReducedfundsturnoverReducedspaceReducedcontrolcostsLargeinventoryqtyMixedflowIndividual‘islands’Flow-orientedproduction,informationInnovationFlow-orientedIn-lineReductionofWIPReductionofhandlingSimplifiedqualitytrackingProgressbyProductionInnovation(2)LargeOrder/DeliveryofPartsPushstyleprovisionInventoryReductionbyLogisticImprovementsInnovationSmallqtyorder/deliveryDeliveronlywhatisusedReductionofRawmaterialsWIPLarge-sizeHighspeedHighperformanceHighpriceManufacturingequipmentInnovationWIPreductionbyproductionlevelingStockPartsInventoryInputOutputProductionlineProvisionDirect‘Refrigerator’‘Kanban’ProductionlineSmallsizeLow-mediumspeedFunctionalLowpriceProgressbyProductionInnovation(3)DividedlaborconveyorproductionstyleduetosingleoperationFromsingleoperationtomulti-operationInnovationMulti-operationandCellproductionmethodWIPreductionbyproductionlevelingDatamanagementbycomputerControlcomprehensiveforanyoneInnovationSelect&OrderFixedplaceFixedqtyFixedmarkingVisualmanagementConveyorlineMulti-operation(Multi-skilledworkers)Cell10000pcs.storageXXShouldbeinstorage?Thereshouldbepcs?Byseeingtheabnormality,aquickresponseispossibleMax(XXpcsMin(pcs)PartAAbnormal!ExampleofBenefitsofProductionInnovation:ReductionofManpower(Actualfactoryexample)94/3995/3996/3997/3998/39personsCumulativeManpowerreductionExampleofBenefitsofProductionInnovation:ReductionofSpace(Actualfactoryexample)94/3995/3996/3997/3998/39m2CumulativeSpaceReductionExampleofBenefitsofProductionInnovation:ReductionofLeadtime(Actualfactoryexample)(days)94/3995/3996/3997/3998/39In-houseproductionExampleofBenefitsofProductionInnovation:Revenue&ProfitNote)Ratio(%)with1992revenueas100ProductionInnovationActivitiesRevenueProfit(Actualfactoryexample)est.ConveyorlineSmallmoduleunittype12ncdebafCart1234nSpiraltypeOnemancarttypeOneman‘stall’type∼∼........FromconveyorlinetovarioustypesofCellProductionPartsStoreChange-overlossoccursLayoutmodificationisdifficultLinebalancelossoccursHandlinglossoccursChapter22.BenefitsofCellProductionMethod2.1CellProductionMethod2.2BenefitsofCellProductionMethod2.3ExamplesofCellProductionMethodTheCellProductionMethodisoneofthebestsolutionsofmanufacturingstylesforsmalllotproduction,inwhichassemblyandworkaredoneinonesingleprocess,byusingsmallmanufacturinginstruments(tools),byoperationofoneorafewworkers.ProductsSmallscalelineSmalllotFloworientedproductionMulti-functionalworkAssemblyInspectionPackagingCellProductionMethodExampleofCellProductionSystemBenefitsofCellProductionMethodProductionTimeLossinproductionlinechangeProductionTimeBynumberofworkersBunumberofcellsConveyorlineCellproductionOperationin3CellsVariousitemsFlexibilityUpQuantityfluctuationVariouslayoutCellsbyproductiontypeProductionbysalesspeedConveyorlineConveyorlineCellproductionLinemultiplicationisdifficultCellproductionLayoutmodificationisdifficultImplementationofvariouscelltypesaccordingtoproductsattributes,levelofoperators,productionquantity;layoutmodificationsarepossibleflexiblyBenefitsofCellProductionMethodProductivityupmanpowerreductionManpowerSpacereductionWorktableBeltconveyorHandlingLossProcessWorktimeLosstimeProductionqtyTimeChange-overLossSpacereductionbyremovalofconveyorEliminationoflossbyreducingin-betweenspacesConveyorlineCellproductionTacttimeSpacereductionManpowerreductionbyeliminationofconveyorlinelossConveyorlineCellproductionBenefitsofCellProductionMethodShorteningofproductionleadtimeInventoryreducti