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1、精益物料管理Lean Materials Management,精益物料管理Lean Materials,A completely transparent system which incorporates simplicity of methods with a high degree of discipline. 这是一个完全透明的系统, 融合了简捷的方式和高度的制约。 Provide material when it is needed by the customer and in only the quantity that is required by the customer.当客
2、户需要时及时提供物料, 且只提供客户所需要的数量。,Lean Materials Management精益物料管理,精益物料管理Lean Materials,Through Lean Materials Management we have: 通过精益物料管理我们将取得: Low Inventory 低库存量 Simple Systems (Computerization) 简捷的系统(计算机化) Minimal Floor Space 最小的占地空间 Minimal Equipment 最少的设备 Support for Operator 对操作人员的支持 Low Handling 减少搬动
3、 Support for Built-In-Quality 支持制造质量,精益物料管理Lean Materials,1) Parts ordering 零件订购,2) Suppliers 供应商,3) Packaging 包装,4) Transport 运输,5) Receiving 接收,6) Temp. stores 临时仓库,7) Material Pull System 物料的拉动式系统,8) Assembly line 装配线,精益物料管理Lean Materials,1) Parts ordering 零件的订购,Parts are ordered in fixed periods
4、, once per week 零件定期订购, 每周一次Enough time for supplier to plan 供应商有充足的筹划时间Enough time for plant to plan 工厂有充足的筹划时间Enough time to decide best transportation method 有充足的时间确定最佳的运输 方式,2) Supplier 供应商,Supplier receives order and produces the right quality and the right quantity, on time 供应商收到定单后按时生产 出确切数量和
5、质量的零件Provides quick feedback and participates in problem solving 迅速提供反馈并参与解决问题Packages and hands-over material to Transporter 包装物料并递交给承运人,精益物料管理Lean Materials,1) Parts ordering 零件订购,2) Suppliers 供应商,3) Packaging 包装,Influences material presentation 影响物料以何种形式呈现在操作者面前Influences amount of line side spac
6、e needed 影响所需的生产线两侧的空间量Influences transportation 影响运输Dictates in-plant conveyance method 决定了厂内输送方式,Minimize 最小化,Maximize 最大化,精益物料管理Lean Materials,4) Transportation 运输,Milk Run 定常路线法Direct 直接法Consolidation 联运法,Methods方式,Method of Transportation Depends On:运输方式取决于:Quantity - strive to increase use of
7、truck bed 数量 - 努力提高货车的利用率Location 位置Frequency 频率,精益物料管理Lean Materials,10 - 11 p.m. 下午10-11点,Milk Run 定常路线法,SUPPLIER A 供应商A,SUPPLIER B 供应商B,SUPPLIER C 供应商C,SUPPLIER D供应商D,8 - 9 a.m. 上午8-9点,10 - 11 a.m. 上午10-11点,2 - 3 p.m.下午2-3点,5 - 6 p.m.下午5-6点,Our Plant我们工厂,精益物料管理Lean Materials,Direct 直接法,Our Plant
8、我们工厂,精益物料管理Lean Materials,Consolidation 联运法,Our Plant我们工厂,Consolidation Center 联运中心,精益物料管理Lean Materials,1 full load = 15 boxes1次满载重量 = 15 箱,Exercise: Which transportation method?练习: 该用哪一种运输方式?,精益物料管理Lean Materials,5) Receiving 接收,6) Temporary stores临时仓库,The receiving area is for checking incoming m
9、aterials only! No storage!接收区域仅供检验进厂物料! 不供储存!,OK parts from receiving go to temporary stores 验收合格的零 件进入临时仓库Temporary stores are as small as possible 临时仓库应尽可能地小Temporary stores are visibly labeled and have a minimum and maximum level of parts 临时仓库有明显的标志,且限定 最低和最高零件存货限量水平,精益物料管理Lean Materials,7) Mater
10、ial Pull System物料的拉动式系统,8) Assembly line装配线,To reduce lineside stock, material must be “pulled” to the work station as stock is used!为了降低生产线边上的存货量, 调用库存物料时应采用斃?动式?系统进入每一工位!Kanban System (for dolly or hand deliveries) 看板系统(适于拖车或人工发送)Material Call (for forktruck deliveries) 物料索取信号系统 (适于叉车发送),OPERATOR
11、ON THE LINE生产线上的操作者,KANBAN System 看板系统,精益物料管理Lean Materials,Operator posts card when picking 1st part from new box操作工从新物料箱中取出第一个零件, 并递送出看板卡,Kanban cards and empty boxes are collected from workstations从该工位上收集看板卡和空箱,Returns empty boxes.Kanban cards are read送回空箱, 阅读看板卡,Driver picks new material fromTem
12、porary Stores based on kanban cards司机根据看板卡从临时仓库中取出新的物料,Driver delivers new material to operator putting a card in each box司机将新的物料运送至操作工处，每一箱子中放入一张看板卡,精益物料管理Lean Materials,The 3 Rules of Kanban 看板系统的3条规则:REMOVE: the kanban card from the container when taking the first part. If there is no card, do no
13、t use the parts and call team leader. 取出: 当你取用第一个零件时，取出箱子中看板卡。如果 其中没 有看板卡, 不要使用零件, 并应叫来班组长。 CONFIRM: the data on the card with the container label and rack label and call team leader if data does not match.核对: 看板卡上的数据与箱子上的标签及货架上的标签是否符 合, 如果数据不符, 应叫来班组长。Kanban number 看板号码Container type 箱子类型Quantity p
14、er container 每个箱子中的数量Line Side Address 生产线沿线地址PLACE: kanban card securely in the Kanban post.放置: 看板卡入看板筒,精益物料管理Lean Materials,Material Call 物料索取系统,Operator pushes the button when down to last x number of pieces in the rack or pallet. 当货架或货盘上用剩最后X个零件时, 操作工将按动按钮,Material Call light is activated . 物料索取
15、灯启动,Forktlift driver takes card from board and presses button to confirm delivery to the operator.叉车司机从信号板上取走物料卡并按动按钮向操作工确认物料的发送,Driver gets materials from temporary stores.司机从临时仓库中拿来物料。,Driver returns empty rack or pallet and returns card to the Material Call Board.司机送回空的物料架或货盘并将看板卡放回物料索取板上,Driver delivers new material to line-side and takes empty away司机沿生产线发送新物料 并取走空箱,
