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,按一下以編輯母片標題樣式,按一下以編輯母片,第二層,第三層,第四層,第五層,*,筆記型電腦供應鏈管理研究小組,製造管理診斷手法與實例,報告人:許棟樑,清華大學工業工程與工程管理系,1,Outline,Part I:A Plant diagnostic methodology,1)Crystallize key aspects of concern(,認清 改善標的,),2),Diagnostics&Improvement Methodology,(,善用 分析與改善手法,),3),Process Re-engineering Approach,Part II:Applications&partial results,1)Index model&useful new indices,2)Improvement drivers,3)Best practice comparisons,4)SMT process re-engineering,2,Part I:Plant diagnostic methodology,I.1)Crystallize Key aspects of concern,(,認清 改善標的),I.2)Diagnostics&Improvement,Methodology (,分析與改善手法),I.3)Mfg Process Re-engineering Approach,3,I.1 Key Aspects of concern,Idea:Top-down systematic deployment of PI -DT,Co.Objectives,Plant Objectives,Key,Perf,Indices,Adm.,Obj,.,Determinants,PIs,DTs,PIs,DTs,PIs,DTs,4,I.1.1 Plant Top-level concerns,Profitability&Customer satisfaction,Productivity/Production,Lead Time&Delivery(target hit rate),Quality&Reliability,Cost,Flexibility,Service,I.1 Key Aspects of concern,5,I.1 KEY ASPECTS OF CONCERN,I,.1.2 Areas of Attention:(DTs),Bottleneck Management/Scheduling&Dispatching(=Productivity),Flow Efficiency&Layout (=Time),Inventory control(Cost/profit),Resource Utilization Effectiveness(=Cost/Profit),Equipment/Facility,Materials(WIP),Human Resources,Space,Process&Change Control(=Quality/variability,Flexibility,etc.),Safety(basic req.),=proper set of PIs for each level.,6,I.2.,分析與改善手法,Basic methodology:,I.2.0 Methodology Overview,I.2.1 Index Model&Standards,I.2.2 Data Representation Forms/Tools,I.2.3 Analysis Methods/Tools,I.2.4 Site tour&Interviews,I.3 Process Re-engineering approach,7,I.2.0 Methodology Overview,Collect Data&BM,-Compare Strength&Weakness,-Seek Improvement,Opport,.,-Rank Performance,Regression Analysis,-Model,Quantitive,Relations Among,Performance Indices&Determinants,-Performance Index=Fn(Determinants),Data Envelop Analysis,-Identify Inefficiencies,-Provide Improvement Direction&Reference,Target Level,Feedback,Recomm,.,-Compare Strength/Weakness,-Identify Improvement Opportunities&target,level,-Best Practice Sharing,Correlation Analysis,-Find Out Improvement Drivers,Trend Analysis,Index Model,-Establish Systematic Performance Indices&Determinants,Analysis Tools,Visit/Interview,-Understand Factory Procedure,-Verify Data,-Clarify Questions,Many other tools.,Simulation,Data rep forms,/questionnaire/tools,-Clearly/completely/Concisely,8,I.2.1 Performance Index Model,Top down/goal driven/Clear linkages,Standardization,Arranged for various levels&Org.,9,I.2.2 Data Representation Tools,表單:,Well-designed forms to concisely&completely document the detail situations.,I.2.2.1 Process/Transport Attribute Table(,流程細目表),Process attribute table,Transport attribute table,I.2.2.2 Layout Diagram,I.2.2.3 S/W modeling tools(doc.Processes),ARIS 4 views/IDEF/Power Designer(etc.),Data view/Function view/Control view/Org view,10,I.2.3 Analysis Methods/Tools(1),I.2.3.1 Data Benchmarking(Bar/line chart)+Hi/Lo/Mean,3.1.1 Direct Data Benchmarking,Horizontal BM,Vertical BM (Trends),3.1.2 Indirect Data Benchmarking,Dunken,method,to differentiate groups for,Various,Perf,Rankings incl.:Equipment performance,AHP,(Analytical Hierarchical Process)Ranking,I.2.3.2 Improvement drivers,Correlation,Regression,I.2.3.3 Input/Output Efficiency Analysis(,DEA,),Plant/Section/Machine levels,11,Data Envelop Analysis,(Concept),Identify in-efficiency&,Impr,.Ref.Target,Can identify,eff,4 multiple inputs&multiple outputs,35,投入人力,月產量,12,I.2.3 Analysis Methods/Tools(2),I.2.3.4 Bottleneck analysis,Line Balance Rate,Process time+Transport time histogram by section,Bottleneck identification/inclination indices,I.2.3.5 Layout analysis,Layout analysis(Layout efficiency),Petri,net analysis,I.2.3.6 Cycle time analysis,Flow efficiency,I.2.3.7 Cost decomposition/Waste analysis,13,I.2.3 Analysis Methods/Tools(3),I.2.3.8 Process&Material flow analysis,Process flow(WIP Journey)Analysis,Key component time journey by org./section,WIP distribution,I.2.3.9 Resource Utilization analysis,Inventory utilization/shortage&Stock waste.,Equipment OEE/Waste analysis,HR(productivity?),Area utilization/productivity,I.2.3.10,Simulation,Simulate existing situation to find out problematic/bottleneck areas,Simulate re-engineered situation to:,Predict possible results.Perform“what if?”analyses,Debug new designs before major capital investments.,14,I.3 Process Re-engineering Approach,Determine,proj,scope&target of study,Preliminary process tour&discussion,Establish PIs&DTs,Data collection(Use Data Representation Tools I.2),AS-IS Process simulation/ARIS Model,Use Analysis Tools(I.2.3)w/external data,=Improvement ideas,Establish TO-BE model,TO-BE Model simulation=,改善效益評估,Feedback to co.&Discussion.,15,Part II:Applications&Result Excerpt,II.1)Index model&Useful new indices,II.2)Improvement drivers,II.3)Best practice comparisons,II.4)SMT Process re-engineering cases,16,II.1 Highlights of Index Model,Organized:,13,Key performance Indices,124 Detail indices(various levels),Created 12 useful N
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