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2022/11/15精益生产之2箱补充拉系统2BinReplenishmentPull(中精益生产之2箱补充拉系统2BinReplenishmentPull(中精益生产之2箱补充拉系统2BinReplenishmentPull

(中2-Bin补充拉系统2-箱补充拉系统的介绍线旁VS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RD011202精益生产之2箱补充拉系统2BinReplenishmentPull(中Lean

SixSigmaImprovementProcessRoadMapAnalyzeControlImproveDefine•IdentifyProblem•DevelopListofCustomers•DevelopListofCTQ’sfromVoiceoftheCustomer•Finaliz

eProjectFocusandKeyMetrics•CompletePDFMeasure•MapBusinessProcess•MapValueStream•DevelopDataCollectionPlan•Conduct

MeasurementSystemAnalysis•CollectData•ConductProcessCapabilityAnalysisAnalyze•ProposeCriticalX’s•PrioritizeCr

iticalX’s•VerifyCriticalX’s•EstimatetheImpactofEachXonY•QuantifytheOpportunity•PrioritizeRootCauses•ConductRootCauseAnalysison

CriticalX’sImprove•CriticalX’sConfirmed•DevelopPotentialSolutions•SelectSolution•OptimizeSolution•PilotSol

utionControl•ImplementProcessChangesandControls•WriteControlPlan•CalculateFinalFinancial/•ProcessMetrics•Transiti

onProjecttoFutureOwners•IdentifyProject•TranslationOpportunitiesMeasureDefine•ProjectIDTools•ProjectDefinitionForm•NetPrese

ntValueAnalysis•InternalRateofReturnAnalysis•DiscountedCashFlowAnalysis•PIPManagementProcess•RACI•QuadCharts•ProcessMapping•ValueAn

alysis•Brainstorming•Multi-VotingTechniques•ParetoCharts•C&E/FishboneDiagrams•FMEA•CheckSheets•RunCharts•Con

trolCharts•GageR&R•Cp&Cpk•SupplyChainAcceleratorAnalysis•Multi-Vari•BoxPlots•InteractionPlots•Regression•ANOVA•C&EMatrices•FM

EA•Brainstorming•PullSystems•SetupReduction•TPM•ProcessFlow•Benchmarking•Affinity•DOE•HypothesisTesting

•ForceField•TreeDiagrams•GanttCharts•CheckSheets•RunCharts•Histograms•ScatterDiagrams•ControlCharts•ParetoCharts•Interact

iveReviews•Poka-YokeRevised1-12-02精益生产之2箱补充拉系统2BinReplenishmentPull(中LearningObjectivesuUnderstandtheva

rioustypesofbinreplenishmentsystemsuKnowthebenefitsofabinsystemuUnderstandwhentouseabinSystemuBeabletosize(calculate)alltheparametersforabinsystem精益

生产之2箱补充拉系统2BinReplenishmentPull(中课程目的u理解箱补充系统的不同类型u知道一个箱系统的好处u理解何时使用一个箱系统u能够去计算一个箱系统的所有参数精益生产之2箱补充拉系统2BinReplenishmentPull(中What’sinItforMe?u

BeabletoapplythistooltoaBlackBeltprojectuAbletoimplementaBinsystem精益生产之2箱补充拉系统2BinReplenishmentPull(中我学到了什么?u能够在黑带项目中应用这个工具u能

够实施一个箱系统精益生产之2箱补充拉系统2BinReplenishmentPull(中2-BinReplenishmentPullIntroductionuA2-BinReplenishmentPullSystemisasimplifiedver

sionofastandardreplenishmentpullsystemandmaintainsthebenefits:nEstablishesstrategicallylocatedbuffersofpartswithinaproces

slRawmateriallManufacturedpartslPurchasedpartslFinishedgoodsnDe-couplesthesupplyingprocessfromtheconsumingprocessviathebufferinventorynPartre

plenishmentis―triggered‖basedonconsumption精益生产之2箱补充拉系统2BinReplenishmentPull(中2-箱补充拉系统的介绍u2-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：n在

一个流程中建立战略性的零件缓冲区l原材料l制造的零件l采购的零件l成品n通过缓冲库存将供应过程和消耗过程联系起来n零件的补充是基于消耗而触发的精益生产之2箱补充拉系统2BinReplenishmentPull(中WhatIsa2-BinReplenishment?uFormanyparts

inaprocess,a2-Binsystemcanbeusedtoreplenishthepartsversusasynchronoussupply:nAbinhasenoughparts/suppliestocoveracalculatedperiodofusage

atthepoint-of-use.nWhenthebinrunsout,a2ndbinistheretotakeitsplacewhilethe―1st‖isbeingrefilled/replenished.uTherearetwoprimaryreplen

ishmentlocations:Line-SideandPointofUse精益生产之2箱补充拉系统2BinReplenishmentPull(中2-箱补充拉系统是什么?u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:n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。n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。u有两个主要的补充地点：线旁和使用点精益生产之2箱补充拉系统2BinReplenishmentPull(中Benefitsof2-BinReplenis

hmentuOrganizedandoverallcleanerappearanceofstoredmaterialsuReducedfrequencyoforderssubmittedtothestockroom/vendoruReducednumberoftripsforre-

supplyuBettermanagementofinventoryontheshopflooruMorepredictableinventorycostsuImproveemployeeproductivityby:nEliminatin

gpart/supplyshortagesatthepoint-of-usenReducetimewastedbypersonnel/supervisionretrievingsupplies/inventoryfromthestockroo

mand/orvendorsnEliminatelostormisplacedmaterialu2-BinReplenishmentcanbeusedforoffice/safetysupplies,productioninventory,production

supplies–evenathome!精益生产之2箱补充拉系统2BinReplenishmentPull(中2-箱补充拉系统的好处u存储的材料外观非常清洁和有条理u提交给库房/供应商的频率减少u重复供应的差错数量减少了u现场库存的管理更好u库存成本更具有预测性u提高员工生产率:n排除在使用

点的零件/供应短缺n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n排除材料的丢失或放错地方u2-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!精益生产之2箱补充拉系统

2BinReplenishmentPull(中WhentoUse2-BinReplenishmentPulluRepetitiveproductoffering/processuRelativelyconsistentdema

nd/volume(lowvariability)uPart/supplyshortagesareaconsistent/costlyproblemuPart/supplyinventorycostsare―outofcontrol‖dueto:nLostormi

splacedparts/suppliesnLackofissue/dispersaldisciplineorcontrol精益生产之2箱补充拉系统2BinReplenishmentPull(中何时使用2-箱补充拉系统u重复的产品供应/流程u重复稳定的需求(底变异)u零件/供应

短缺是常事，且是一个代价很大的问题u零件/供应库存成本是失控的，由于：n零件/供应品丢失或放错地方n缺乏投料/分发的一致性或控制精益生产之2箱补充拉系统2BinReplenishmentPull(中WhatIsaBin?uDoesn’tnecessarilylooklike

a―bin‖nCanbeastandardplasticbin(Acro-bin)nCanalsobethebox/containerthepart/supplyisshippedin(alsocalleda―standardpack‖–purchasingdefinitio

n)uWhenthebox/containermethodisused,a―bin‖canbeonestandardpackorseveralstandardpacks.Examples:n1boxofscrewsn2boxesofscrewsn1drumofoiln30ba

gsofconnectorsn1rolloflabelsn4tubesofsealant精益生产之2箱补充拉系统2BinReplenishmentPull(中一箱是什么?u这并不是说一定要看上去像个“箱子”n它可以是一个标准的

塑料箱n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”)u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：n1盒螺钉n2盒螺钉n1打油n30包连接器n1卷标贴n4管子密封剂精益生产之2箱补充拉系统2BinReplenishmen

tPull(中2-BinReplenishmentDataParameters/NeedsuDemand/Usage(DMD)nTypicallyexpressedintermsofAverageDailyUsage(ADU)inunitsuLeadTime(LT)nThetimeitt

akesfromwhenatriggerissenttowhenreplenishmentarrivesnInthiscase,canalsobethoughtofas―RestockingTime‖uOrderFr

equency(OF)nIforders/triggersaresentatscheduledtimes(i.e.,noteveryday,suchasonceperweek)nTypical2-Binsyste

msdonotuseanOrderFrequency,asreplenishmentcanoccureveryday/shift(ormore)uBox/ContainerQuantitynIfstock/supplyroomorvendordoesnotb

reakdownshippingquantity,thenthebinquantitymaybesetequaltosomemultipleofthebox/containerquantity(standardpack)thatthepart/supp

lyisshippedinuSafetyStocknTypically1/2themax(LT,OF)*DMD,maybesetotherwisedependentonindividualconditions精益生产之2箱补充拉系统2BinReplenishmentPull(中2-箱

补充系统数据参数/要求u需求/使用(DMD)n一般来说用平均每天用量（ADU）来表达u交货期(LT)n从补充需求触发到补充品到达的时间。n在这里，也可以被认为是“再进货时间”。u订单频率(OF)n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）n2-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）u盒子/容器数量n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u安全库存n一般来说的设定为

1/2max(LT,OF)*DMD,否则根据独立的情况来看精益生产之2箱补充拉系统2BinReplenishmentPull(中StockRoomorVendor12FullBin/CardMove1to2when2ispulled,SendTriggerUseComponen

tsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)2-BinReplenishment(“Line-Side”Stocking)uReducespart/suppl

yshortagesincreasingproductivityuFacilitatesWIPreductionuWillresultinsignificantproductivityimprovementsinstock/supplyroomuR

educes/eliminatesstockroomimpactonlotsizesuMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF2精益生产之2箱补充拉系统2BinRe

plenishmentPull(中库房或供应商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)u减少零件/供应品库存，增加生产效率u促进WIP的降低u将导致在库房里的显著的生产力提高u降低/消除库

房在批数量上的影响u可以简单化存货/周转的计算流程线旁库存LTOF2SS/2DMDOF),LTmax(箱数量+*=精益生产之2箱补充拉系统2BinReplenishmentPull(中FullBin/CardPul

lfrom1untilempty,sendtriggerandpullfrom2untilempty,sendtrigger,etc.UseComponentsEmptyBin/Card2-BinReplenishment(

“Point-ofUse”Stocking)LTOF12-BinPOUstockingisusedwhenre-stockingisnotanissue.StockRoomorVendorPoint-Of-Us

e(POU)LocationsorWork-In-Process(WIP)2精益生产之2箱补充拉系统2BinReplenishmentPull(中拉动从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)L

TOF1SS/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)精益生产之2箱补充拉系统2BinReplenishmentPull(中2-BinReplenish

mentCalculationsuBinQuantity=Max(LT,OF)+SS/2nIfreplenishinginstandardpacks,BinQuantityisroundeduptotheneareststandar

dpackmultipleuExample:nCalculatetheBinQuantityforthefollowing(standardpackreplenishment):lPartNumber:4

0567lDescription:RubberGloveslDemand/Usage:25pairs/daylLeadTime:2days(trigger-stock/supplyroom-replenishment)lOrd

erFrequency:N/AlBoxQuantity:50pairsnBinQuantityl=[Max(2days,N/A)*25pairs/day]+.5*[Max(2days,N/A)*25pairs/day]/2l=63pairsnButwehavetoroundupt

otheneareststandardpack,so:lBinQuantity=100pairs=2boxes精益生产之2箱补充拉系统2BinReplenishmentPull(中2-箱补充的计算u箱数量=Max(LT,OF)+SS/2n如果是标准包的补充，箱数量应该是近似于标

准包的倍数u举例:n计算下列数据的箱数量(标准包补充):l零件号码:40567l描述:橡胶手套l需求/用量:25双/天l交货时间:2天(触发–库房–补充)l订单频率:不适用l箱数量:50双n箱数量l=[Max(2天,N/A)*25双/天]

+.5*[Max(2天,N/A)*25双/天]/2l=63双n但是我们要取一个近似标准箱的数量，所以:l箱数量=100对=2箱精益生产之2箱补充拉系统2BinReplenishmentPull(中Exercise#1:2-BinReplenishmentuCalcu

latetheBinQuantityforthefollowingsupplyitemina2-BinLine-SideReplenishmentprocessdirectlylinkedtothesupplier:nPartNumber:80886nDescrip

tion:PrinterPapernDemand/Usage:22reams/daynLeadTime:4days(trigger-purchasing-supplier-receiving-replenishme

nt)nOrderFrequency:5daysnBoxQuantity:10reamsuBinQuantityn=[Max(,)*]+.5*[Max(,)*]/2n=.uButwehavetorounduptotheneareststandardpack,so:nBinQuantity

==.精益生产之2箱补充拉系统2BinReplenishmentPull(中练习#1:2-箱补充u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:n零件号码:80886n描述:打印纸n需求/用量:22令/天n交货时间:4天(触

发–采购–运输–收货–补充)n订单频率:5天n箱数量:10令u箱数量n=[Max(,)*]+.5*[Max(,)*]/2n=.u但是我们要取一个近似标准包的数量，所以:n箱数量==.精益生产之2箱补充拉系统2BinReplenishmentPull

(中Exercise#2:2-BinReplenishmentuCalculatetheBinQuantityforthefollowingassemblyitemina2-BinLine-SideReplenishmentprocesslinkedtothewarehouse

:nPartNumber:A44B2nDescription:4"Dia.SteelExtrusionnDemand/Usage:225ft/daynLeadTime:1day(trigger-warehouse-replenishment)nOrderFrequency:

N/AnExtrusionLength:30ftuBinQuantityn=[Max(,)*]+.5*[Max(,)*]/2n=.uButwehavetorounduptotheneareststandardpack,so:nBinQuant

ity==.精益生产之2箱补充拉系统2BinReplenishmentPull(中练习#2:2-箱补充u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:n零件号码:A44B2n描述:直径4―的钢铁拉丝n需求/用量:225英尺/天n交货

时间:1天(触发–仓库–补充)n订单频率:不适用n拉丝长度:30英尺u箱数量n=[Max(,)*]+.5*[Max(,)*]/2n=.u但是我们要取一个近似标准包的数量，所以:n箱数量==.精益生产之2箱补充拉系统2BinReplenishmentPull(中12-BinR

eplenishmentBinLabelingandInformationuEachBin/StorageLocationshouldhaveabarcodelabelortag.nMakesurenottouse

apermanentlabelappliedtoarack/bin,becauseyouwilleventuallywanttoresizeandmayhavetomakenewlabels!nLabelsforLineSideBins/TagsforResupplyBinsuPartN

umber,Description,andLocationarePrinted.uBinQuantityshouldnotbeprinted(requirestoomanylabelchangeswhenresizing–tri

ggermechanismorsystemwillhaveBinQuantity)uEachBinLocationshouldbeuniquetoavoidconfusionwhenrestocking.uExamplesareintheAppendix.Locatio

nPartNumberDescription2LocationPartNumberDescription精益生产之2箱补充拉系统2BinReplenishmentPull(中12-箱补充箱标贴和信息u每个箱/库存地点都应该有一个条码

标贴或标签u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！n在线旁的需要重新补充的箱上的标贴u被打印的零件号码,描述,地点等u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)u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u举例在附件里.地点零件号码描述2地点零件号码描述精益生产之2箱补充拉系统2BinReplenishmentPull(中N

otesona1-BinSystemuAonebinsystemisanexceptiontothe2-binforveryslowmovingparts/supplies.u1-binpartsarenotstoredi

n2-binsbecauseof:nHighinventorycostnSpacerequirementsnRacking/storagecostu1-binsarereplenisheduponstockoutattheLine-Sidelocati

on.uStockoutimpactshouldbelowbecause:nParts/suppliesareverylowusers.nParts/suppliesarealsoatpointofusewhenLine-Sidestockoutoc

curs.nParts/suppliesarestockedinnearbystock/supplyroom–easytoreplace.精益生产之2箱补充拉系统2BinReplenishmentPull(中1-箱系统的注意u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.u1-箱零件不象2-箱那样被存储，因为:n高库存成本n空间需要n货架/仓储成本u在线旁的地点库存短少时，1-箱被补充。u库存短少的影响应该是微弱的，因为:n零件/供应品是非常少的使用者。n当线旁

的存货短缺发生时，零件/供应品也同样在使用点.n零件/供应品被存放在库房附近—容易补充.精益生产之2箱补充拉系统2BinReplenishmentPull(中StockRoomorVendor11FullBin/CardMove1to2

when2ispulled,SendTriggerUseComponentsEmptyBin/CardPoint-Of-Use(POU)LocationsorWork-In-Process(WIP)1-BinReplenishment(Typicallyfrom“Line-S

ide”)uReducespart/supplyshortagesincreasingproductivityuFacilitatesWIPreductionuWillresultinsignificantproductivityimprovementsinstock/supplyr

oomuReduces/eliminatesstockroomimpactonlotsizesuMaysimplifyinventory/cyclecountprocessesLine-SideStorageLTOF1精益生产之2箱补充拉系统2BinReplenishm

entPull(中库房或供应商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DMD精益生产之2箱补充拉系统2

BinReplenishmentPull(中StockroomorVendor1LinePOU1-BinReplenishmentTransactionsu1-BinSysteminventorytransactionsmirrorthoseofthe2-B

insystemnFrontflushforreducingtransactionsbutreduceoverallinventoryaccuracynBackflushforincreasinginventorya

ccuracy(slightly)butincreasenumberofsystemtransactions11-binCardPartXYZTriggerReplenishment1-binCardPartXYZ

精益生产之2箱补充拉系统2BinReplenishmentPull(中库房或供应商1线POU1-箱补充事务处理u1-箱系统库存交接与2-箱系统相似n前端堆积减少交接过程但降低总体库存量的准确性n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XYZ精益生产之2箱补充拉系统2BinReplenishmentPull(中TakeawaysuKnowthethevarioustypesofBinReplenishmentsystemsuBe

abletodescribethebenefitsofaBinsystemuHowtosize(calculate)alltheparametersforaBinsystem精益生产之2箱补充拉系统2BinReplenishmentPull(中总结u知道箱补充

系统的不同类型u能够描述一个箱系统的利益u能够去计算一个箱系统的所有参数精益生产之2箱补充拉系统2BinReplenishmentPull(中APPENDIX2-BinReplenishmentPull精益生产之2箱补充拉系统2BinReplenishmentPull(中附录2-箱补充拉

系统精益生产之2箱补充拉系统2BinReplenishmentPull(中InstructionsforTypicalCardTriggered2-BinReplenishmentThisprocessusesgreenandredcard

stotriggerreplenishment;―bins‖areactuallythebox/containerthepart/supplyisshippedin.1.Employeeremoves

abinanddropsitsgreen2-bincardintothemailbox:nPullpartsfrom―bin‖withgreencardbeforeusinganywiththeredcard.2.Atsa

metime(s)eachday,thecardsarepickedupfromthemailboxandreturnedtothestock/supplyroom.3.Thestock/supplyroompullsproperamountofpa

rts/material(notedoncard,setequaltothecalculated―bin‖quantity).4.Inventorytransactionsareperformed(dependingonissuemethod),andthemater

ialsandcardsaredeliveredtothestoragelocation.5.Employeestocksmaterialinstoragelocationandreturnscardtoitsproperplace.nWhenstock/supplyroomrepl

acesthematerial,ensurethattheredcardisplacedonthefullbin.lAlwaysleavesyouafullredbinremainingwhengreenbinrunsout.lIfnot,youcould

rundownbothbinsandstockoutbeforeeitherisreplaced;ifaredcardisinthereplenishmentprocess,apartshortageisim

minent–actfast!精益生产之2箱补充拉系统2BinReplenishmentPull(中典型的卡触发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:n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.n当库房补充材料时，确保红色卡被放在添满的箱上.l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.l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。精益生产之2箱补充拉系统2BinReplenishmentPull(中MaintainingaCardTriggered2-BinProcessuCheckperiodi

callyforlostcardsandreplace.nBesttimeisrightafterreplenishment;anycardsnotreplacedorinthemailboxarelost.uPolicetheproperuseofc

ards:nSupervisor/Leaddropgreencardswhengreenbinisempty.nSupervisor/Leaddropredcardsonstockout–investigate!nSupervisor/Leadensurecardsarer

eplacedwhenpartsarerestocked.nGreenbinsarecompletelyusedbeforeredbins.uResizebinswhendemandchanges.uAddcardsforn

ewparts,deletecardsforobsoleteparts.精益生产之2箱补充拉系统2BinReplenishmentPull(中保持卡触发2-箱系统的过程u定期检查卡片是否丢失并更换.n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u维持卡片的合理使用:n当绿卡箱用完变空时，主管/组长投放绿卡.n当存货用完时，主管/组长投放红卡–调查!n当零件重新补充时，主管/组长确保卡片被更换.n在用红卡箱前，确保绿卡箱已经被用完.u当需求改变

时需要重新调整箱的数量.u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.精益生产之2箱补充拉系统2BinReplenishmentPull(中Bin1Bin2ExampleCardTriggeredLine-Side2-BinRackBin1Bin2Bin1Bin2Bin1Bin2

Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin12-BinMailboxOrderCards1.Alwayspullmat

erialfrombinwithGREENcardifitisthere.2.Store/supplyroomreplacesmaterialandswitchesREDcardtomaterialjustreplace

d.3.Thecardsareattachedtomagneticstriplabels(foreaseofmovementforresizing).Bin1Bin1Bin2精益生产之2箱补充拉系统2BinReplenishmentP

ull(中Bin1Bin2举例：由卡触发的线旁2-箱货架Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2Bin1Bin2

Bin1Bin2Bin1Bin12-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).Bin1Bin1Bin2精益生产之2箱补充拉系统2BinReplenishmentPull

(中ExampleCardTriggeredLine-Side2-BinSystem精益生产之2箱补充拉系统2BinReplenishmentPull(中举例：由卡触发的线旁2-箱系统精益生产之2箱补充拉系统2BinReplenishmentPull(中ExampleCardTri

ggeredLine-Side2-BinSystemu2-BinCardsareGreenandRed,pertheprocess.uCardsareplacedintoplasticsheathstoprotectthemfromge

ttingknockedofftheracking.uClearplasticsheathsareattachedtometalrackingviastickymagneticstripmakeresizingeasier.uBinlab

elsarewhitestickybackedandplacedinsideofplasticsheathforprotection.uAclearplasticsheathoverawhitelabelindicatesthatthebinisbeingre

plenished.精益生产之2箱补充拉系统2BinReplenishmentPull(中举例：由卡触发的线旁2-箱系统u根据流程的需要，2-箱卡是绿卡和红卡.u卡片可装入塑料套中以防止摩擦磕碰.u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.u料箱标签为白色的，贴在塑料套内背面加以保护.u塑料套显示出白色时表明料箱正在补充.精益生产之2箱补充拉系统2BinReplenishmentPull(中Ifaclearplasticsheath/pouchi

susedtohousethelabelandthecard,thenaclearpouchovertheracklabelindicatesthatthepartisonorder–aneasywaytoP

oka-Yoketheprocess.Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:boxUnitsperPack:6000STOCKOUT4Box(es)HaveBeenOrder

edLocation=A25Physical=S-10002-BinR1-L3-S3CommonNamePartNumberPartDescriptionIndicatesPartisonOrderIndic

atesQuantityonOrderLine-SideLocationRackandSpaceLocationSampleBin/RackLabel精益生产之2箱补充拉系统2BinReplenishmentPull(中如果一个空塑料套/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

架标签实例精益生产之2箱补充拉系统2BinReplenishmentPull(中Weatherstrip40130W/STRIP.270HT.187BKFSWStandardPack:boxUnitsperPack:6000Order:4Box(es)WhenNobox(

es)AreLeftLocation=A252-BinSpace=S-10002-BinR2-A-4CommonNamePartNumberPartDescriptionIndicatesQuantityonOrderLine-SideLocationRackand

BinLocationCardsaretypicallycoloredlightredorlightgreenandlaminatedforprotection.Sample2-BinCard精益生产之2箱补充拉系统2BinReplenishment

Pull(中挡风胶条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=A252-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精益生产之2箱补充拉系统2BinReplenishmentPull(中SampleRackLayout–FrontRacklayoutsdrawninExcel/ot

hermakeexcellentimplementationandupkeepmapstoguidestocking/restockingefforts.Manytimesitisgoodtohaveparts/suppliesononlyonesideofarack–thatwayyouc

an―pullfromoneside‖and―replenishfromtheother.‖精益生产之2箱补充拉系统2BinReplenishmentPull(中货架排布的样板–前面货架布置一般可用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”。精益生产之2箱补充拉系统2BinReplenishmentPull(中SampleRackLayout–BackIfarackhasafrontandabacks

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

oidconfusion.精益生产之2箱补充拉系统2BinReplenishmentPull(中货架排布的样板–前面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.精益生产之2箱补充拉系统2BinReplenishmentPull(中Measurementof2-BinEffectiveness2-BinEffectivenessismeasuredby:uStockouts

whenmaterialwasinthestock/supplyroomnNumberofpartsperday/week/month/yearnIndicatesthatthebinisnotsizedcorrectly,ORthereplenishmentleadtimeisinco

rrect,oralackofdisciplineintheprocessuArepartsorganized?nYes/NonTypicallyavisualcheckoftheprocesswillsuffice,BU

Ttheprocessmustbeauditedatperiodicintervals(once/month)uAreunscheduledreplenishmentsbeingmade?nHowmanyperday/week/m

onth?nConsistentunscheduledreplenishmentsmayindicatethatdemandhasincreasedandthebinneedstoberesized.精益生产之2箱补充拉系统2BinReplenishmentPull(中2-箱

效果的量测2-箱效果可以由下列方法量测:u当材料在库房时的物料短缺n每天/周/月/年的零件数量n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u零件是否有组织的?n是/否n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）u是否有计划

外补充现象?n每天/周/月有多少次?n持续的计划外补充表明需求增加，箱数量需调整。精益生产之2箱补充拉系统2BinReplenishmentPull(中StockroomorVendor2-BinLine-SideReplenishmentB

ackflushingInventory1.PartsarepulledfromlinePOUlocation,backflushingrelievesconsumedinventoryfromline-sidelocation.2.Binispulledfromline-side

storagetore-supplyPOUlocation.3.Trigger(card,bin,etc.)isreturnedtostockroomorvendor.4.Binisrefilledwithappropria

tequantity.5.Inventoryistransferredfromstockroomtoline-sidelocation.6.Fullbinwithtriggerreturnstoline.2-binCardPartXYZTrigger

Replenishment2-binCardPartXYZInventoryTransferOccursHere1Line-SideStorage2InventoryBackflush(Charge-Off)OccursHereLinePOU2精益生产之2箱补充拉系统2BinReplenish

mentPull(中库房/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POU2精益生产之2箱补充拉系统2BinReplenish

mentPull(中StockroomorVendor2-BinLine-SideReplenishmentFrontflushingInventory1.PartsarepulledfromlinePO

Ulocation.2.Binispulledfromline-sidestoragetore-supplyPOUlocation.3.Trigger(card,bin,etc.)isreturnedto

stockroomorvendor.4.Binisrefilledwithappropriatequantity.5.Inventoryisfront-flushedoutofstockroomtoWIPorexpenseaccou

nt.6.Fullbinwithtriggerreturnstoline.2-binCardPartXYZTriggerReplenishment2-binCardPartXYZInventoryFrontfl

ush(Charge-Off)OccursHere1Line-SideStorage2LinePOU22022/11/15精益生产之2箱补充拉系统2BinReplenishmentPull(中演讲完毕，谢谢听讲!再见，seeyouagain3rew