流程标准化[1]

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,流程标准化1,*,流程标准化,2024/11/28,流程标准化1,议程 Agenda,目的 / 结果 Purpose / results,与流线生产有关的问题 Issues relating to flow,流程标准化六步骤 6 steps to routing standardization,流程标准化1,学习内容 What Youll Learn,根据相似流程，将成品 (零件) 分类,How to group products (parts) into families according to common routings,如何简化零件流程,How to simplify part routings,根据零件系列，将流线生产单元文件化，并予以实施,How to implement and document flow production cells around part family groups,流程标准化1,及时生产原理 JIT Principles,跟上“节拍”时间,Pace to “takt” time,达成流线生产,Create flow production,结合“拉动”系统,Incorporate “pull” system,流程标准化1,流程标准化的目的,Purpose of Routing Standardization,减少独特流程的数量,Reduce the number of unique routings,简化个别零件的流程,Simplify individual part routings,制定标准化工作,Develop standard work,流程标准化1,贵司的流程象哪个？ Which Is Your Process?,流线型,非流线型,零件,零件,零件,零件,零件,零件,零件,零件,流程标准化1,不良流线的原因 Causes of Poor Flow,演化式增长,Evolutionary growth,人员安排变化,Staffing changes,标准成本会计,Standard cost accounting,产能高峰 Capacity peaks,共用设备 Shared equipment,数量变化 Quantity variations,流程技术 Process technology,流程变化 Routing variations,外部交接点 External handoffs,回环工序 Loopbacks,换模时间太长 Setups too long,不同零件的数量,Number of different parts,超级机器 Super machine,大批量 Large batches,流程思维 Process thinking,必要的操作 (修理),As-required operations (repair),流程标准化1,变化的种类 Types of Variation,数量变化 Quantity variation,产品变化 Product variation,流程标准化1,变化的程度 Degree Of Variation,产量比例 零件数量比例,特征,种类很少,制造业里最常见，种类非常多,种类极多，变化极大 (很罕见),流程标准化1,流程标准化六步骤6 Steps To Routing Standardization,进行零件-数量 (P-Q) 分析,Prepare part-quantity (P-Q) analysis,2.进行流程分析,Prepare process route analysis,3.根据相似流程，对零件进行分类,Group parts by routing similarity,4.定义设备可用性,Define equipment availability,5.简化零件流程,Simplify part routings,6.实施新的流程系列，并将其文件化,Implement and document new process family groups,流程标准化1,零件-数量 (P-Q) 分析Part-Quantity (P-Q) Analysis,* 由于圆整问题，各个比例之和并不等于100%,Individual percentages dont equal 100 % due to rounding,零件代号,Part Number,数量,Quantity,数量比例,% of Quantity,累计数量比例,Cumulative Quantity (%),A,B,C,D,56841,525,24%,24%,23168,480,22%,46%,23515,360,17%,63%,98512,285,13%,76%,75651,145,7%,83%,21698,130,6%,89%,18996,105,5%,94%,456,46,80,4%,98%,15695,65,3%,100%*,流程标准化1,零件-数量 (P-Q) 关系图 Part-Quantity (P-Q) Chart,数量,零件代号,累计数量比例,流程标准化1,流程分析 Process Route Analysis,工作中心 Work Center,零件 Part #,数量,Quantity,车削,Lathe,镗,Bore,机加工,Mach,焊,Weld,磨,Grind,机加工,Mach,铣,Mill,检验,Insp,56841,525,23168,480,23515,360,98512,285,75651,145,21698,130,18996,105,456,46,80,15695,65,1,1,1,1,1,1,1,1,1,2,3,4,2,2,2,2,2,2,2,3,3,3,3,3,3,3,3,4,4,5,4,4,4,4,4,4,2,流程标准化1,零件系列 (1) Part Family Group (1),工作中心 Work Center,零件 Part #,数量,Quantity,车削,Lathe,镗,Bore,机加工,Mach,焊,Weld,磨,Grind,机加工,Mach,铣,Mill,平衡,Bal,检验,Insp,5681,150,6510,100,4233,90,3210,80,4533,50,1,2,3,4,5,7,6,4,3,2,1,5,7,4,6,8,9,9,8,3,2,1,5,6,9,8,7,1,2,3,4,5,7,6,8,9,9,8,7,6,5,3,4,2,1,流程标准化1,零件系列 (2),Part Family Group (2),= 外部工序 Outside process,工作中心 Work Center,零件,Part #,数量,Quantity,车削,Lathe,磨,Grind,热处理,HT Treat,滚光,Tumble,喷涂,Coating,内圆磨,ID Grind,机加工,Mach,检验,Insp,1289,175,7651,100,6444,75,1658,5,1,1,1,1,2,2,2,2,3,3,3,3,4,4,4,4,5,5,5,5,6,6,6,6,7,7,7,7,8,8,8,8,9,9,9,9,流程标准化1,定义设备可用性,Define Equipment Availability,识别现有设备,Identify existing available equipment,分配设备予各个流程组别,Allocate equipment to process groups,识别潜在瓶颈问题,Identify potential bottlenecks,流程标准化1,简化零件流程 Simplify Part Routings,简化操作顺序,Simplify the sequence of operations,同一系列的所有零件都制定标准化流程,Develop a standard route for all parts in a family,减少工序数量,Reduce the number of operations,消除单元外的交接点,Eliminate out-of-cell handoffs,避免回环工序,Eliminate loop-backs,避免共用装卸中心,Eliminate shared load centers,考虑使用标准化流程模块,Consider using standard routing templates,消除替换流程,Eliminate alternative routings,流程标准化1,演讲完毕，谢谢听讲,!,再见，see you again,3rew,2024/11/28,流程标准化1,