6
Sequential Application of Tools 工具运用的顺序
Degree
of
Change +
Impact
变化 程度 + 影响
Time 时间 价值流是基础
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Heijunka 平准化
Level Loading 平衡生产
Heijunka is a Forcing Function平准化是强制作用
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Heijunka 平准化
生产控制 客户需求
更加平衡的生产 客户
节拍控制点
•单个计划控制点 •下游流程化
成品仓
Pacemaker Sets the Pace for Upstream Processes 节拍控制点决定上游流程的速度。
Байду номын сангаас
Stop @
Abnormality 异常停止 Autonomation 自动化 Sequencing 作业顺序
Single Piece Flow
单片流 Takt Time Production 节拍生产 Level Loading 平衡生产
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Objective 目标
•
Introduce Flextronics Lean Enterprise (FLE) and its elements 伟创力精益企业介绍和它的要素 • Heijunka 平准化
• Guide to Level Load 平衡生产简介
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Overview & Scope
• Lean Manufacturing is a generic process management philosophy derived mostly from the Toyota Production System (TPS) but also from other sources.It is renowned for its focus on reduction of ‘Seven Wastes' in order to improve overall customer value. 精益生产 是一门流程管理哲学，主要来自于丰田制造系统（TPS)。其焦点在如何减少“7大浪费”以 增加客户价值。 • Toyota's achievement made "Lean" a hot topic in management science in the first decade of the 21st century.
很显然，客户的需求不可能保持不变。为了满足客户的需求，你必须通过平衡生产数量 和种类来达到拉式生产。
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From Batch to Pull 从批量生产到拉式生产
Flextronics Lean Enterprise : Answer to ‘Load & Chase’
Lean Training
Lean Basic 2
Design. Build. Ship. Service. Business Excellence
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Version Control
Document Title: Lean Basics 2 Revision: 03 Document# GBE-KPO-2-002-00 Document Owner: Chuah Khar Yee APPROVALS NAME Ganesh Maniam TITLE Director DEPT NAME Global Business Excellence Organizaation: Global Business Excellence Effective Date: December 11. 2008
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Heijunka 平准化
Leveled production 平衡生产
Customer Demand 客户需求
• How Can a Shop Resource This ?车间怎样规划？ • How Can the Supply Chain Cope ? 供应链如何整合？ • What if the Supply Chain is Global ?如果是全球供应链又怎样？
Stop @
Abnormality 异常停止 Autonomation 自动化 Sequencing 作业顺序
Level Loading = Process of smoothing the overall schedule by more frequent mixing of High & Low volume Sequencing = The order in which the parts on a multi-product line or cell are processed.
REVISION 03
REVISION HISTORY DESCRIPTION OF CHANGE Document formatted as per DMS policy
ORIGINATOR Chuah Khar Yee
This document is proprietary and confidential property of flextronics.
Key Elements of Level-scheduling 均衡计划的要素
Production units are stratified according to planned sales volume 按销售额将产品分类


The production sequence combines Build To Order (BTO) and Customer Forecast
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Table of Contents
Contents Slide(s)
Overview & Scope Objective 目标
概述和范围
3 4 伟创力精益型企业 5
The Flextronics Lean Enterprise (FLE)
•
丰田的成功使“精益”成为21世纪前10年管理科学的热点。
•Lean Manufacturing can be defined as 精益可以被定义为: "A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.“ “从客户拉货到产品源头的整个流程不断改善，识别并消除浪费（无价值活动），使之日臻 完善的一种系统方法。“
原材料超市只存储小批量产品的库存。
Fill orders first from FG, second WIP, & third sequence them (attach the order to the production plan) 从成品开始排单，然后是在制库存，最后将其序列化（排单附于生产计划上）
生产顺序由根据定单生产和根据客户需求来生产两种
Sequence is designed to achieve the combined TAKT time for all items
生产顺序应该可以满足所有产品的节拍时间
Eliminating production rate variance is required to achieve TAKT time 消除产品变化的差异是达到节拍时间的前提 Build only high volume products to FG supermarket based on business model 根据产品形态，对大量生产的品种，可在成品仓留有库存。 Lower volume items are only sequenced with firm orders小批量产品在定单不确定时不排入生产。 Hold components in Raw Materials supermarket only for low volume items.
Heijunka
平准化
7
11 17 节拍生产 23
Guide to Level Load Guide to Sequencing Takt Time Production
Single Piece Flow
Standard Work Tools for 3P
单片流
标准作业
30
38 45 50 54
Pull Production 拉式生产 Kanban System 看板系统
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Guide to Level Load
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Guide to Level Load
Purpose目的: To provide guidelines for developing the method and tools for level-loading (or level-scheduling) the shop floor.为生产现场实施均衡化生产（或均衡计划）提供指导。