精益生产培训课程

Supplier kanban
rotates between the factory and suppliers
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Common Techniques for Reducing Setup Time
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Common Techniques for Reducing Setup Time (cont.)
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Production kanban
authorizes production of goods
Withdrawal kanban
authorizes movement of goods
Kanban square
a marked area designated to hold items
Q-R
Bin 2 R
b) Kanban inventory system Kanban
R
Q = order quantity R = reorder point - demand during lead time
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Types of Kanban
goods
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Sample Kanban
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Origin of Kanban
a) Two-bin inventory system Bin 1
Reorder card
Internal setup
Can be performed only when a process is stopped
External setup
Can be performed in advance
SMED Principles
Separate internal setup from external setup
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Components of Lead Time
Processing time
Reduce number of items or improve efficiency
Move time
Reduce distances, simplify movements, standardize routings
Copyright 2006 John Wiley & Sons, Inc.Biblioteka Signal kanban
a triangular kanban used to signal production at the previous workstation
Material kanban
used to order material in advance of a process
on each other
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▪ Inventory Hides Problems
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▪ Less Inventory Exposes Problems
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Lean Production
Doing more with less inventory, fewer workers, less space
Just-in-time (JIT)
smoothing the flow of material to arrive just as it is needed
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Waste in Operations
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Waste in Operations (cont.)
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Waste in Operations (cont.)
maintenance Supplier networks
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Flexible Resources
Multifunctional workers
perform more than one job general-purpose machines perform
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Pull System
Material is pulled through the system when needed
Reversal of traditional push system where material is pushed according to a schedule
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Small Lots
Require less space and capital investment
Move processes closer together Make quality problems easier to
detect Make processes more dependent
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Lecture Outline
Basic Elements of Lean Production Benefits of Lean Production Implementing Lean Production Lean Services
comprised of dissimilar machines brought together to manufacture a family of parts
Cycle time is adjusted to match takt time by changing worker paths
dL + S (150 x 0.5) + 7.5
N= C =
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75 + 7.5
=
= 3.3 kanbans or containers
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Round up to 4 (to allow some slack) or down to 3 (to force improvement)
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Determining Number of Kanbans
average demand during lead time + safety stock
No. of Kanbans =
container size
where
dL + S N= C
N = number of kanbans or containers d = average demand over some time period L = lead time to replenish an order S = safety stock C = container size
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Basic Elements
Flexible resources Cellular layouts Pull production system Kanban production control Small lot production Quick setups Uniform production levels Total productive
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Standard Operating Routine for a Worker
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Cellular Layouts
Manufacturing cells
Forces cooperation Prevent over and underproduction While push systems rely on a predetermined
schedule, pull systems rely on customer requests
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Copyright 2006 John Wiley & Sons, Inc.