现代生产管理-需求式流程技术

DemandFlowTechnology需求式流程技术GeneralTrainingmaterialforStaff职员培训资料FlexFactoryDemandFlowTechnologyFlextronicshasadoptedDemandFlowTechnologyastheManufacturingStrategy伟创力采用DFT作为制造策略FlextronicswasintroducedtoDFTbyLifescan–Johnson&Johnsonin1994.强生公司于1994年将DFT引入伟创力公司。DemandFlowTechnology–HowitstartedinFlextronicsDFTisaproductoftheJohnCostanzaInstituteofTechnologyDFT是JCIT公司的产品。WhatDrivesProductCostsMaterial物料75-90%Labour劳动力5%Overhead管理费用15%Profit利润5%ProductCostPercentage*产品成本百分率•TotalCostofMaterialisthehighest(Handling,Storing,ShelfLife,Scrap,CapitalTieUp,PurchaseCost,etc)物料的总成本是最高的(包括处理、储存、限期保存、废料、资源占用、采购成本等等)•InTraditionalManufacturing,focusismainlyonreductionoflaborcost(mistakenly)在传统的制造业里，将重点放在了减少劳动力成本(是错误的)•Materialandfinishedgoodsinventorycostsareoftenoverlooked物料和制成品库存成本往往被忽视*TheQuantumLeap,JCiTDFTfocusesonreductionofoverallmaterialandoverheadcostDFT注重所有物料成本和管理费用的减少4SevenTypesofWastes*1•Over-production过量生产•Waitingtime等待时间•Transportation运输•Processingwaste处理废料•Inventory存货•Motion移动•Productdefects次品CommonSolutions共同的解决方法:Back-to-BasicDisciplines回到基本的纪律:•The5-SandWorkPlaceOrganization5-S和工作场所的规范•Simplify,CombineandEliminate简单化，组合和清除*1ToyotaManufacturingSystem丰田制造体系*2TheMachineThatChangedTheWorld机器改变世界byJamesP.Womack,DanielT.Jones&DanielRoos-IMVP,MassachusettsInstituteofTechnologyProducts/Servicesthatarenotrequiredbyconsumers–The8thWaste*2产品/服务并不是客户所要求的-第8种浪费WhatisDFT?•ItisaDemandPullProcess是一个需求式拉动过程•ProducesthehighestpossiblelevelofQuality使生产达到尽可能高的质量水平•ProvidingtheCustomerwithmaximumFlexibility为客户提供最大的灵活性•Atpre-determinedResponseTime预先设定响应时间•AchievehighestpossibleInventoryTurns达到尽可能高的存货循环•EliminatingNonValueAddedactivities(Waste)消除无附加值活动(浪费)8ManufacturingtheTraditionalWayStore货仓Plan计划Queue排期Work工作Buffer缓冲区Stock库存Buffer缓冲区Buffer缓冲区Buffer缓冲区Buffer缓冲区Buffer缓冲区Buffer缓冲区Buffer缓冲区Plan计划Queue排期Work工作Plan计划Queue排期Work工作Plan计划Queue排期Work工作ManufacturingTheDFTWay•DFTlinksManufacturingProcessestogetherDFT将所有制造过程联结在一起•Materialsarekeptclosetopointofuse(RIP)物料的储存靠近使用点(RIP)•ReducesWorkInProcessInventoryorBuffers减少在线存货量和缓冲区MANUFACTURINGFLOWPROCESS补充程序机器#2机器#1机器单元供应商生产流程存货区成品在线暂存料在线暂存料WhatDFTwillachieve??WithDFTwewill：用DFT我们将达到:•Minimizenon-valueaddedwork最小化无附加价值工作•Reduceproductcycletime减少生产周期•Reducetheinventorylevels降低存货水平•Reducefloorspacerequirements减少空间需求•Reducescrapandrework降低废料和返工•Reduceproductcost降低产品成本DFTDevelopmentCycleSEQUENCEOFEVENTSGOALS/TARGETSVA/NVA1QUALITYPRODUCTSQUALITYCRITERIA2ON-TIME-DELIVERYPRODUCTTOTALCYCLETIME3INVENTORYTURNSSYNCHRONIZATIONPROCESSEFFICIENCY4MANUFACTURINGCYCLETIME5VA/EMPLOYEELINEDESIGNFORECASTDEMANDFLOWRATETAKTTIMELINEBALANCEDESIGNREVIEWBETTERMANUFACTURABILITY/DFTDOCUMENTATIONTESTABILITYTQCWORKSHEETNVAELIMINATIONSOELINELAYOUTQUALITYIMPROVEMENTPROCESSTRAININGRECORDSYIELDIMPROVEMENTCUSTOMERSATISFACTIONMATERIALHANDLINGKANBANSIZETRAININGRIPGENERICTRAININGKANBANCARDPRODUCT/PROCESSTRAININGDEMANDFENCEFLEXINGCUSTOMERRESPONSIVENESSSUPPLIERPARTNERSHIPLINEARPLANNINGQUALITYDELIVERYKANBANTESTSCREENPRINTINGSMT(TOP)REFLOWSMT(BOTTOM)DemandFlowTechnologyTQCCheckstencilset-upbythemaintenanceiscorrect.(Pastikanstencilbetultelahdisediakanolehmaintenanace.)CheckforthecorrectPCBRevandsolderpasteusedisasstatedinworkcontent.(PastikanPCBRevdansolderpasteyangbetuldigunakansepertiyangditentukan.)Checkforthefollowingparameters.(Pastikanparametersepertidibawah)Squeegeetype:MetalSqueegee.Printingspeed:30mm/sPrintingpressure:4.5TO5.5kgFSolderpastethickness:6–9milsWORKCONTENTS/NP/NUMBERDESCRIPTIONQTYLOC159574FPCB1-2SOLDERPASTEKester,RMA222REMARKS:Loadinthepanelintomachineinthedirectionshown.(Masukkanpanelkedalammesinpadaarahyangditunjukkan.)Pressstartbuttontostarttheprintingprocess.(Tekansuis‘Start’untukmemulakanprocessseterunya.)VERIFYEnsurethesolderthicknesshourlyisaccordingtospecbyusingtheZ-Checker(Pastikanketebalansolderpastesetiapjammengikutspecdenganmenggunakan“Z-Checker”.)Ensurethereisnosolderpastedefectssuchasnosolderpaste,insufficientsolderandmisalignment.(Pastikantiadakecacatansolderpastesepertitiadasolderpaste,kekurangansolderpastedan’misalignment’.)Afterprintingofevery5panels,stencilhastobecleanedbybrushandmicro-wirepaper.(Bersihkanstencildenganberusdan‘micro-wirepaper’selepasdi‘print’5panel.)LOADINGDIRECTION11SP.WMFASSEMBLYNo.PCBASEQUENCEOFEVENTSPROCESSI.D.LINE#3SEQNo.TASKDESCRIPTIONSETUPMLMOVEMLMACHINELABORTQCINFORMATION10Loadmachineprogram4.0Verifyprogramcode20StagerawPCB4.0VerifyPCBalignment30PickandPlace6.0Verifycomponentplacement40Reflow4.0Verifymachinesettings50PCBAcleaning4.0VisualforforeignmaterialsVAXXMANUFACTURINGFLOWPROCESS10KKKKKKKKPROCESSEND101010101010101010101010KKIN-PROCESSKANBANFEEDERLINEFEEDERLINE10FEEDERLINEKKKFlexFactory记分卡生产线设计需求预测流动速率/TAKT校正SOE线上平衡生产线布局DFT工作指引方法表格(MPI/PTI)设计评审DFM/DFTNVA消除物料垃动系统WIP/RIPKanban大小Kanban卡系统信号灯系统质量改进过程提高产量客户满意培训一般性/灵活性产品/过程客户响应线性计划需求障碍供应商合作性质量,交货,KanbanDemandFlowTechnologyDFT监控审核系统跟踪绩效ASSEMBLYNo.PCBASEQUENCEOFEVENTSPROCESSI.D.LINE#3SEQNo.TASKDESCRIPTIONSETUPMLMOVEMLMACHINELABORTQCINFORMATION10Loadmachineprogram4.0Verifyprogramcode20Sta