04 工厂布局与物料路径10

冠卓•精益生产FactorylayoutandmaterialrouteFactorylayoutandmaterialrouteReducemovingwaste,improveefficiency冠卓•精益生产FactorylayoutFactorylayoutThelayoutplanformachineandequipmentinthefactory,(currentorthefuture),tooptimizetheprocess,fromrawmaterialreceivingtoFGshipping,andthatwillresultmaterialflowinlowestcostandleastmoving.Effectivelycombinedthemanpower,materialandmachine,equipmentanyunitneeded,coordinatewiththeequipmentinsidetheplant,expecttogetsafe,highefficiencyandlowoperationcost.冠卓•精益生产Problemscausedbybadlayout♦Longmovingdistance♦Largebatchsize♦Waitingtime♦Transportationdamage♦Unnecessarymoving♦Idleequipment♦Highlaborintensity♦lowefficiency♦Safetyproblems♦……冠卓•精益生产BenefitoflayoutoptimizationReasonableplantlayout,willdecrease10%-30%costImproveproductionefficiencybythreetimesCommonmethod:Reduceoreliminateunnecessaryprocess:suchasreducespare,Reduceoreliminateunnecessaryprocess:suchasreducespare,reducematerialstop,moving,inventoryreducematerialstop,moving,inventoryViewofflow.EffectiverunningofcompanyrelyonreasonableViewofflow.Effectiverunningofcompanyrelyonreasonablepersonflow,materialflow,informationflowpersonflow,materialflow,informationflowSystematicallyanalyze,fullyoptimizeSystematicallyanalyze,fullyoptimizeEmphasisthefactorofperson:suchasspace,aisle,light,color,Emphasisthefactorofperson:suchasspace,aisle,light,color,temperature,humidity,noisefortheimpactofefficiencyandhealtemperature,humidity,noisefortheimpactofefficiencyandhealthth冠卓•精益生产ExampleBefore23457891006908070203040506010DBA01010DBA01020DBA01030DBA01040DBA01050DBA01060DBA01070DBA01080DBA01100DBA01090冠卓•精益生产OptimizedflowP54-AO54P55O55P54A23457891006908070203040506010DBA02020DBA02010DBA02040DBA02060DBA0205023457891006908070203040506010DBA02030DBA02070DBA02080DBA02100DBA02090DBA01010DBA01020DBA01030DBA01040DBA01050DBA01060DBA01070DBA01080DBA01100DBA01090SWEN冠卓•精益生产InternalmaterialrouteAmaterialsupplysystem,fromrawmaterial,WIPtoFG,includedeliverybyhandandbatchmoving,andemptycontainerrecyclingsystem,thissystembaseonexisteddeliveryrouteandperiodicallyrecycle.Thissystemcaneffectivelysupportthepullsystemrunning.InternalDeliveryRoute123457896123457896C1C2冠卓•精益生产Thematerialcanbedividedinto:SpecialmaterialSmallqty,notexpensiveSmallqty,andexpensiveLargeamount,andexpensiveLargeamount,notexpensiveCommonmaterialDifferentmethodfordifferentmaterialInternalmaterialroute冠卓•精益生产Example:MaterialRouteReceivingDockReceivingDock123457896InternalDeliveryRouteShippingDockShippingDockReceivedMaterialSupermarketFinishedGoodsSupermarketDocksTime123etc.6:00AM6:30AM7:00AM7:30AM8:00AM8:30AM9:00AM9:30AM10:00AM10:30AM11:00AM11:30AMetc.Carrier1(CustomerA)Carrier1(CustomerA)TTCarrier1(CustomerB)Carrier1(CustomerB)SSTTCarrier2(CustomerC)Carrier2(CustomerC)PPCarrier2(CustomerD)Carrier2(CustomerD)Carrier3(CustomerD)Carrier3(CustomerD)Carrier4(CustomerF)Carrier4(CustomerF)Carrier4(CustomerF)Carrier4(CustomerF)Carrier3(CustomerD)Carrier3(CustomerD)Carrier3(CustomerJ)Carrier3(CustomerJ)Carrier1(CustomerG)Carrier1(CustomerG)Carrier1(CustomerH)Carrier1(CustomerH)Carrier2(CustomerD)Carrier2(CustomerD)Date:SHEDULEDWINDOWSHIPPINGTTSSPPKEY:=MetWindow=ProductionIssue(Shortage)=TranspotationIssue(Late/Miss)=ShippingIssue(Delay)DocksTime123etc.6:00AM6:30AM7:00AM7:30AM8:00AM8:30AM9:00AM9:30AM10:00AM10:30AM11:00AM11:30AMetc.Carrier1(CustomerA)Carrier1(CustomerA)TTCarrier1(CustomerB)Carrier1(CustomerB)SSTTCarrier2(CustomerC)Carrier2(CustomerC)PPCarrier2(CustomerD)Carrier2(CustomerD)Carrier3(CustomerD)Carrier3(CustomerD)Carrier4(CustomerF)Carrier4(CustomerF)Carrier4(CustomerF)Carrier4(CustomerF)Carrier3(CustomerD)Carrier3(CustomerD)Carrier3(CustomerJ)Carrier3(CustomerJ)Carrier1(CustomerG)Carrier1(CustomerG)Carrier1(CustomerH)Carrier1(CustomerH)Carrier2(CustomerD)Carrier2(CustomerD)Date:SHEDULEDWINDOWSHIPPINGTTSSPPKEY:=MetWindow=ProductionIssue(Shortage)=TranspotationIssue(Late/Miss)=ShippingIssue(Delay)Supplier123451234512345123457896123457896In-ProcessSupermarket揃In-ProcessSupermarketA1A2A3C1C2BLeanLogisticsPFEPMT抯MT抯P/N-1234P/N-5678Dept.ABCMMEXPRESSMMEXPRESS冠卓•精益生产More…IndustrialEngineering(IE)hassubjecttostudyFactoryLayoutMainlyconsiderfrombelowtopics:ProcessrequiredProductscharacterProductiontime,quantityMaterialroute……