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2022年11月15日星期二精益生产之2箱补充拉系统2-Bin_Replenishment_Pull(中MeasureAnalyzeControlImproveLeanSixSigma2-Bin补充拉系统2-箱补充拉系统的介绍线旁V

S使用点库存2-箱数据的要求和计算库存部署选择卡触发2-箱流程1-箱系统附录RD011202LeanSixSigmaImprovementProcessRoadMapAnalyzeControlImproveDefine•Ide

ntifyProblem•DevelopListofCustomers•DevelopListofCTQ’sfromVoiceoftheCustomer•FinalizeProjectFocusandKeyMetrics•CompletePDFMeasure

•MapBusinessProcess•MapValueStream•DevelopDataCollectionPlan•ConductMeasurementSystemAnalysis•CollectData•ConductPro

cessCapabilityAnalysisAnalyze•ProposeCriticalX’s•PrioritizeCriticalX’s•VerifyCriticalX’s•EstimatetheImpactofEachXonY

•QuantifytheOpportunity•PrioritizeRootCauses•ConductRootCauseAnalysisonCriticalX’sImprove•CriticalX’sConfirmed•Deve

lopPotentialSolutions•SelectSolution•OptimizeSolution•PilotSolutionControl•ImplementProcessChangesandC

ontrols•WriteControlPlan•CalculateFinalFinancial/•ProcessMetrics•TransitionProjecttoFutureOwners•IdentifyProject•TranslationOpportuni

tiesMeasureDefine•ProjectIDTools•ProjectDefinitionForm•NetPresentValueAnalysis•InternalRateofReturnA

nalysis•DiscountedCashFlowAnalysis•PIPManagementProcess•RACI•QuadCharts•ProcessMapping•ValueAnalysis•Brainstorming

•Multi-VotingTechniques•ParetoCharts•C&E/FishboneDiagrams•FMEA•CheckSheets•RunCharts•ControlCharts•GageR&R•Cp&Cpk•SupplyChainAccelerat

orAnalysis•Multi-Vari•BoxPlots•InteractionPlots•Regression•ANOVA•C&EMatrices•FMEA•Brainstorming•Pull

Systems•SetupReduction•TPM•ProcessFlow•Benchmarking•Affinity•DOE•HypothesisTesting•ForceField•TreeDiagrams•GanttCharts•CheckSheets•RunCharts•Histo

grams•ScatterDiagrams•ControlCharts•ParetoCharts•InteractiveReviews•Poka-YokeRevised1-12-022-BinReplenishmentPul

lLearningObjectivesUnderstandthevarioustypesofbinreplenishmentsystemsKnowthebenefitsofabinsystemUnderstandwhentous

eabinSystemBeabletosize(calculate)alltheparametersforabinsystem2-BinReplenishmentPull课程目的理解箱补充系统的不同类型知道一个箱系统的好处理解何时使用一个箱系统能够去计算一个箱系统的所有参数2-Bi

nReplenishmentPullWhat’sinItforMe?BeabletoapplythistooltoaBlackBeltprojectAbletoimplementaBinsystem2-BinReplenishmentPull我学到了什么?能

够在黑带项目中应用这个工具能够实施一个箱系统2-BinReplenishmentPull2-BinReplenishmentPullIntroductionA2-BinReplenishmentPullSystemisasimplifiedversionofast

andardreplenishmentpullsystemandmaintainsthebenefits:EstablishesstrategicallylocatedbuffersofpartswithinaprocessRawmaterialManufacturedparts

PurchasedpartsFinishedgoodsDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventoryPartrepl

enishmentis―triggered‖basedonconsumption2-BinReplenishmentPull2-箱补充拉系统的介绍2-箱补充拉系统是一个标准的补充拉系统的简化版本，其好处是：在一个流程中建立战略性的零件缓冲区原材料

制造的零件采购的零件成品通过缓冲库存将供应过程和消耗过程联系起来零件的补充是基于消耗而触发的2-BinReplenishmentPullWhatIsa2-BinReplenishment?Formanypa

rtsinaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:Abinhasenoughparts/suppliestocoveracalculatedp

eriodofusageatthepoint-of-use.Whenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe―1st‖isbeingrefilled/replenished.Therearetwoprimar

yreplenishmentlocations:Line-SideandPointofUse2-BinReplenishmentPull2-箱补充拉系统是什么?对于在流程中的众多零件而言，一个2-箱系统可以被用来补充零件相对于同步供应:一箱有足够零件/

供应品以满足在使用点上已计算出的用量周期。当第一箱用完了后，在补充/重新装料时，第二箱取代第一箱的位置继续满足使用。有两个主要的补充地点：线旁和使用点2-BinReplenishmentPullBenefitsof2-BinReplenishmentOr

ganizedandoverallcleanerappearanceofstoredmaterialsReducedfrequencyoforderssubmittedtothestockroom/vendorRed

ucednumberoftripsforre-supplyBettermanagementofinventoryontheshopfloorMorepredictableinventorycostsImp

roveemployeeproductivityby:Eliminatingpart/supplyshortagesatthepoint-of-useReducetimewastedbypersonnel/supervis

ionretrievingsupplies/inventoryfromthestockroomand/orvendorsEliminatelostormisplacedmaterial2-BinReplenishmentcanbeusedforoffice/safetysuppl

ies,productioninventory,productionsupplies–evenathome!2-BinReplenishmentPull2-箱补充拉系统的好处存储的材料外观非常清洁和有条理提交给库房/供应商的频率减少重复供应的差错数量

减少了现场库存的管理更好库存成本更具有预测性提高员工生产率:排除在使用点的零件/供应短缺减少由于人员/管理等，从库房和/或供应商重新找回供应/库存的时间浪费排除材料的丢失或放错地方2-箱补充可以被使用在办公室，安全供应，生产库存

，生产供应—甚至在家里!2-BinReplenishmentPullWhentoUse2-BinReplenishmentPullRepetitiveproductoffering/processRelat

ivelyconsistentdemand/volume(lowvariability)Part/supplyshortagesareaconsistent/costlyproblemPart/supplyinventorycostsare―outofcontrol‖du

eto:Lostormisplacedparts/suppliesLackofissue/dispersaldisciplineorcontrol2-BinReplenishmentPull何时使用2-箱补充拉系统重复的产品供应/流程重复稳定的需求(底变异)零

件/供应短缺是常事，且是一个代价很大的问题零件/供应库存成本是失控的，由于：零件/供应品丢失或放错地方缺乏投料/分发的一致性或控制2-BinReplenishmentPullWhatIsaBin?Doesn’tnecessarilylooklikea―bin‖

Canbeastandardplasticbin(Acro-bin)Canalsobethebox/containerthepart/supplyisshippedin(alsocalleda―standardpac

k‖–purchasingdefinition)Whenthebox/containermethodisused,a―bin‖canbeonestandardpackorseveralstandardpacks.Examples:1boxofs

crews2boxesofscrews1drumofoil30bagsofconnectors1rolloflabels4tubesofsealant2-BinReplenishmentPull一箱是什么?这并不是说一定要看上去像个“箱子”它可以是一个标准的塑

料箱它也可以是用于零件运输的一个盒子或容器(也可以用采购的定义被称为一个“标准包‖)当盒子/容器方式使用了后,一个“箱”可以是一个标准的包或几个标准包。例如：1盒螺钉2盒螺钉1打油30包连接器1卷标贴4管子密

封剂2-BinReplenishmentPull2-BinReplenishmentDataParameters/NeedsDemand/Usage(DMD)TypicallyexpressedintermsofAverageDailyUsage(ADU)inunitsLeadTi

me(LT)ThetimeittakesfromwhenatriggerissenttowhenreplenishmentarrivesInthiscase,canalsobethoughtofas―Restoc

kingTime‖OrderFrequency(OF)Iforders/triggersaresentatscheduledtimes(i.e.,noteveryday,suchasonceperweek)Typical2-BinsystemsdonotuseanOrderFr

equency,asreplenishmentcanoccureveryday/shift(ormore)Box/ContainerQuantityIfstock/supplyroomorvendordoesnotbreakdownshippingquantity,thent

hebinquantitymaybesetequaltosomemultipleofthebox/containerquantity(standardpack)thatthepart/supplyisshippedinSafetyStockTypically1/2themax(L

T,OF)*DMD,maybesetotherwisedependentonindividualconditions2-BinReplenishmentPull2-箱补充系统数据参数/要求需求/使用(DMD)一般来说用平均每天用量（ADU）来表达交货期(LT)从补充需求触发到补充品到达

的时间。在这里，也可以被认为是“再进货时间”。订单频率(OF)如果订单/触发信号的发放是按预定时间（如：并不是每天，而是每周一次）2-箱系统是不需要用订单频率的。补充可以发生在每天、每班（或更多）盒子/容器数量如果库房或供应商没有列出运输数量的明细分类，那么箱数量可以设定为等于运

送零件/供应品的若干盒子/容器数量安全库存一般来说的设定为1/2max(LT,OF)*DMD,否则根据独立的情况来看2-BinReplenishmentPullStockRoomorVendor12FullBin/CardMove1to2when2i

spulled,SendTriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)2-BinReplenishment(“Line-Side”Stocking)Reducespart/

supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresultinsignificantproductivityimproveme

ntsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-SideS

torageLTOF2SS/2DMDOF),LTmax(QuantityBin2-BinReplenishmentPull库房或供应商12添满的箱/卡当2被拉动时，移动1到2，发送触发信号使用的部件空的箱/卡使用点位置(POU)或工作库

存(WIP)2-箱补充(“线旁”库存)减少零件/供应品库存，增加生产效率促进WIP的降低将导致在库房里的显著的生产力提高降低/消除库房在批数量上的影响可以简单化存货/周转的计算流程线旁库存L

TOF2SS/2DMDOF),LTmax(箱数量2-BinReplenishmentPullFullBin/CardPullfrom1untilempty,sendtriggerandpullfrom2untilempty,sendtr

igger,etc.UseComponentsEmptyBin/Card2-BinReplenishment(“Point-ofUse”Stocking)LTOF1SS/2DMDOF),LTmax(QuantityBin2-BinPOUstockingisusedwhenre-stocki

ngisnotanissue.StockRoomorVendorPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)22-BinReplenishmentPull拉动从1开始直到用完为止,发送

触发信号，然后拉动从2开始直到用完为止，发送触发信号,等等.使用部件2-箱补充(“使用点”库存)LTOF1SS/2DMDOF),LTmax(箱数量当重新备库存不是一个问题时，使用2-箱POU库存库房或供应商2添满的箱/卡空的箱/卡使用

点位置(POU)或工作库存(WIP)2-BinReplenishmentPull2-BinReplenishmentCalculationsBinQuantity=Max(LT,OF)+SS/2Ifreple

nishinginstandardpacks,BinQuantityisroundeduptotheneareststandardpackmultipleExample:CalculatetheBinQuantityforthefollowing(standardpackreplenishme

nt):PartNumber:40567Description:RubberGlovesDemand/Usage:25pairs/dayLeadTime:2days(trigger-stock/supplyroom-replenishment)OrderFrequency:

N/ABoxQuantity:50pairsBinQuantity=[Max(2days,N/A)*25pairs/day]+.5*[Max(2days,N/A)*25pairs/day]/2=63pairsButwehavetoroundu

ptotheneareststandardpack,so:BinQuantity=100pairs=2boxes2-BinReplenishmentPull2-箱补充的计算箱数量=Max(LT,OF)+SS/2如果是标准包的

补充，箱数量应该是近似于标准包的倍数举例:计算下列数据的箱数量(标准包补充):零件号码:40567描述:橡胶手套需求/用量:25双/天交货时间:2天(触发–库房–补充)订单频率:不适用箱数量:50双

箱数量=[Max(2天,N/A)*25双/天]+.5*[Max(2天,N/A)*25双/天]/2=63双但是我们要取一个近似标准箱的数量，所以:箱数量=100对=2箱2-BinReplenishmentPullExercis

e#1:2-BinReplenishmentCalculatetheBinQuantityforthefollowingsupplyitemina2-BinLine-SideReplenishmentprocessdirectlylinkedtothesu

pplier:PartNumber:80886Description:PrinterPaperDemand/Usage:22reams/dayLeadTime:4days(trigger-purchasing-su

pplier-receiving-replenishment)OrderFrequency:5daysBoxQuantity:10reamsBinQuantity=[Max(,)*]+.5*[Max(,)*]/2

=.Butwehavetorounduptotheneareststandardpack,so:BinQuantity==.2-BinReplenishmentPull练习#1:2-箱补充如下供应品的2-箱线旁补充流程直接连接着供应商，计算箱数量:

零件号码:80886描述:打印纸需求/用量:22令/天交货时间:4天(触发–采购–运输–收货–补充)订单频率:5天箱数量:10令箱数量=[Max(,)*]+.5*[Max(,)*]/2=.但是我们要取一个近似标准包的数量，所以:

箱数量==.2-BinReplenishmentPullExercise#2:2-BinReplenishmentCalculatetheBinQuantityforthefollowingassemblyitemina2-BinLine-

SideReplenishmentprocesslinkedtothewarehouse:PartNumber:A44B2Description:4"Dia.SteelExtrusionDemand/Usage:225ft/dayLeadTime:1day(trigger-ware

house-replenishment)OrderFrequency:N/AExtrusionLength:30ftBinQuantity=[Max(,)*]+.5*[Max(,)*]/2=.Butwehavetorou

nduptotheneareststandardpack,so:BinQuantity==.2-BinReplenishmentPull练习#2:2-箱补充如下组装线2-箱线旁补充流程直接连接着供应商，计算箱数量:零

件号码:A44B2描述:直径4“的钢铁拉丝需求/用量:225英尺/天交货时间:1天(触发–仓库–补充)订单频率:不适用拉丝长度:30英尺箱数量=[Max(,)*]+.5*[Max(,)*]/2=.但是我们要取一个近似标准包的数量，所以:箱数量==

.2-BinReplenishmentPull12-BinReplenishmentBinLabelingandInformationEachBin/StorageLocationshouldhaveabarcod

elabelortag.Makesurenottouseapermanentlabelappliedtoarack/bin,becauseyouwilleventuallywanttoresizeandmayhavetomakenewlabels!

LabelsforLineSideBins/TagsforResupplyBinsPartNumber,Description,andLocationarePrinted.BinQuantityshouldnotbeprinted(requirestoomanyla

belchangeswhenresizing–triggermechanismorsystemwillhaveBinQuantity)EachBinLocationshouldbeuniquetoavoidconfusionwhe

nrestocking.ExamplesareintheAppendix.LocationPartNumberDescription2LocationPartNumberDescription2-BinReplenishmentPull12-箱补充箱标贴和信息

每个箱/库存地点都应该有一个条码标贴或标签确保不要用永久的标签贴在一个货架/箱。因为你将会调整大小，且贴上一个新的标贴！在线旁的需要重新补充的箱上的标贴被打印的零件号码,描述,地点等箱数量不应该被打印出来(当

调整大小时需要太多的标签变化–触发机制或系统将有箱数量)每个箱地点必须是独一无二的以避免在重新补充库存时混淆举例在附件里.地点零件号码描述2地点零件号码描述2-BinReplenishmentPullNotesona1-BinSystemAonebinsystemisanexcep

tiontothe2-binforveryslowmovingparts/supplies.1-binpartsarenotstoredin2-binsbecauseof:HighinventorycostSpacerequirementsRacking/storagecost

1-binsarereplenisheduponstockoutattheLine-Sidelocation.Stockoutimpactshouldbelowbecause:Parts/suppliesareverylowusers.Parts/suppliesarea

lsoatpointofusewhenLine-Sidestockoutoccurs.Parts/suppliesarestockedinnearbystock/supplyroom–easytoreplace.2-BinRepleni

shmentPull1-箱系统的注意对于流动非常缓慢的零件/供应品来说，一个1-箱系统是2-箱系统的例外.1-箱零件不象2-箱那样被存储，因为:高库存成本空间需要货架/仓储成本在线旁的地点库存短少时，1-箱被补充。库存短少的影响应该是微弱的，因为:零件/供

应品是非常少的使用者。当线旁的存货短缺发生时，零件/供应品也同样在使用点.零件/供应品被存放在库房附近—容易补充.2-BinReplenishmentPullStockRoomorVendor11FullB

in/CardMove1to2when2ispulled,SendTriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)1-BinRepleni

shment(Typicallyfrom“Line-Side”)Reducespart/supplyshortagesincreasingproductivityFacilitatesWIPreductionWillresu

ltinsignificantproductivityimprovementsinstock/supplyroomReduces/eliminatesstockroomimpactonlotsizesMaysimplifyinventory/cyclecountprocessesLine-

SideStorageLTOF1SS/2DMDOF),LTmax(QuantityBin2-BinReplenishmentPull库房或供应商111-箱补充(特别是从“线旁”)LTOF1添满的箱

/卡空的箱/卡当2被拉动时，移动1到2，发送触发信号使用点位置(POU)或工作库存(WIP)减少零件/供应品库存，增加生产效率促进WIP的降低将导致在库房里的显著的生产力提高降低/消除库房在批数量上的影响可以简单化存货/周转的计算流程线旁库存SS/2OF),LTmax(箱数量使

用的部件DMD2-BinReplenishmentPullStockroomorVendor1LinePOU1-BinReplenishmentTransactions1-BinSysteminventorytransactionsmirr

orthoseofthe2-BinsystemFrontflushforreducingtransactionsbutreduceoverallinventoryaccuracyBackflushforincreasinginventoryaccuracy(slightly)butincr

easenumberofsystemtransactions11-binCardPartXYZTriggerReplenishment1-binCardPartXYZ2-BinReplenishmentPu

ll库房或供应商1线POU1-箱补充事务处理1-箱系统库存交接与2-箱系统相似前端堆积减少交接过程但降低总体库存量的准确性后端堆积增加了库存准确性（幅度轻微）但增加了系统处理的事务量11-箱卡零件XYZ触

发补充1-箱卡零件XYZ2-BinReplenishmentPullTakeawaysKnowthethevarioustypesofBinReplenishmentsystemsBeabletodescribethebenefitsofaBinsystemH

owtosize(calculate)alltheparametersforaBinsystem2-BinReplenishmentPull总结知道箱补充系统的不同类型能够描述一个箱系统的利益能够去计算一个箱

系统的所有参数2-BinReplenishmentPullMeasureAnalyzeControlImproveLeanSixSigmaAPPENDIX2-BinReplenishmentPullMeasureAnalyzeControlImproveLeanS

ixSigma附录2-箱补充拉系统InstructionsforTypicalCardTriggered2-BinReplenishmentThisprocessusesgreenandredcardstotrig

gerreplenishment;―bins‖areactuallythebox/containerthepart/supplyisshippedin.1.Employeeremovesabinanddropsitsgr

een2-bincardintothemailbox:Pullpartsfrom―bin‖withgreencardbeforeusinganywiththeredcard.2.Atsametime(s)eachday,thecardsarepickedupfromt

hemailboxandreturnedtothestock/supplyroom.3.Thestock/supplyroompullsproperamountofparts/material(notedoncard,setequaltothecalculated―b

in‖quantity).4.Inventorytransactionsareperformed(dependingonissuemethod),andthematerialsandcardsaredeliveredtothestoragelocati

on.5.Employeestocksmaterialinstoragelocationandreturnscardtoitsproperplace.Whenstock/supplyroomreplacesthemateria

l,ensurethattheredcardisplacedonthefullbin.Alwaysleavesyouafullredbinremainingwhengreenbinrunsout.2-BinReplenishmentPull典型的卡触发2-箱补充的介绍这

个流程用绿色和红色卡来触发补充；“箱”是实际用来发货零件/供应品的盒子/容器.1.员工清掉一个箱后，将绿色的2-箱卡放入邮箱:在使用有红色卡的零件前，先从有绿卡的箱中拉零件2.每天的同一时候,邮箱卡片被收集并返回到库房中.3.库房拉动零件/材料的适合数量(在卡上注明，将之设定为

计算出的“箱”数量).4.库存处理被执行了(根据发放的方式),然后材料和卡被传送到仓储地点.5.员工将物料放在仓储地点然后将卡返回到适合的地方.当库房补充材料时，确保红色卡被放在添满的箱上.当绿箱被放出去使用时，始终保持红卡箱中的零件已经被

填满.如果不是这样，在任一箱补充前你将用尽每个箱存货；如果红卡在补充过程中，零件短缺现象即将出现—尽快采取行动。2-BinReplenishmentPullMaintainingaCardTrigger

ed2-BinProcessCheckperiodicallyforlostcardsandreplace.Besttimeisrightafterreplenishment;anycardsnotreplacedorinthemailboxarelost.Pol

icetheproperuseofcards:Supervisor/Leaddropgreencardswhengreenbinisempty.Supervisor/Leaddropredcardsonstockout–investigate!Supervisor/Lead

ensurecardsarereplacedwhenpartsarerestocked.Greenbinsarecompletelyusedbeforeredbins.Resizebinswhendemandchanges.Addcardsfornewpar

ts,deletecardsforobsolete2-BinReplenishmentPull保持卡触发2-箱系统的过程定期检查卡片是否丢失并更换.最佳时间是在补充之后，如果卡片未被更换或未在邮箱都视为丢失维持卡片的合理使用:当

绿卡箱用完变空时，主管/组长投放绿卡.当存货用完时，主管/组长投放红卡–调查!当零件重新补充时，主管/组长确保卡片被更换.在用红卡箱前，确保绿卡箱已经被用完.当需求改变时需要重新调整箱的数量.新增的零件要增加不同的卡，过期的死库存零件要将卡片毁尸灭迹.2-BinReplenish

mentPullBin1Bin2ExampleCardTriggeredLine-Side2-BinRackBin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2B

in1Bin2Bin1Bin12-BinMailboxOrderCards1.AlwayspullmaterialfrombinwithGREENcardifitisthere.2.Store/supplyro

omreplacesmaterialandswitchesREDcardtomaterialjustreplaced.3.Thecardsareattachedtomagneticstriplabels(foreaseofmovementforresizing).Bin1Bi

n1Bin22-BinReplenishmentPullBin1Bin2举例：由卡触发的线旁2-箱货架Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1

Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-箱邮箱订单卡片1.如果这里有绿卡箱，那么必须要从绿卡箱里拉材料.2.库房补充材料并将红卡换到刚补充的材料里.3.卡片最好是有磁性的(这样在调整数量

时可以方便移动).Bin1Bin1Bin22-BinReplenishmentPullExampleCardTriggeredLine-Side2-BinSystem2-BinReplenishmentPull举例：由卡触发的线旁2-箱系统2-BinR

eplenishmentPullExampleCardTriggeredLine-Side2-BinSystem2-BinCardsareGreenandRed,pertheprocess.Cardsareplacedintoplasticsheathstoprotectthemfr

omgettingknockedofftheracking.Clearplasticsheathsareattachedtometalrackingviastickymagneticstripmakeresizingeasier.Bi

nlabelsarewhitestickybackedandplacedinsideofplasticsheathforprotection.Aclearplasticsheathoverawhitelabelindicatesthatthebini

sbeingreplenished.2-BinReplenishmentPull举例：由卡触发的线旁2-箱系统根据流程的需要，2-箱卡是绿卡和红卡.卡片可装入塑料套中以防止摩擦磕碰.透明塑料套通过磁

性体吸附到金属货架上以便容易的调整数量.料箱标签为白色的，贴在塑料套内背面加以保护.塑料套显示出白色时表明料箱正在补充.2-BinReplenishmentPullIfaclearplasticsheath/pouchisused

tohousethelabelandthecard,thenaclearpouchovertheracklabelindicatesthatthepartisonorder–aneasywaytoPok

a-Yoketheprocess.Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:boxUnitsperPack:6000STOCKOUT4Box(es)HaveBeenOrderedLocation=A25

Physical=S-10002-BinR1-L3-S3CommonNamePartNumberPartDescriptionIndicatesPartisonOrderIndicatesQuanti

tyonOrderLine-SideLocationRackandSpaceLocationSampleBin/RackLabel2-BinReplenishmentPull如果一个空塑料套/袋用来收集标贴或卡片时，那么它在货

架上表示该零件已经是在途订单，这是很好的防错措施挡风胶条40130W/STRIP.270HT.187BKFSW标准包装:盒每包件数：6000用完4箱已订货地点=A25物理位置=S-10002-BinR1-L3-S3名称零件号码零件描述指示零件在订货中显示订货数量线旁场

所货架和空间位置箱/货架标签实例2-BinReplenishmentPullWeatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:boxUnitsperPack:6000Order:4Box(es)WhenNo

box(es)AreLeftLocation=A252-BinSpace=S-10002-BinR2-A-4CommonNamePartNumberPartDescriptionIndicatesQuanti

tyonOrderLine-SideLocationRackandBinLocationCardsaretypicallycoloredlightredorlightgreenandlaminatedforprot

ection.Sample2-BinCard2-BinReplenishmentPull挡风胶条40130W/STRIP.270HT.187BKFSW标准包:盒子每包数量:6000订货:当无剩余时，需要4箱订货地点=A

252-箱空间=S-10002-BinR2-A-4卡片一般是亮红或亮绿颜色，并有压膜保护。2-箱卡样板名称零件号码零件描述显示订货数量线旁场所货架和空间位置2-BinReplenishmentPullSampleRackL

ayout–FrontBin1Bin2Bin1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Shelf2Bin1Bin2Shelf1Rack1(SideA)52404SashLock52404Sas

hLock55081LiftBlock-1/1655081LiftBlock-1/1655080LiftBlock-1/855080LiftBlock-1/853221GlazingTape53221GlazingTape57179UpperSas

hLiftBlock57179UpperSashLiftBlock56195FOAMPAD45872PivotBarScrew45872PivotBarScrew50160LockandTiltLatchScrew50160Locka

ndTiltLatchScrew52404SashLock52404SashLock56195FOAMPAD53221GlazingTape53221GlazingTape55474MullionScrew55474MullionScrew

56162Q-LON56162Q-LONBin1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Bin1Bin2Shelf2Shelf1Rack1(SideB)44525LHTiltLatch44525LHTil

tLatch44526RHTiltLatch44526RHTiltLatch56761BalancerScrew56761BalancerScrew56391MullPlug56391MullPlug55230PIVO

TBAR55230PIVOTBAR53221GlazingTape53221GlazingTape53221GlazingTape53221GlazingTape57092SillLiftBlock57092SillLiftBlock5616

2Q-LON56162Q-LON52404SashLock52404SashLock52404SashLock52404SashLock52404SashLock52404SashLockRacklayo

utsdrawninExcel/othermakeexcellentimplementationandupkeepmapstoguidestocking/restockingefforts.Manytimes

itisgoodtohaveparts/suppliesononlyonesideofarack–thatwayyoucan―pullfromoneside‖and―replenishfromtheother.

‖2-BinReplenishmentPull货架排布的样板–前面Bin1Bin2Bin1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Shelf2Bin1Bin2Shel

f1Rack1(SideA)52404SashLock52404SashLock55081LiftBlock-1/1655081LiftBlock-1/1655080LiftBlock-1/855080LiftBlock-1/853221GlazingTape53

221GlazingTape57179UpperSashLiftBlock57179UpperSashLiftBlock56195FOAMPAD45872PivotBarScrew45872PivotBar

Screw50160LockandTiltLatchScrew50160LockandTiltLatchScrew52404SashLock52404SashLock56195FOAMPAD53221GlazingTape532

21GlazingTape55474MullionScrew55474MullionScrew56162Q-LON56162Q-LONBin1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Bin1Bin

2Shelf2Shelf1Rack1(SideB)44525LHTiltLatch44525LHTiltLatch44526RHTiltLatch44526RHTiltLatch56761Balancer

Screw56761BalancerScrew56391MullPlug56391MullPlug55230PIVOTBAR55230PIVOTBAR53221GlazingTape53221GlazingTape53221GlazingTape53221GlazingTa

pe57092SillLiftBlock57092SillLiftBlock56162Q-LON56162Q-LON52404SashLock52404SashLock52404SashLock52404SashLock52404SashLock52404SashLoc

k货架布置一般可用EXCEL或其他工具来做优秀的实施，画张图来指导库存/再次补充库存的努力，大多数是一侧取用零件/供应品，你可以“从一侧拉”并“从另一侧补充”。2-BinReplenishmentPullSampleRackLayout–BackBi

n1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Shelf2Bin1Bin2Bin1Bin2Bin1Bin2Shelf1Rack2(SideA)40130W/ST

RIP40130W/STRIP55148Yellow2155148Yellow2155148Yellow2155148Yellow2155148Yellow2155148Yellow2155142Red

2455142Red2455142Red2455142Red2455142Red2455142Red2455136Blue1255136Blue1255136Blue1255136Blue1255136Blue1255136Blue1255135Blue9551

35Blue955135Blue955135Blue955135Blue955135Blue955145Green2155145Green2155145Green2155145Green2155145Green21

55145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2

155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155148Yellow2155148Yellow2155148Yellow2155148Yellow2155148Yellow215514

8Yellow2140130W/STRIP40130W/STRIP40130W/STRIP40130W/STRIP56762Red956762Red955146Green2455146Green24Bin1Bin2Bin1Bin2Bin1B

in2Bin1Bin2Bin1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bi

n1Bin2Shelf2Shelf1Rack2(SideB)54265NAMIWhite(egress)Label54265NAMIWhite(egress)Label54266RedNAMILabel54266RedNAMILabel54267BlueNAMILabel54267BlueNA

MILabel54268YellowNAMILabel54268YellowNAMILabel57033ClearLabel(specials)LABEL57033ClearLabel(specials)55285Blue

1855285Blue1855138Red1255138Red1255139Red1555139Red1555140Red1855140Red1855286Blue2155286Blue2155147Green2755147Green2755149Yellow24

55149Yellow2455141Red2155141Red2155149Yellow2455149Yellow2455141Red2155141Red2155144Green1855144Green1855303Orange1255303Orange12Ifara

ckhasafrontandabackside,makesuretolabelboth.Also,ifapart/supplystandardpackcanbeseenfrombothsidesoftherack(largebox/container),labelONLYonesidetoav

oidconfusion.2-BinReplenishmentPull货架排布的样板–前面Bin1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Shelf2Bin1Bi

n2Bin1Bin2Bin1Bin2Shelf1Rack2(SideA)40130W/STRIP40130W/STRIP55148Yellow2155148Yellow2155148Yellow2155148Yellow2155148Yellow

2155148Yellow2155142Red2455142Red2455142Red2455142Red2455142Red2455142Red2455136Blue1255136Blue1255136Blue1255136Blue1255136Blue1255136Blue1255135B

lue955135Blue955135Blue955135Blue955135Blue955135Blue955145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green

2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Green2155145Gr

een2155145Green2155145Green2155145Green2155145Green2155145Green2155148Yellow2155148Yellow2155148Yellow2155148Yellow2

155148Yellow2155148Yellow2140130W/STRIP40130W/STRIP40130W/STRIP40130W/STRIP56762Red956762Red955146Gree

n2455146Green24Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Shelf4Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Shelf3Bin1Bin2Bin1Bin2Bi

n1Bin2Bin1Bin2Bin1Bin2Shelf2Shelf1Rack2(SideB)54265NAMIWhite(egress)Label54265NAMIWhite(egress)Label54

266RedNAMILabel54266RedNAMILabel54267BlueNAMILabel54267BlueNAMILabel54268YellowNAMILabel54268YellowNAMILabel57033ClearLabel(spec

ials)LABEL57033ClearLabel(specials)55285Blue1855285Blue1855138Red1255138Red1255139Red1555139Red1555140Red1855140Red1855286Blue2155286Blue21551

47Green2755147Green2755149Yellow2455149Yellow2455141Red2155141Red2155149Yellow2455149Yellow2455141Red2155141Red2155144Green

1855144Green1855303Orange1255303Orange12如果货架是分正反面时，两面都要有标贴。同样，如果零件/供应品的包装箱在货架两侧都可以看见，标签只在一侧标识，以防止混淆.2-

BinReplenishmentPullMeasurementof2-BinEffectiveness2-BinEffectivenessismeasuredby:Stockoutswhenmaterialwasinthes

tock/supplyroomNumberofpartsperday/week/month/yearIndicatesthatthebinisnotsizedcorrectly,ORthereplenishmentleadtimeisincorrect,oralackofdisci

plineintheprocessArepartsorganized?Yes/NoTypicallyavisualcheckoftheprocesswillsuffice,BUTtheprocessmus

tbeauditedatperiodicintervals(once/month)Areunscheduledreplenishmentsbeingmade?Howmanyperday/week/month?

Consistentunscheduledreplenishmentsmayindicatethatdemandhasincreasedandthebinneedstoberesized.2-BinReplenishmentPull2-箱效果的量测2-

箱效果可以由下列方法量测:当材料在库房时的物料短缺每天/周/月/年的零件数量指出箱数量不正确，或补充交货时间不正确，或过程缺乏组织性零件是否有组织的?是/否一般可以目视检查过程的执行能力，但

应定期对过程进行审核（每月一次）是否有计划外补充现象?每天/周/月有多少次?持续的计划外补充表明需求增加，箱数量需调整。2-BinReplenishmentPullStockroomorVendor2-BinLine-SideReplenishmentBa

ckflushingInventory1.PartsarepulledfromlinePOUlocation,backflushingrelievesconsumedinventoryfromline-sidelocation.2.Binispulledfromline-s

idestoragetore-supplyPOUlocation.3.Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4.Binisrefilledwithappropriatequantity.5.Inv

entoryistransferredfromstockroomtoline-sidelocation.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryTransferOccursHere1Line-Sid

eStorage2InventoryBackflush(Charge-Off)OccursHereLinePOU22-BinReplenishmentPull库房/供应商2-箱线旁补充后端堆积库存1.零件从线使用点（POU）的位置被拉动,后端堆积减轻了从线旁消耗的库存.2.箱被拉动着从线旁库存到使

用点（POU）补充位置.3.触发信号(卡,箱,等.)被返回到库房或供应商.4.箱被重新添满到适合的数量.5.库存被转移从库房到线旁位置.6.满箱将回到线旁.2-箱卡零件XYZ触发补充2-箱卡零件XYZ库存转移发生

在这里1线旁库存2库存后端积压(Charge-Off)发生在这里线POU22-BinReplenishmentPullStockroomorVendor2-BinLine-SideReplenishmentFrontflushingInvento

ry1.PartsarepulledfromlinePOUlocation.2.Binispulledfromline-sidestoragetore-supplyPOUlocation.3.Trigger(card,bin,etc.)isret

urnedtostockroomorvendor.4.Binisrefilledwithappropriatequantity.5.Inventoryisfront-flushedoutofstockroomtoWIPorexpenseaccount.6.Fullbinwithtriggerre

turnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryFrontflush(Charge-Off)OccursHere1Line-SideStorage2Line

POU22-BinReplenishmentPull