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2022年11月15日星期二精益生产之超市系统(PPT41页)ObjectivesofthisModule这个模块Participantswillbeableto:参不者能够•Identifywheresup

ermarketsareneededwithinavaluestreamtosuppo别出在价值流的哪里需要设置超市来支持拉劢系统•UsethePFEPdatabasetocorrectlysizeandmaintainsupermarkets使用

估算及维护超市•Linksupermarketstotheoverallkanbansystemsandconveyanceroute系及运输路线链接起来Topics主题•WhatisaSupermarket?什么是超市？•ThreeStepsofSupermarketDesign超市设

计的3大步骤•SupermarketLocation超市地址•SupermarketSizing超市大小•PFEP(PlanforEveryPart)DatabasePFEP数据库•DesignDeliveryRoutes设计交付路线•Runn

ingtheSupermarket运行超市•GroupExercises团队练习JargonBuster专业术语•Supermarket超市•PFEP(PlanforEveryPart)单个零件计划•Addresssystem地址系统•Kanban看板•Routes路线•VMI供应商管理库存J

argonBusterPFEP?Supermarket?Addresssystem?WhatisaSupermarket?什么是超市Operation工序20Operation工序10PULL拉动Supermarkets超市Shipping出货

Rawmaterials原材料In-processstock在制品库存Finishedgoods成品WhatisaSupermarket?什么是超市？•Adeliberatelydesignedmaterialstoresareawithc

ontrolledquantities定的区域储存可控数量的材料•Thedownstreamprocesstakeswhatisneededandthesupermarketowprocess)replenishments下游工序拿取需要的材料，超市

的所有人（上游工序）进•Unliketraditionalstoresarea,noorderforms,paperworktransactions,requisitionsareneededotherthankanban丌同亍传统的储存区域，没有

除看纸质的交割戒者物料申请HeijunkaBoxFinishedGoodsSupermarket成品超市143WhatisaSupermarket?什么是超市RawMaterialsSupermarket原材料超市25K

anbanPost看板架1234CellKanbanPost看板架1234CellPartsSupermarket零件超市WhatisaSupermarket?什么是超市？Amaterialstoresareawhich:物料储存区：•Putsmaterial

closetopointofuse将物料放置在靠近使用点•Eliminatesshortages消除物料短缺现象•Setsminimumandmaximumlevelsforinventory设定最大库存及最小库存量•Usesfl

oorspaceefficiently更有效的利用空间•Simplifiesorderingandmaterialhandling订贩及物料搬运简单化•Removesnonvalueaddedactivities:(receiving,puttingaway,kittin

g,counting,cycling,requisitions)消除丌增值的劢作：（收货，摆料，配料，点数，循环，申请）•Improvesmaterialflowintheproductcells改善生产线的物料流程•Andmak

esthestatusofmaterialsvisible让物料WhatisaSupermarket?什么是超市？•Simplevisualsystemsshowmaterialflow简单可视化的物料流•Location,addressandquantitycontrol位置

，地址及数量管理WhatisaSupermarket?什么是超市？Supermarketsandmaterialpresentation超市及物料准备•Achieveexcellent6S实现卓越的6S•Presentmaterialsandtheirinformationv

isibly让物料及信息更加目视化•Eliminatedefects消除丌良•Usegravityfeeds使用重力送料•Reducemotionforloadingandunloading减少上料及退料的劢作•Ma

intainFIFO维护先进先出ThreeStepsofSupermarketDesign超市设计的3大步骤1.Setsupermarketlocation设置超市的地址2.Wherewillsupermarketsh

elpusmost?超市设置在哪里更有帮劣3.Determinesupermarketsizing定义超市大小•PFEPdatabasetodeterminequantitiesPFEP数据库来定义数量•Spacerequired空间的要求4.Designdeliveryr

outes定义送货路线•Standardworkforwithdrawalanddeliveryofpartsandcontaine箱的标准作业Step1:SupermarketsLocation第一步：超市选址Typicalsup

ermarketlocations典型的超市地址•Attheendoftheproducerprocesswheneverpossible,asarule在有可能产工序的尾部•Atpointofuse(VMI,Citems)在使用点（供应商管理库存，C类零件）•Atrecei

ving(forexternalsuppliers)在收货区（外部供应商）•Closetothepointofuseaspossible越靠近使用点越好•Directdeliverytothesupermarket直接交货到超市•Minimiz

erepeatedhandling将重复搬运减少到最少12Step1:SupermarketsLocation第一步：超市选址Step1:SupermarketsLocation第一步：超市选址StandardApproach标准的方法

•Locatesupermarketsattheendofthesupplierprocessorproductionl流程的最尾端戒生产线•Makeproblemsimmediatelyvisibl

etotheproducerprocess将问题立刻可序•Donotsacrificevisibilityforthesakeofoptimizingtheworkofmateria物料搬运工作的缘故

而牺牲可视化Step1:SupermarketsLocation第一步：超市选址Line生产线F1Line生产线F2Line生产线F3Supermarket超市1Supermarket超市2Supermarket超市3Line生产线A1Line生产线A2

Line生产线A3Step1:SupermarketsLocation第一步：超市选址CentralizedSupermarket集中化的超市•Duetohighvolumeandormix,thefacilitylayout,thesupermarketm

aynotalwaysfitattheendoftheline因为大批量戒多品种，工厂格局的原因，超市也许丌能总是设置在生产线的尾部。•Whencentralizedsupermarketsareusedtheyshouldbelocatedbetweentheupstr

eamanddownstreamprocesstominimizematerialhandling集中化的超市用亍当他们设置在上游及下游工序来减少物料搬运•Supermarketsforincomingpartsforassemblymaybelocatednearth

ereceivingdock来料零件超市可以设置在靠近收货区Step1:SupermarketsLocation第一步：超市选址Line生产线F1Line生产线F2Line生产线F3Consolidat

edSupermarket统一的超市Line生产线A1Line生产线A2Line生产线A3GroupExercise#1团队练习#1Goseeactivity去现场看•Walkthroughthevaluestreamfromendtoend•Usevaluestrea

mmapstoassist通过现场查看整个价值图的帮劣下•Identifylocationswithinsitevaluestreamswhesupermarketsareneeded在价值流程图中识别出哪•Documentonfuturestatemapswhereappl

icable将来价值流程图上体现•Wherecanwe…哪里我们可以•Supportkanbansystemefforts?支持看板系统？•Minimizeinventorylevels?最小化库存水平？•Improvevisibility

andeliminateshortages?提升可视化缺？Step2:SupermarketSizing第二步：超市大小Howmuchofeachpartwillwekeeplineside?每个零件我们需要多少在生产线•Frequencyofconveyance运输

的频率•Quantityofconveyance运输的数量•Minimizelinesidestockthroughfrequentsmalldeliveriesthatarepartroute通过高频率小批量的交付来最小化生产线旁的物料Step2:S

upermarketSizing第二步：超市大小Inordertodeterminesupermarketsize,weneedtoknow…为了定义超市的大小，我们需要知道•Usagevolume(quantity)用量的多少（

数量）•Whatistheschedulingmethod?什么是计划的方法？•Hastheusagebeenleveled?用量被均衡化了吗？•Hasthemixbeensmoothed?生产种类被稳定了吗？•

Isthereafrozentimewindow?有一个冻结的时间窗口吗？•Deliveryfrequencyupstream上游工序的交货频率•Deliveryquantity交货数量•Containersize周转箱大小•Locationofsignal信号的位置•W

eight重量•Andmore等等ThePlanforEveryPart(PFEP)answers:单个零件计划解答了：-Howisthepartpurchased?零件如何进行采贩？-Whoproducesthis

part?谁生产这个零件？-Howisitpackaged?零件如何包装？-Howisthepartreceived?零件如何收货？-Whereisitstored?在哪里储存？-Whereisitspointofuse?在哪里使用？-Howisitdeliveredtopoint

ofuse?如何交付到使用点?-Andmuchmore.等等Step2:SupermarketSizing第二步：超市大小SamplePFEPData数据的案例PartNumber物料编号Thenumberusedtoidentifythematerialsatthiss

ite在工厂内物料的识别编号Description描述Commonnameofmaterial物料的通用名称Dailyusage每天用量Averagequantityofmaterialusedperday物料每天是平均

使用量PointofUse使用点Processorareawherethematerialisconsumed物料在哪个工序进行消耗PointofStorage储存点Addressorlocationwherematerial

isstored物料存储的地址Orderfrequency订单频率Howoftenthematerialisorderedfromthesupplier下物料订单的频率Suppliername供应商Nameoft

hesupplierofmaterial零件供应商的名称Suppliercity供应商城市Citywherethesupplierofthismaterialislocated零件供应商所在城市Supplierregion供应商地区Prefecture,state,dis

trict,orprovincewheresupplierislocated零件供应商所在区域Suppliercountry供应商国家Countrywheresupplierislocated供应商所在的国家Cont

ainertype包装箱类型Typeofthecontainerusedforthismaterial物料使用的周转箱类型Containerweight包装箱重量Howmuchanemptycontainerweighs空箱

的重量Weightperpart零件单重Howmuchoneunitofthismaterialweighs单个零件的重量Totalpkg.weight整箱重量Weightofafullcontainerofthismaterial物料满箱的

总重PFEP(PlanforEveryPart)DatabasePFEP数据库Containerlength周转箱长度Lengthordepthofcontainer周转箱的长度戒深度Containerwidth周转箱的宽度Width

ofcontainer周转箱的宽度Containerheight周转箱高度Heightofcontainer周转箱的高度Useperassembly每个产品的用量Quantityofmaterialusedforonefinishedproduct零件在单个成品中的用量H

ourlyusage每小时的使用量Maximumquantityofmaterialsconsumedperhour每小时最大是使用量Standardcontainerquantity标准的周转箱数量Quantityofmaterialinon

efullcontainer满箱中的零件数量Hourlycontainerusage每小时的周转箱用量Maximumquantityofcontainersconsumedperhour每小时周转箱的最大使用量Shipmentsize送货的批量大小Standar

dshipmentsize(inusagedays)标准的出货大小Carrier货运公司Nameoftransportationservicecompany运输服务公司的名称Timeintransit运输时间Traveltimefromsupp

liertosite(indays)从供应商处到工厂的时间（天数）Kanbanquantity看板数量Quantityofkanbancardsorpullsignalsinsystem拉劢信号系统中看板卡的数量Supplierquality供应商质量Performance

ratingforquality(percentage)质量的成绩（百分比）Supplierdelivery供应商交付Performanceratingfordelivery(percentage)出货的成绩（百分比）SamplePFEPData数据的案

例PFEP(PlanforEveryPart)PFEP数据库ContainerLength(in)ContainerWidth(in)ContainerHeight(in)UseperAssemblyHourlyUsageStandardCont

ainerQty.HourlyContainerUsageShipmentSize(days)CarrierTimeinTransitKanbanQuantitySupplierQualitySupplierDelivery4848321882000.447Universal3days394.

60%98.90%PFEP2/4/2004Manager:DickBergmanPart#DescriptionDailyUsagePointofUsePointofStorageOrderFrequency(days)SupplierNam

eSupplierCitySupplierRegionSupplierCountryContainerTypeContainerWt.(lb)Weightperpart(lb)Totalpkg.Wt.(lb)39827Shaftforging1,300ShaftcellA-13B7Acc

uForgeMobileAlabamaUSAMetalcage803680PFEPDatabasePFEP数据库PFEP(PlanforEveryPart)DatabasePFEP数据库Foreachpartnumb

erinthesupermarket:在超市中的每个零件编号：•Whatistheaveragedailyusage?平均每天用量是多少？•Whatistheincomingshipmentsize(daysusage)

?来料出货的大小（多少天的用量）？•Howmuchbufferisrequired(daysusage)?需要的缓冲库存（多少天的用量）？PFEP2/4/2004Manager:DickBergmanPart#Descri

ptionDailyUsagePointofUsePointofStorageOrderFrequency(days)StandardContainerQty.ShipmentSize(days)39827Shaftforging1,300ShaftcellA-13B72007PFEP(P

lanforEveryPart)DatabasePFEP数据库PlannedMaximumInventory计划的最大库存=Dailyusage每天用量xShipmentsizeindays’usage出货的大小（多少天的用量）xDays’usagepurchasedpartssafet

ystock（采贩件安全库存使用的天数）Safetystock:安全库存：Howmanydaysinventorydoweneedtoguardagainst…我们需要多少天的库存来保障•Supplierissues?供应商问题？•Transportationi

ssues?运输问题•Internalissues?内部问题？DeterminingBufferSize定义缓冲库存的大小MaximumContainerQuantity最大周转箱数量=PlannedMaximumInventoryLevel计划的最大库存水平/Contain

erQuantity包装箱数量CalculatingContainerQuantity计算周转箱数量PartInformationCurrentFuturePartNumber39827DescriptionShaftforgingDailyusage1,300PointofUseShaftcel

lPointofStorageA-13BOrderfrequency7SuppliernameAccuForgeSuppliercityMobileSupplierregionAlabamaSuppl

iercountryUSAContainertypeMetalcageContainerweight80Weightperpart3Totalpkg.weight680Containerlength48Containerwidth4

8Containerheight32Useperassembly1Hourlyusage88Standardcontainerquantity200Hourlycontainerusage0Shipmentsize7C

arrierUniversalTimeintransit3daysKanbanquantity3Supplierquality94.60%Supplierdelivery98.90%Reasonforchange:Increasedeliveriestore

duceWIP.Submittedby:____________________________Position:_______________________________Date:___________________

_______________Approvedby:____________________________ProductionControlApprovedby:____________________________OperationsApprovedby:____

________________________EngineeringPFEPChangeRequestFormProductionControlDepartmentUpdatingthePFEP更新PFEPGroupExercise#2团队练习#2Sup

ermarketsizing超市大小•CreatePFEPDatabase创建PFEP数据库•Usethisinformationtosizethesupermarket使用这些信息来确定超市大小•Designpilotsupermarketbasedonsizeandeaseofst

orageandretriev容易程度设计试产的超市的大小Step3:DesignDeliveryRoutes第三步：设计送货路线HeijunkaBox均衡化生产箱FinishedGoodsSupermarket成品超市1234CellKanbanPost看板架143Raw

MaterialsSupermarket原材料超市251234CellKanbanPost看板架PartsSupermarket零件超市Step3:DesignDeliveryRoutes第三步：设计送货路7.Setroutedrivetimeatnomoret

han33%ofthenon-loadtimeoftheroute设置路线运输时间丌超过路线空载时间的33%8.Onlymovematerialwhenauthorizedbythepullsignal只有在收到被授权的拉劢信号

后才移劢物料9.Ensurekanbansystemrulesarefollowedandworkersremovepullsignalswhenusingthefirstpieceinacontainer确保员工按照规则操作：在使用周转箱中第一个物料时员工发出信号10.Synchroni

zethelunchandbreaktimesofthematerialhandlerontheroutewiththoseoftheworkersintheareasbeingsupported将物料搬运员不生产线员工的午饭时间及休息时间进

行同步11.Followspecificroutetimesandfrequenciesandinsurethatroutedeliveryisnotinterruptedforanyreason按照特定的路线时间及频率来保证运输交货丌被仸何原

因被打断12.Standardizeworkonthedeliveryroutetoeliminateallwastedmotionandimprovecontinuously标准化在交货路线上的作业来消除所有的劢作浪费

及持续进行改进Step3:DesignDeliveryRoutes第三步：设计送货1.Designateone-wayandtwo-wayaislesalongnaturalflowpathsinthefacility指定的单向和双向沿自然流劢路径的通道设施2.Des

ignallroutestoflowthroughtheplantandbacktothesupermarket设计所有的通过工厂的路线及迒回到超市3.Designstopsanddeliverypointsalongtheroutetominimizethe

nonvalue-addedworkforthematerialhandler在路线上设计停止点及交货点来最小化物料员非增值的工作4.Designstopsanddeliverypointsalongtheroutetominimizenonvalue-a

ddedworkfortheoperatorwhoisbeingsupplied在路线上设计停止点及交货点来最小化生产线员工非增值的工作5.Startwithone-hourdeliveryroutes,aimingfora95%effici

ency(57minutes)从一小时的送货路线开始，目标达到95%的效率6.Setloadingtimeatthesupermarketat33%orlessofthecoupleddeliverytime在超市设置取料时间是总交货时间的33%戒更

少MaterialHandlerStandardWorkExample物料员标准作业的案例Step步骤StandardWorkElements标准作业步骤ConveyanceCycleTime运输周期时间1Traveltofir

stdeliverypoint到第一个送货点120seconds秒秒2Pickupwithdrawalkanbanatfirststation(deliverypoint)从第一个工位拿取补料看板卡10seconds秒3Pickupemptycontaine

rsandloadontotrolley拿取空箱放置到物料车上20seconds秒4Delivermaterialtofirststation将物料交付到第一个工位45seconds秒5Travelt

onextdeliverypoint移劢到下一个送货点10seconds秒6Traveltoseconddeliverypoint移劢到第二个送货点15seconds秒7Pickupwithdrawalkanb

anatfirststation(deliverypoint)从第一个工位拿取补料看板卡10seconds秒8Pickupemptycontainersandloadontotrolley拿取空箱放置到物料车上20seco

nds秒9Delivermaterialtosecondstation将物料交付到第二个工位45seconds秒10Traveltosupermarket移劢到超市120seconds秒11Sortkanbancardsforbestpick

ingsequence根据取料的顺序挑选看板卡10seconds秒12Dropoffemptycontainerspickedupduringroute将空箱放置到相应的位置45seconds秒13Collectcontainersneededforpickingandconveyanc

e收集需要的周转箱及运输45seconds秒14Pickpartsandplacethemontrolley(averageof10itemsx10seconds秒perpick)取物料及将物料放置到运输车上（

平均10个零件X每次10秒）100seconds秒15Placewithdrawalkanbancardsinrespectivecontainers将补料看板卡放置到相应的周转箱10seconds秒Totaltimeforroute总的路线时间

625sec秒Step3:DesignDeliveryRoutes第三步：设计送货路线PUSH-basedMaterialHandlingRoute推动-基于物料搬运路线CCBACCBBAASupermarket超市C

BA•Bulkdelivery(E.g.4hoursupply)交货大小•Requiresextraspace需要额外的空间AAABBBBACCCCC123PULL-basedMaterialHandlingR

oute拉动-基于物料搬运路线CBACBACCBBAASupermarket超市CBA1234567•Time-fixeddelivery(30minutessupply)固定时间的交货•Mixedloadconveyance多品种的运输Line#1Line#28:

009:0010:0011:0012:0012:3013:30Shift1Finishedgoodssupermarket成品超市CustomerPull客户拉劢ABProductionLine生产线Kanbancollected,delivered看板收集及交付Link

SupermarketwithPullSystem将超市与拉动体系进行链接Tofinishedgoodssupermarket送至成品超市Heijunkabox均衡化生产箱GroupExercise#3团队连续#3Designroutes路线设计•Designmaterialhan

dlingroutesbetweensupermarketsandpointsofu及使用点间的运输路线•Practice,timeanddocumentthework练习，时间及将工作文件化•Documentprovisionalstandardwork,

practiceandimprove文件化暂定的标RunningtheSupermarket运行超市SupermarketGoldenRules超市的金科玉律•Theproducingprocesstakesownershipoftheinventoryinth

esupermarket(regardlessofphysicallocation)生产工序负责超市中的库存（丌管实质的地址）•Thedownstreamprocessregularlywithdraws(pulls)whattheyneedintheamounttheyneed

下游工序定期的取他们所需要的物料•Clearsignalsareexchangedbetweenupstreamanddownstreamprocesseswhenmaterialiswithdraw

nfromthe1.Setminimumandmaximuminventorylevelsforallpartsinthesupermarket在超市中设置最大及最小的库存水平2.Locatethepurchasedpartssupermarke

tclosetothereceivingdock将采贩件超市设置到靠近收货区3.Identifythepointofuseaddressonthestoragelocationfortheitemsinthesuper

market在存储地点识别出超市内的物料的使用点4.Simplifyhandlingofcontainers(useflowracks,etc.)简单化的搬运周转箱5.Createanoverflowareainahighl

yvisibleplace在目视化的区域设计过量库存区RunningtheSupermarket运行超市Measurementsforcontinuousimprovementofsupermarketoperation:持续改进超市操作的测

量•Safety:recordableincidents安全：可记录的事故•Quality:zerodefects质量：零缺陷•Delivery:zerolinestops交货：零停线•Cash:inve

ntoryreduction现金：库存减少•Productivity:numberofmaterialhandlers生产力：物料员的数量RunningtheSupermarket运行超市