精益生产之线平衡模式 Line Balance Models (中英文版)

MeasureAnalyzeControlImproveLeanSixSigmaLineLeanSixSigmaImprovementProcessRoadMapDefinition–LineBalanceModelDesignPrinciplesValueDefinitionsApproachestoLineBalanceExerciseRD011202MeasureAnalyzeControlImproveLeanSixSigmaLineLeanSixSigma改善过程路径定义–线平衡模型设计原则价值定义线平衡方法练习RD011202ControlLineBalanceModel3LeanSixSigmaImprovementProcessRoadMapAnalyzeControlImproveDefine•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-YokeRevised1-12-02ControlLineBalanceModel4精益6过程改善流程分析控制改进定义•选定题目•列出客户•从顾客之声中列出关建需求•定出项目焦点和重要指标•完成PDF测量•绘制业务流程图•绘制价值流程图•制定数据收集计划•测量系统分析•收集数据•过程能力分析分析•提出关键因子•区分关键因子•验证关键因子•评枯每个关键因子对结果的影响•量化机会•根本原因排序•寻找根本原因针对关键因子改进•关键因子确认•发掘潜在的解决方法•选择方案•优化方案•实行方案控制•过程变革和控制•制定控制计划•计算最终财务•过程指标•项目过渡给未来项目管理者•项目鉴别•转化机会测量定义•项目编号工具•项目定义表•净现值分析•内部回报率分析•折算现金流分析？（按现值计算的现金流量分析）•PIP管理过程•RACI•Quad表•过程图•价值分析•脑力风暴•投票归类法•柏拉图•因果图/鱼骨图•FMEA•查检表•运行图•控制图•量具R&R•Cp&Cpk•供应链加速器分析•多变动图i•盒状图•交互作用图•回归分析•ANOVA•C&E矩阵图•FMEA•脑力风暴•拉系统•减少设置•TPM•流程图•标杆管理•亲和图•DOE•假设检验•力场分析图•树状图•甘特图•查检表•运行图•柱状图•散布图•控制图•柏拉图•互动回顾•愚巧法Revised1-12-02ControlLineBalanceModel5LearningObjectivesHowtodesignandimplementaprocesssupportedbyalinebalancingmodelthatensuresoptimaluseof:PeopleFloorspaceCapitalAssetsMaterialKnowhowtomaximizeproductivityControlLineBalanceModel6学习目标如何设计和实施由“线平衡模型”支持的一个流程以确保优化配置：人地方固定资产材料知道如何使生产率最大化ControlLineBalanceModel7What’sinItforMe?AbletodesignandimplementabalancedprocesslineUnderstandtheissuesinatypicalprocessenvironmentandhowtoimpactthoseissuesControlLineBalanceModel8益处能够设计和实施一个线平衡的生产线了解典型流程环境中的问题及如何影响那些问题ControlLineBalanceModel9LineBalanceModelALineBalancingModelallowstheusertoviewtasktimesacrossaprocesstoidentifybottlenecksandthuscalculateoutputrates(throughput)andTaktTimes.Inaddition,theuserwillbeabletovisuallyseeunbalancedareasandwheretaskscanbeshiftedtobalancetheprocess.TheLineBalancetechniquesareapplicableintransactionalaswellasmanufacturing,e.g.,orderentryoperations.ControlLineBalanceModel10线平衡模型线平衡模型允许用户在一个流程中确定瓶颈问题，并计算产出比率（产能）和TaktTimes。除此，用户将能直观地看到不平衡的区域和使流程平衡所做的任务。线平衡方法与生产互动一样是可行的，如订单进入生产。ControlLineBalanceModel11PrimaryIssuesinTypicalProcessEnvironmentsLargeorerraticbatchesExcessiveWIPPoorfloorspaceutilizationLowemployeeefficiencyLong/erraticcycletimesPoorbalanceofoperationsandlaboracrossprocessstepsConveyance,standbyandmotionwasteDisorganizedworkspaceandcomponent/supplystorageHighvariabilityofdemandonmultipleprocessingcenters,e.g.,callcenters/flowlinesControlLineBalanceModel12典型的流程环境中的主要问题大批量或反复无常的批量过多的WIP地方利用的差较低的员工效率长的/反复无常的周期时间流程步骤中差的生产平衡和劳动力传送、备用和启动浪费无规则的工作地点和元件/供应存储对于多重的流程中心，需求变化差异大2，如电话中心/流出线ControlLineBalanceModel13LineBalance–DesignPrinciplesMinimizeBatchSize/TransferQuantity/WorkInProcessMinimize/StabilizeCycleTimeMaximizeLaborEfficiencyOptimizenumberofworkstations/processstepsBalancetasks/laboracrossworkstationsMaximizespaceutilizationMinimizetaktvarianceMinimizeNVA(conveyance,standby,andmotionwastes)Minimizetheneedtore-balanceasdemandrequirementschangeMinimizevolumevariability(combineproductcategorydemand)MaximizeflexibilitytoallowforproductintroductionsanddiscontinuationsControlLineBalanceModel14线平衡–设计原则使批量规模/转移质量/在制品最小化将周期时间最小化/稳定化使劳动效率最大化优化配置工作站/流程步骤平衡任务/工作站里的劳动最大限度利用空间使takt的变化最小化最小化NVA(运送、备用和启动浪费)根据需求的变化使再平衡的需求最小化使批量差异最小化(综合产品种类需求)使柔性最大化以允许产品引入和非持续性ControlLineBalanceModel15ValueDefinitionsValueAdd:Addingform,fit,orfunctiontotheproduct.Ataskoractivityforwhichthecustomerwouldbewillingtopay.Example–AssemblerscrewingaboltintoapieceofaluminumrequiredtoholdthewindowtogetherExample–FinancialServicesemployeeaddingcredithistorytoacreditapplicationBusinessValueAdd:AtaskthatisrequiredtobuildawindowbutforwhichthecustomerisnotwillingtopayExample–Thetimeittakesf