鞋厂LEAN的标准作业

Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業WhatisStandardWork何謂標準作業Definition定義AStandardWorkisacombinationofmen,materialsandmachinetocarryoutproductioninamaximallyefficientway.標準作業是指如何安排人員、材料及機器使能發揮最佳的生產效率之組合StandardWorkisdifferentfromStandardOperationProcedure標準作業是不同於作業標準Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業FunctionsofStandardWork(1/2)標準作業之作用(1/2)(1)Trainingmaterialsfornewcomer做為教導新人之教材(2)Toolsformanagement做為管理之工具a)DesignofProductionLine生產線設計b)ManpowerRequirementplan人員需求計劃c)EquipmentRequirementplan設備需求計劃Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業FunctionsofStandardWork(2/2)標準作業之作用(2/2)d)On-HandWIPplan手持量計劃e)Targetofproductionspeed目標生產速度f)VisualManagement現場目視管理(3)ToolforKaizen做為改善之工具Noimprovementcantakeplace沒有標準作業withoutStandardWorkbeing就沒有改善definedfirst.Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業ElementsofStandardWork標準作業之要件(1)TAKTTime產距時間(2)On-HandWork-In-Process手持量(3)OperatorWorkSequence作業者動線順序Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業TAKTTIME產距時間Definition定義TaktTime產距時間=TargetTime目標時間=T.TExample例:WorkingTimeperday每日工作時數Unitsdemandperday每日生產需要數T.T=8Hours小時x3600sec.秒T.T=1000Units個/day天=28.8Sec秒/Unit個Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業On-HandWork-In-Process手持量Meaning意義ReferstotheminimumWIPneededtoperformrepetitiveoperations,e.g.,partsmountedtomachines,partsonconveyors,partsneedingtimetocool.為使生產線能重複進行生產活動，而必須擁有的最少必要的在製品數量。稱為手持量。包含在機器上、輸送帶上、等待泠卻之在製品等Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業OperatorWorkSequence作業者動線順序Meaning意義•Theorderofoperationsinwhichanoperatorcarriesobjects,mountsthemonmachinesandremovesthemetc..指作業者操作各個不同工序的順序•Thisshouldbedistinguishedfromtheproductprocesssequenceaccordingtowhichaproductismade,whichwillinfluencethenumberofOn-HandWIP.作業者的動線順序方向可與產品的加工順序流向不同。方向之不同會影響手持量之多寡Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業FormsofStandardWork標準作業常用表格(1)ValueStream/ProcessFlowChart價值流/流程圖(2)TimeMeasurementSheet時間觀測表(3)ProcessCapabilitySheet加工能力表(4)StandardWorkCombinationSheet標準作業組合票(5)Process/CycleTimeChart作業配分表(6)StandardWorkSheet標準作業票Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究Exercise1:習題1ValueStream/ProcessFlowChart價值流程圖SimulationCase:模擬案例UseaA4sizepapertoproduceabox使用一張A4尺寸之紙張，做成一個盒子-DrawtheValueStream/ProcessFlowChart做出此產品的“價值流程圖”Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業SymbolsforValueStream/ProcessFlowChart價值流/流程圖之符號(1/4)Customer顧客Supplier供應商Materialpushflow前推式物流Materialpullflowbywithdrawkanban領取看板后拉式物流Materialpullflowbyproductionkanban生產看板后拉式物流Materialpullflowbysignalkanban信號看板后拉式物流WPSSince19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業SymbolsforValueStream/ProcessFlowChart價值流/流程圖之符號(2/4)Informationflow資訊流動BufferInventory緩衝庫存SafetyInventory安全庫存ProductionCell生產線Leveling(Heijunka)平準化Supermarket超級市場BSSince19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業SymbolsforValueStream/ProcessFlowChart價值流/流程圖之符號(3/4)KanbanPost看板收集箱ProductionPlanningControl生產計劃管制Material,beforeprocess材料，加工前FinishedGoods,afterprocess成品，加工後Processandsequencenumber加工及序號ppc1Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業SymbolsforValueStream/ProcessFlowChart價值流/流程圖之符號(4/4)Self100%Inspection自主全數檢查Walkingoperation走動作業QASamplingInspection品管抽樣檢查Waiting/Storage等待/儲蓄CombineOperation加工與檢查Withinspection同時作業243Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業APISValueStreamFlowChart價值流程圖Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業TimeMeasurementandCalculation時間觀測及計算(1/2)HT=HumanWorkTime人工機器MT=MachineWorkTime機器時間PBS=ProcessBatchSize加工批量m=Numberofstationof某一特定工序specificprocess之工作站數OT=OverlappingTime重疊時間betweenHTandMTSince19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業TimeMeasurementandCalculation時間觀測及計算(2/2)PT=ProcessTime加工時間PT=HT+MT-OTCT=CycleTime週期時間CT=PT/PBS/mWhenPBS=1piecem=1stationThenCT=PTSince19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究Exercise2:習題2TimeMeasurement時間觀測•MeasuretheHT,MT,OTofeachprocess.測量每一個工程的HT,MT及OTSince19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究Exercise3:習題3LineBalance生產線平衡Studythebestlinebalancebyyourownidea.以你自己的想法，安排生產線的最佳平衡配置•Determinetheprocessbatchsize決定加工批量•CalculatePT計算PT•Determinethelinebalancespeed決定生產線的平衡速率•Calculatethenumberofstation/machineforeachprocess計算每一個工序所需之工作站數目或機台數目•CalculatetheCTforeachprocess計算每一個工序的CTSince19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究Exercise4:習題4StandardWork標準作業票•Basedonthelinebalanceresult,establishyourStandardWorkSheet依據生產線平衡的結果，繪出你的標準作業票Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究StandardWork標準作業APISStandardWorkLayoutSheet標準作業票Since19901990創立APISKaikaku台新企管CopyRightReserved版权所有翻印必究Exercise5:習題5ProductionLeadTime生產交期時間•BasedontheinformationontheValueStream/ProcessFl