精益生产之仓库模拟游戏

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,Title of Presentation,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,Title of Presentation,*,Warehouse Simulation Game,Warehouse Simulation Game,10/28/2024,2,During the Warehouse Simulation Game the principles of Lean are shown and we ask you to apply them on the spot,The game makes you think about what is value add for the customer,what is the employees role and value add in the process,and to let go of traditional roles and seemingly independent tasks,The goal is to make Lean more concrete and easier to apply,It is an interactive way to get you acquainted with the Lean principles.,To understand the opportunity to improve quality,cost,and delivery performance in traditional warehousing,To gain an awareness of how JIT warehousing differs from traditional warehousing,To gain an appreciation of the following LEAN terms:,Eight types of waste,Continuous flow processing,Takt time,Objectives,10/28/2024,3,Agenda,Case introduction,Practice round,Round 1“Waste”,Round 2“Flow”,Round 3“Takt”,Summary,10/28/2024,4,Run,(do),Redesign&,Prepare,(plan),Analyze,(check),LEAN,theory&examples,(act),Structure of simulation rounds,“Set up new round”,“Design improved warehouse system”,“Simulate operation”,“Measure performance and identify issues”,10/28/2024,5,Agenda,Case introduction,Practice round,Round 1“Waste”,Round 2“Flow”,Round 3“Takt”,Summary,10/28/2024,6,Context,10/28/2024,7,You are 6,12,18,or 24 employees in a warehouse that produces kits for the consumer industry,The packing for these products requires special treatment,but has a similar setup,The company is currently unable to deliver the quality,cost,and delivery promises made to its customers,Operation,Each order is made from sheet of A4,1 photo film tube and 2 to 12 paperclips,Each operator has a workstation with 1 work instruction,10/28/2024,8,1,Receive and check packing,2,Cut packing into quarter sheets,3,Prepare box,add pick list,4,Pick pack items required for order,QC,Ship,&,5,Check quality,seal order,6,Material handler,Units,Goal,Number of good orders delivered,Percent wrong picked/packed items from total number of items,Good orders delivered/number of employees,Number of 1/4 paper sheets in production area,Average throughput time(minutes),Indexed against round 1(=100%),Tracking key performance indicators,KPI,Description,Cost or Revenue,Comment,1.,Quantity,#of correct orders delivered,Revenue,100,2.,Late penalty,#of orders late,Cost,-50,3.,Quality penalty,#of incorrect orders delivered,Cost,-50,4.,WIP,Number of 1/4 paper sheets in production area,Cost,-10,5.,Space,#tables used,Cost,-100,6.,Personnel,#employees,Cost,-200,7.,Overhead,Cost,-300,Fixed,8.,Productivity,#orders delivered/#employees,9.,Lead Time,Time it takes to finish first order,10/28/2024,9,Agenda,Case introduction,Practice round,Round 1“Waste”,Round 2“Flow”,Round 3“Takt”,Summary,10/28/2024,10,Agenda,Caseintroduction,Practice round,Round1“Waste”,Round2“Flow”,Round3“Takt”,Summary,12/29/2022,11,Round1:Traditionalmanufacturing,Everyprocesshasabatchsizeof4,Everybatchmustbepreparedtogetherandthematerialhandlermustbe,requested,todeliverthecompletebatchtothenextprocess(materialhandlercanonlytakeonebatchatatime),Everyoperatorshouldworkasfastaspossible,1.Receipt,5.Inspect/ship,4.Pickpacking,3.Preparation,2.Cutting,Layoutisbyprocess,2m,6.Materialhandler,12/29/2022,12,Simulationround1,Customersdemand:,24ordersin10minutes,12/29/2022,13,Time,12/29/2022,14,Units,Goal,Number of good orders delivered,Percentwrong picked/packeditems from totalnumberof items,Goodordersdelivered/numberofemployees,Number of 1/4 papersheets in productionarea,Averagethroughput time(minutes),Indexedagainstround 1(=100%),Round 1analysis:,Trackingkeyperformanceindicators,KPI,Description,Cost or Revenue,Comment,1.,Quantity,#of correct orders delivered,Revenue,100,2.,Late penalty,#of orders late,Cost,-50,3.,Quality penalty,#of incorrect orders delivered,Cost,-50,4.,WIP,Number of 1/4 paper sheets in production area,Cost,-10,5.,Space,#tables used,Cost,-100,6.,Personnel,#employees,Cost,-200,7.,Overhead,Cost,-300,Fixed,8.,Productivity,#orders delivered/#employees,9.,Lead Time,Time it takes to finish first order,12/29/2022,15,Round1 analysis:,Learningpoints,What wentwell?,What werethe mostsignificantproblems?,WIPlevels,Bottlenecks,Waiting time,Workerstress/boredom,Team interaction,Defectrate,Whatweretherootcausesoftheseproblems?,Howcantheseberesolved?,Quality,Firstpassyield,Cost,Productivity,Inventory,Delivery,%ontimetocustomer,Leadtime,Performance,Howcanperformancebeimproved?,12/29/2022,16,Inflexibility,Waste,Variability,Reducingwaste(,“,“muda,”,”)meansloweringcosts,improvingqualityandachievingconsistentthroughput(servicelevel),Customerdemand,Output,Customerdemand,Output,Reducinginflexibility(,“,“mura”)means becoming abletodelivertotheclient whatheasksattherightt