Examples 例子
1
Few
Y
很少
Y
Y
Y
N
SWCS
SMT
Standard
Work
标准作业
2
Few 很少
Y
Y
Y
Y
Work Load Hand Load
N
Leveling Assembly
Chart/SWCS 手动作业装配
Receiving,
Work
Standard 3
Y
Y
N
N
作业标准
Y
Water Spider,
= Takt Time X Product Up x Process Up X Number of Line = 2 sec X 6 products per panel X 4 Panel per pallet X 2 Lines = 96 sec
Scenario 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec 情节2：如果正反面产品同时在一条生产线生产，节拍时间则为一半，48秒。
13
What is Standard WIP 什么是标准WIP
Process To Process WIP (PTP WIP) 制程间WIP
• WIP between 2 different processes with big gap cycle time 两个周期时间相差很大的不同制 程间的WIP.
10
What is Standard WIP 什么是标准WIP
The purpose of Standard WIP is: 标准WIP的目的： 1. Separation between machine job and man job 区分机器作业和手动作业 2. Ensures quality requirements 确保质量要求 3. Ensures smooth flow based on Takt time 确保基于节拍时间的连续流
Before Kaizen, Manual Insert (MI) Line Process WIP =9 pcs. After Kaizen MI Process WIP is 3. Standard WIP for each station is 1pc. 改善前，插件拉的制程WIP=9 pcs。改善后插件拉制程 WIP=3pcs。每个工位的标准WIP为1pcs.
Example 1: 例子1 WIP in the reflow oven for curing with process time 6 min and Takt time 30 sec. 在回流焊炉中固化的WIP，制程时间 6 min，节拍时间 30 sec.
Standard WIP in the curing oven = Process Time / Takt Time
• However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and bottle neck 然而，在完全达到标准WIP数量前，你需要经过不同的阶段了解制程中的浪费和瓶颈。
回流焊炉的标准WIP
= 6 min / 30 sec
= 12 Pcs
11
What is Standard WIP 什么是标准WIP
Example 2: 例子2 WIP in the tester at backend assembly with process time 60 sec and Takt Time 30
8
What is Standard WIP 什么是标准WIP
Various types of WIP in our manufacturing process 生产过程中存在各种类型的WIP
1. Standard WIP
标准WIP
2. Process WIP
制程WIP
3. Process To Process WIP
sec. 后段组装线测试机的WIP，制程时间 60 sec，节拍时间 30 sec.
Standard WIP in the Test station = 60 sec/ 30 sec
测试工位的标准WIP
= 2 pcs
• In other words, Standard WIP in order to fulfill the above 1), 2), 3) functions, It is the compulsory WIP in the machine / process before establish standard work for the process.
• PTP WIP Is needed due to changeover in upstream line. 上游制程需要转拉，则需设定制程间 WIP.
Based on Step 1, Takt Time is 2 second to produce 1 pcs. 根据步骤1，节拍时间是每 2 秒生产 1 件产品。
7
How to start the Takt Time Calculation
Based On Product and Process Design怎样根据产品和制程设计计算节拍时间
换句话说，标准WIP能够确保上述1),2),3)达成，在建立标准作业前，标准WIP是 机器和制程强制的WIP。
12
What is Standard WIP 什么是标准WIP
Process WIP 制程WIP
• WIP within same process with low variation of cycle time
制程与制程间WIP
4. Station To Station WIP工位与工位间WIP
9
What is Standard WIP 什么是标准WIP
• WIP means INVENTORY. INVENTORY is Basically ‘bad’. WIP就是库存。库存从根本上说是“不好”的。
• Standard WIP is the Ideal or Should be conditions for WIP 标准WIP是理想WIP或者是WIP的应有状态。
Y
Andon 异常报警系
统
HR, Testing 收货，水蜘蛛
，HR，测试
4
3 Types of Standard Works 3种标准作业
Type 1 : Standard Work to support machine (90%) & man (10%) combination task. 类型1：标准作业适用于90%的机器作业和10%的手动作业的组合作业方式。 Type 2 : Standard Work to support man (90%) & machine (10%) combination task. 类型2：标准作业适用于90%手动作业和10%机器作业的组合作业方式。 Type 3 : Standard Work (also called as Work Standard) to support task carried out once signal is triggered. 类型3：标准作业（也叫做作业标准）适用于当信号产生时才去执行相应任务的作业方式。
No Std Work means no Kaizen … Std Work is the Mother of all Kaizen 没有标准作业就没有改善……标准作业是改善之母
5
How to start the Takt Time Calculation
Based On Customer Demand 怎样根据客户需求计算节拍时间
客户每月需求量是792K。每天工作小时是22小时，一个月20天。
Takt Time
AvailableTime 有效时间 CustomerDemand客户需求
22Hoursx 20 daysx 3600s 792,000pcs
1,584,000 792,000
2 sec
•Takt Time calculation shall display all the variable and units to make clarity to all. 计算节拍时间时要显示所有变量及单位，便于大家理解。
情节1：产品设计为每块PCB板由 6 块小板组成，节拍时间是每块PCB板 12 秒; 制程设计治具 同时放置 4 块PCB板，则制程的节拍时间是 48 秒/治具。如果同时有 2 条生产线生产， 制程的节拍时间则为 96 秒。
As such the Process Takt Time Calculation as following: 制程节拍时间计算如下：
Time 60 sec
51 45 58 43
T.T
variance
Time 60 60 60 12 60
T.T
sec
AB C D
Before
Person
Process WIP = 9, No standard WIP
AB C D
After
Person
Process WIP = 3, Standard WIP = 1
精益生产管理手册中英文版
3 Types of Standard Works 3种标准作业
Type Machine
类型
机器