lean-manufacturing-matrix

LeanManufacturing精益生产FordMotorChinaSourcingOffice福特汽车中国采购中心FirstTimeThroughCalculation(FTT)Definition:FirstTimeThroughisthepercentageofunitsthatcompleteaprocessandmeetqualityguidelinesthefirsttimewithoutbeingscraped,rerun,retested,divertedforoff-linerepair,orreturned.Itisameasureofthequalityofthemanufacturingprocess.定义:首次通过率是指一次性完成一个生产过程并且满足质量要求的零件的百分率，不包括报废，返工，再测试，下线修理或返回。FTT用于衡量制造过程的质量。FTT=Unitsenteringprocess-(scrap+reruns+retests+repairedoff-line+returns)UnitsenteringprocessFirstTimeThroughCalculation(FTT)单工序：进入数量=1000报废=10返工=15测试=5下线修理=0FTT%=1000-（10+15+5+0）1000FTT%=97.0%多工序：FTT(工序1)=92.87%FTT(工序2)=87.65%FTT(工序3)=82.34%最终检验(工序4)=82.34%总FTT%=92.87%X87.65%X82.34%X82.34%TotalFTT%=44.22%TotalDockToDockCalculation(DTD)Definition:DocktoDockistheelapsedtimebetweentheunloadingofrawmaterialsandthereleaseoffinishedgoodsforshipment.DTDmeasureshowfastrawmaterialsareconvertedtofinishedgoodsandshipped.Itisameasureofthespeedofmaterialthroughtheplant,notthespeedoftheprocesses.定义:DTD指从原材料到发运产品之间的总运转时间间隔。DTD用于测量原材料转化成成品发运的速度。也就是指材料通过工厂的速度，而不是加工工艺的速度。DTD(SingleOperation)=TotalUnitsofControlPartEndoflineRateDTD(MultipleOperation)=DTD(OP1)+DTD(OP2)+…EndoflineRateTotalDockToDockCalculation(DTD)TheEndofLineRateiscalculatedoffthelastoperationinthemanufacturinglineforaproduct:总产量=730（最终工位）生产时间=12小时（正常生产时间10小时+加班时间2小时）EndofLineRate=730/12=60.83各区域数量=原材料+半成品+最终产品原材料=300工序1=181工序2=3工序3=3最终产品=200DTD（原材料)=300/60.83=4.93小时DTD(工序1)=181/60.83=2.98小时DTD(工序2)=3/60.83=0.05小时DTD(工序3)=3/60.83=0.05小时DTD(最终产品)=200/60.83=3.29小时TotalDTD=4.93+2.98+0.05+0.05+3.29=11.3小时OverallEquipmentEffectiveness(OEE)Definition:OEEisacombinationofthreedifferentcalculations.Itisameasureoftheavailability,performanceefficiency,andqualityrateofagivenpieceofequipment.OEEdatawillhelpidentifyseveralwastescausedbymachine/processinefficiencies.Stretchobjective:85%定义：OEE是三个不同计算值的乘积，用于测量指定设备的利用率，性能效率和质量率。OEE数据可以帮助识别由设备/过程不足引起的不同的浪费。接受标准：85%OEE=AvailabilityXPerformanceEfficiencyXQualityAvailability=OperationTimeNetAvailableTimePerformance=IdealcycletimeXTotalpartsrunEfficiencyOperatingTimeQuality=Totalpartsrun–TotaldefectsTotalpartsrunOverallEquipmentEffectiveness(OEE)利用率：总计划时间（包括加班）=720分钟计划停线时间（30分钟午饭+30分钟休息）=30+30=60分钟净利用时间=720-60=660分钟其它停线时间=45+45=90分钟作业时间=660-90=570分钟可利用率=570/660=86.3%性能效率:理想循环时间=0.33分钟/件总零件数=1440作业时间=570分钟性能效率=0.33X1440=83.4%570OverallEquipmentEffectiveness(OEE)质量率：总零件数=1440返工数=50报废数=40质量率=1440–(50+40)=93.8%总设备利用率：利用率=86.3%性能效率=83.4%质量率=93.8%总设备利用率=86.3%X83.4%X93.8%OEE=67.5%BuildtoSchedule(BTS)Definition:Buildtoscheduleisthepercentageofproductsshceduledforagivendaythatareproducedonthatday,inthecorrectsequence.BTSreflectstheplant’sabilitytoproducewhatit’scustomerswant,whenit’scustomerswantit,andintheorderthecustomersusetheproduct.BTS%=Volume%XMix%XSequence%VolumePerformance:VolumePerformance,isthetraditionalmeasurethatmanufacturinghasusedtomonitortheirperformancetoschedule.MixPerformance:TheMixcomponentofBTSmeasuresthepercentageofproductderivatives/models/typesthataplantbuildsontherightday.SequencePerformance:ThesequencecomponentofBTSmeasuresthepercentageofthoseproductsbuiltontherightdaythatwerealsobuiltintherightsequence.Processwithasequenced‘batchofmany’scheduleBuildtoSchedule(BTS)定义:BTS是指在指点的生产日按照正确的生产顺序完成生产计划的比例情况。BTS反映了工厂能够按照客户的要求完成生产的能力,客户需何种产品,何时需要和客户使用产品的顺序。BTS%=Volume%XMix%XSequence%VolumePerformance:产量性能用于监控生产计划完成情况。MixPerformance:BTS的混线性能用于测量在厂内制造的产品系/型号/类型等在适当的生产日的完成比率。SequencePerformance:BTS的顺序性能用于测量在适当的生产日按照正确的生产顺序完成生产任务的比率。Processwithasequenced‘batchofmany’scheduleBuildtoSchedule(BTS-1)FOCUS/COUGAR/JAGUARCONDENSER生产计划实际生产批序号型号数量批序号型号数量1Cougar2001Cougar1902Focus1002Focus403Cougar200N/AJaguar604Focus1504Focus3005Cougar1603Cougar100810690Processwithasequenced‘batchofmany’scheduleBuildtoSchedule(BTS-1)冷凝器类型计划产量实际产量混线生产Cougar560290290Focus250340250Jaguar0600810690540计划批次顺序实际批次顺序混线批次按顺序生产批次11YesYes22YesYes3N/ANoN/A44YesYes53YesNo4批3批Processwithasequenced‘batchofmany’scheduleBuildtoSchedule(BTS-1)Volume=690x100=85.2%Performance810Mix=540X100=78.3%Performance690Sequence=3X100=75.0%Performance4BuildtoSchedule=85.2%X78.3%X75.0%=50%Processwithasequenced‘batchofmany’scheduleBuildtoSchedule(BTS-2)Severalnon-serializedproductsmadeondifferentproductionlineswithinanareaofaplant冲压线计划生产的零件和生产序号计划产量实际生产的零件序号生产数量混线生产数量按序生产数量10A1000A100010001000B2000B50050050020C4000C70004000400030D1000E100010001000E1000D200010000F1000F000总共100001150075006500Severalnon-serializedproductsmadeondifferentproductionlineswithinanareaofaplantBuildtoSchedule(BTS-2)Volume=11,500=100%Performance10,000Mix=7500=75%Performance10,000Sequence=6500=87%Performance7500BuildtoSchedule=100%X75%X87%=65%BuildtoSchedule(Roll-ups)星期一星期二星期一和星期二总和21003000510020452300434520152150416518501725357597.4%76.7%85.2%98.5%93.5%95.9%91.8%80.2%85.8%88.1%57.5%70.1%计划产量实际产量混线产量按序生产产量VolumePerformanceMixPerformanceSequencePerformanceBTSBuildtoSchedule(Roll-ups)Volume=(2045+2300)=100%Performance(2100+3000)Mix=(2015+2150)=75%Performance(2045+2300)Sequence=(1850+1725)=87%Performance(2015+2150)BuildtoSchedule=85.2%X