KanbanSystem看板系统.ppt

,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,KanbanSystem看板系统,Objectives of this Module,这个模块的目的,Participants will be able to:,参与者能够：,Name the types of Kanban and their uses,说出看板种类的名称及用法,Describe the steps in circulating kanban,描述看板循环中的步骤,Calculate Kanban quantities,计算看板数量,Name the 6 prerequisites of Kanban,说出,6,中看板必要条件,Describe the relationship of Kanban and production smoothing(heijunka),描述看板与平稳生产的关系,Evaluate the readiness to implement Kanban system,评估实施看板系统是否准备就绪,Follow the steps to design and set up a complete pull system within a value stream,在价值流中根据步骤设计以个完整的拉动系统,Topics,主题,Section 1:What is Kanban?,什么是看板？,Section 2:Two-card Kanban Systems 2,张看板卡系统,Section 3:Kanban Calculation,看板的计算,Section 4:Managing the Kanban System,管理看板系统,Section 5:Kanban System Implementation,看板系统的实施,Jargon Buster,专业术语,Kanban,看板,Supermarket,超市,Production Instruction Kanban,生产指示看板,Withdrawal Kanban,取料看板,Supplier,供应商,Signal Kanban,信号看板,Safety stock,安全库存,Buffer stock,缓冲库存,Jargon Buster,Kanban?,2-bin?,Supermarket?,Section 1 Topics,第,1,章 主题,What is Kanban?,什么是看板？,Definitions is kanban,看板的定义,Functions of kanban,看板的功能,Forms of kanban,看板的形式,What is Kanban?,什么是看板,A tool of the pull system,拉动系统的工具,A signal that authorizes production or movement(withdrawal)of items,授权生产或移动物料的信号,The actual card,container or physical signal itself,实物卡，周转箱或者实际的信号,A visual method of controlling workflow,invented in the days before IT,一个目视化的控制生产流的方法，在,IT,之前发明,The system that uses kanban,这个系统使用看板,What is a Kanban System,什么是看板系统,Kanban is a simple and effective method for visually controlling material flow,看板是一个针对目视化管理物料流的简单高效的方法,The kanban system itself is full of waste such as handling,inventory and processing,看板体系本身也是充满了浪费,例如物料搬运，库存及操作,Kanban is the acknowledgement of the failure to implement one piece flow,看板承认不能实现单件流的表现,What is Kanban?,什么是看板,“See”,“board”,“Signboard”such as you see in front of a store,“信号板”例如在库存前看到的,What does Kanban Do?,看板能做什么？,Sets limits,设定限制,Kanban is like currency you cannot buy parts without paying for them!,看板就像货币,你不能在没有付钱的情况下买东西,Nothing is made or moved without a kanban,在没有看板的情况不生产或者移动物料,Makes problems visible,让问题可视化,Kanban=inventory=waste,看板,=,库存,=,浪费,The Two Functions of Kanban,看板的,2,种功能,Instruct processes to produce,指示工序进行生产,Limits overproduction,限制过量生产,Instruct material handlers to move product,指示物料员运送产品,Withdrawal from upstream by downstream process,下工序从上工序取料,In a push system there are many and complex production and transport instructions,在一个推动系统中有很多复杂的生产及运输指示。,Triggered by previous process(producer)=push,通过上一个工序来触发（生产者）,=,推动,The Two Functions of Kanban,看板的,2,种功能,Production Kanban,Withdrawal Kanban,Heijunka Box,In a pull system there are a few simple production and transport instructions,在一个拉动体系中只有,1,个简单的生产及运输指示,Triggered by next process(customer)=pull,通过下工序（客户）来触发,=,拉动,The Two Functions of Kanban,看板的,2,种功能,Forms of Kanban,看板的形式,A kanban can be:,看板能够表现为,Classic“two card”system(uses production and withdrawal cards),经典的“,2,种卡”系统（使用生产及取料看板）,“One card”system uses one of the following,“看板”系统使用以下的方式,Card,卡片,Triangular plates,三角板,Containers,周转箱,Carts,推车,Colored balls,不用颜色的球,Electronic signal,电子信号,Or anything that conveys only the necessary information.,或者其他人能能够转换必要信息的工具,Forms of Kanban,看板的形式,Container,or simple devices,周转箱或简单的装置,Card,or information-bearing token,卡片或象征性的信息,Electronic,电子的,Ease to implement,容易实施,High,高,Medium,中,Low,低,Visibility,目视化,Medium,中,High,高,Low/Medium*,低,/,中,Ease of upkeep,容易维护,Low,低,Medium,中,High,高,Best used,但是用于,for steady demand items in close proximity,稳定需求的零件及容易接近的地方,when prerequisites conditions are met,当必要条件都满足,after mastering card kanban,在熟练纸质看板后,*Pure electronic signals are invisible,e-kanban combined with printed cards or video monitors are medium or high visibility,单纯的电子信号时无形的，电子看板与纸质的看板合并或者,视频监控是中等或高能见度,“One Card”Kanban Signal Examples,“卡片”看板信号的例子,Full,1 of 3,Full,2 of 3,Full,3of 3,Full,1 of 3,Full,2 of 3,Full,3 of 3,Do not produce,Empty,2 of 3,Empty,1 of 3,Full,3 of 3,Full,1 of 3,Full,2 of 3,Full,3 of 3,Do not produce,Empty,1 of 3,Empty,2 of 3,Empty,3 of 3,Full,1 of 3,Full,2 of 3,Full,3 of 3,Fill 4 bins,Empty,1 of 3,Empty,2 of 3,Empty,3 of 3,Empty,1 of 3,Full,2 of 3,Full,3 of 3,Fill 4 bins,Empty,1 of 3,Empty,2 of 3,Empty,3 of 3,Empty,1 of 3,Empty,2 of 3,Full,3 of 3,Fill 4 bins,Empty,1 of 3,Empty,2 of 3,Empty,3 of 3,Empty,1 of 3,Empty,2 of 3,Empty,3 of 3,Empty,1 of 3,Full,2 of 3,Do not produce,Full,3 of 3,Full,1 of 3,Full,2 of 3,Full,3 of 3,“Empty Space”Kanban,“空的空间”看板,Containers or Simple Devices,周转箱或简单的装置,The 2-bin system,（,2,箱系统）,Two bins with an equal amount of goods and information about the contained goods(name,location,quantity)are prepared,准备好的,两箱与同等数量的商品和信息所包含的货物（名称，位置，数量）的制备,Parts are taken from the first bin,零件从第一箱中拿取,When the first bin is empty it is the signal to replenish two more bins,当第一桶是空的，这是补充两箱的信号,The second bin slides forward into position of use,第二箱向前滑动到使用位置,Material handler replenishes two bins within agreed lead-time(before all parts are consumed),物料员在约定的交货时间内补充第,2,箱（在所有零件都被消耗前）,“Please replenish”,1,2,3,4,5,Containers or Simple Devices,周转箱或简单的装置,Limitations of container/device kanban,周转箱或简单装置的局限性,Visibility:,line of sight only,as devices typically do not travel(except carts,etc.),目视化：唯一的视线，作为设备通常不移动（除推车，等）,Quantity:,a large number of devices will be needed to support high mix,low volume production,数量：大量的设备需求来支持多品种，小批量生产,Flexibility:,the cost to make or modify devices is high compared to printed cards,灵活性：相对于印刷卡制作或修改设备成本高,Kanban Cards,看板卡,A kanban card:,看板卡：,Is the most common and best known signaling method,是最常见的和最知名的信号方法,Travels with the parts between supplier and customer processes(from downstream to upstream),与零件一起在供应商和客户的过程之间移动。（从下游向上游）,Contains information(human and machine readable)such as,包含的信息,(,人和机器能识别,),例如：,Part name and number,零件名及编号,Supplier process name,供应工序名,Pack out quantity,包装数量,Delivery address,运送地址,Storage address,储存地址,Withdrawal frequency,补料频率,Kanban Cards,看板卡,A kanban card:,看板卡,Differs most significantly with 2-bin in that,the card is pulled as soon as the first part is taken,与,2,箱系统,最显著不同是当第一个零件被拿取后立即拉动,Can be either a“move”or a“make”signal for dedicated,first-in first out lines,以指“移动”或“制造”的专用信号，先进先出,Most typically uses two types of cards:the withdrawal kanban and production instruction kanban,通常使用两种类型的卡：领取看板和生产指令看板,Two-card Kanban Cycles 2,张看板卡循环,Producer Process,生产工序,Consumer Process,使用工序,Material handler“move”loop,物料员移动物料循环,Responsible for withdrawal cards and material movement,用于取料卡及物料移动,Operator“make”loop,员工生产循环,Responsible for production cards and making things,用于生产看板卡及生产产品,Section 2 Topics,第,2,部分 主题,Two-card Kanban Systems 2,种卡看板系统,Types of kanban,看板的类型,Production instruction kanban,生产指示看板,Signal kanban,信号看板,Lot making board,批量生产板,Withdrawal kanban,取料看板,Supplier kanban,供应商看板,Kanban cycles,看板循环,Types of Kanban,看板的类型,Kanban,看板,Production instruction kanban,生产指示看板,Withdrawal kanban,取料看板,In-process kanban,在制看板,Signal kanban,信号看板,Supplier kanban,供应商看板,Inter-process kanban,内部工序看板,Part Number,产品的名称,Part Description,产品的描述,Supplier Process Name&Location,供应的工序,名称及地址,Consumer Process,Name&Location,使用的工序,名称及地址,Quantity Per Container,每箱数量,Number of Cards in System,片的数量,(E.g.1 of 3),Basic Card Design,基本的卡片设计,Information on a Kanban Card,看板卡上的信息,The action(make,move,etc.),行动（制造，移动）,Part number,物料名称,Part description,物料描述,The supplier(or process)name,供应商（工序）名称,Quantity,数量,Container quantity,周转箱数量,The source location,物料存储的地址,The delivery location,物料运送地址,The timing of the action(kanban cycle),行动的时间（看板循环时间）,Etc.,等等。,Production Instruction Card Example,生产指示卡案例,Machining,机器,finished goods,Supermarket,成品超市,Supplier,：,供应商,Machining cell#11,机器,#11,Location,：,地址,B2,V7,Part#,：,Part description,：,Gyro motor housing,Quantity,数量,：,12,Production Line,：,生产线：,Sub-assembly Cell#8,半制品组装,#8,Location,：,地址,Assembly Dept.,装配部,25210,Point of use information,使用点信息,Product information,产品信息,Supplier process information,供应工序信息,Production Instruction Kanban,生产指示看板,Lot for lot,Changeover times are not an issue,换型时间不存在问题,Can be produced“lot for lot”as needed,根据需要进行批量生产,Quantity in container is set by pace of customer withdrawal,周转箱内的数量根据客户取料的节拍设定,Production kanban always stays with the producer(circulates internally),生产看板往往在生产处（内部循环）,Remove card(trigger)when first part is removed from container,当第一个零件冲周转箱中拿取时拆下看板卡（触发）。,Production Instruction Card:In-process,生产指示卡：工序内,Producer Process,Downstream process uses withdrawal kanban to pull material,下游工序使用补料看板卡来拉动物料,Production instruction card is removed,生产指示看板卡被触发,Team leader collects cards from post and places them on kanban board as instruction to produce,组长收集看板卡并公布在看板板上用于指示生产,Operator attaches production instruction card material container,removes withdrawal card and places it in post,begins production as instructed by kanban,操作员将生产指示卡附在,物料周转箱上，拆下补料看板，并开始按照看板指示进行生产。,3,2,1,4,Kanban in a Batch Process,批量生产工序的看板,There are three primary methods for linking kanban to a batch process,有,3,个初级的方法将看板与批量生产工序链接起来,Signal kanban at reorder point,信号看板,Pattern production,模式生产,Lot making board,批量生产板,Production Instruction:Signal Kanban,生产指示：信号看板,Signal card(triangle)places the order,信号卡（,3,角）下订单,Material card(rectangle)instructs raw material preparation,物料卡（矩形）指示原材料准备,Fixed quantity,variable time only,数量固定，时间可变,Normally used when the set-up time is too long to maintain single piece or small lots,通常情况下用于设立时间太长以至于不能保证单件或者小批量,Signal position=reorder point,信号位置,=,下订单点,Reorder quantity=production lot size,订购数量,=,生产批量大小,Lot size is greater than usage quantity,批量大小大于用量数量,Signal Kanban Example,信号看板案例,Part Number,零件号,23-8765,Container Qty.,包装数量,50,Order Point,订单点,7,Store Location,储存位置,13-B-8,Lot Size,批量大小,25,Line No.,生产线,11,Withdrawal kanban,取料看板,Production kanban(material preparation),生产看板,Signal kanban,信号看板,Signal Kanban,信号看板,Withdrawal kanban,取料看板,Lot production process,Signal Kanban,信号看板,1,4,3,2,Pattern Production,模式生产,Following a fixed sequence(pattern)of production that is repeated,按照一个重复的固定的生产顺序,ABCDEFG,ABCDEFG ABCDEFG etc.,Optimized around changeover difficulty(e.g.color change from lighter to darker),优化换型的难度（例如：颜色从淡到深）,Pattern replenishment cycle determines supermarket inventory level(e.g.1 day pattern=1 day supply of stock),模式的补料循环时间定义了超市库存的水平（例如：,1,天模式,=1,天的库存）,A,B,C,D,E,F,F,G,G,A,Visual Wheel for Pattern Production,模式生产的目视化转盘,Pattern Production,模式生产,Advantages of pattern production,模式生产的优势,Simple method may not require kanban,简单的方法,-,也许不需要看板,Predictable changeover sequence,可预见的换模顺序,Batch size allows buffer for variability,批量大小考虑缓冲及变化性,Disadvantages of pattern production,模式生产的劣势,Fixed sequence cannot be changed,固定不能更改的顺序,Hides problems less need to reduce changeover times,隐藏了问题,减少了换模时间减少的必要性。,Requires periodic reanalysis of the demand pattern,要求预先对生产需求的模式进行分析,Part#,Reorder Point Line,订购点,Minimizes changeovers by running the same part numbers as a batch,批量生产相同的品号来减少换模时间,When the arriving kanban crosses the reorder point,those parts must be produced next,当收到的看板卡超过订货点，这些零件必须马上进行生产,Lot Making Board,批量生产板,A01,A02,B01,B02,B03,B04,C01,C02,C03,Triggered!,触发,Produce quantity specified on the 5 cards,生产数量设定为,5,张卡,=production instruction kanban cards,生产指示看板卡,Lot Making,批量生产,Advantages of lot making boards,批量生产板的优势,More frequent information flow back to the producer process(compared to signal kanban),Visually displays inventory consumption rates,Problems can be seen earlier,Disadvantages of lot making boards,批量生产板的劣势,Accuracy of board depends on how quickly kanban cards are returned o the board,批量板的准确性基于看板卡能够多快的返回批量板,Creates a temptation to build ahead(before trigger point is reached),创建一个诱惑点在生产前（在触发点到达前）,Withdrawal Kanban,补料看板,Internal circulates between processes within a site,内部,在工厂内部的不同工序间循环,External circulates between customer and supplier sites,外部,在客户及供应商之间循环,Point of use information,使用点信息,Product information,生产信息,Source Dept.,Molding,Machine#:,IM-P9Q2,Location:,地址,R1K09B,Part description:,零件描述,Lower basin,Quantity,数量,:,10,Kanban card:,3 of 9,看板卡：,3 of 9,Operation,工序,30,Delivery location:,运送地址,Sub assembly cell#2,半制品生产线,#2,Part#,零件号,：,M-8532,Upstream process,上游工序,Inter-process Withdrawal Kanban,内部工序补料看板卡,Supplier(Withdrawal)Kanban,供应商（取料）看板,Travels between two different companies customer and supplier,在,2,加不同的公司间移动,客户与供应商,Card contains part-specific information for both companies(part number,location,etc.),卡片包含零件在两家公司特定的信息（零件编号，地址等）,Each kanban card serves as a commercially binding order based on blanket purchase order specifying various terms,每个看板卡服务于一个基于特定不同时期的空白订单,Supplier Kanban Circulation,供应商看板循环,3,2,1,4,5,Finished goods supermarket,成品超市,Supplier,供应商,Supplier kanban are removed from container when the first part is used and placed in post,当第一个零件被使用时将供应商看板从周转箱上取出,Kanban cards are collected from the post at a set time and delivered to sorting machine,看板卡被收集并公布定期被公布及送至相应的机器,Sorted kanban cards are placed in suppliers slot,分类过的看板卡放置在对应的供应商的槽内。,Supplier picks up kanban at the when they arrive to make a delivery,当供应商抵达及送货时取回看板卡,Supplier kanban are sorted and distributed to shipping areas,分类后的供应商看板分发到出货区域,Kanban are matched with parts and prepared according to specified delivery cycle,看板卡与相应的物料对应起来根据特定的交货循环准备好,Parts are delivered from the supplier to the receiving are or the line,供应商将零件交付到收货区域或生产线。,6,7,Supplier Kanban Circulation,供应商看板循环,Kanbans flowing between customers and suppliers are part of existing the framework of blanket POs and do not need to pass through sales or purchasing organizations,客户与供应商之间的看板流程是现有的空白订单的架构，不需要通过销售及采购组织。,The kanban cards do pass through sorting center managed by production control,生产控制部门通过挑选中心来管理看板卡,Supplier Kanban System Example,供应商看板案例,Toyota final assembly plant,丰田成品组装工厂,15,000 vehicles per month 15000,辆车,/,月,1,200 employees 1200,名员工,All supplier parts are controlled by kanban,所有的供应商零件通过看板进行管理,Sorting and distribution center for withdrawal kanban cards(supplier transport),用于挑选及分发补料看板卡的中心（供应商运输）,Two full time production control people2,个全日制的生产管理人员,Supplier Kanban Card Example,供应商看板卡案例,Point of use information,使用点信息,Product information,产品信息,Supplier code:,03-952,Supplier:,Superior Machine,Supplier location:,321 Industry Rd,Industry,USA,Part description:,Crank shaft,Quantity:,8,Kanban cycle:,1-4-2,Receiving dock:,4,Supermarket location:,B3-K-12,Part#,：,D-7632,Supplier information,供应商信息,Delivery timing,Supplier Kanban Cycles,供应商看板循环,The meaning of“1-4-2”on example card:,案例上“,1-4-2,”的意思,1=parts on the card will be delivered within,one day,of the card being pulled 1,=,在卡上将在一天内被交付的零件,4=a suppliers truck will deliver these parts to the supplier,four times per day,供应商的卡车将会将这些零件每天,4,次交付到供应商,2=this kanban card will return not on the next truck but on the,2,nd,truck,arriving 2,=,这张看板卡将不会在下一辆卡车上返回，但是会在第二辆卡车返回,Kanban Delivery Cycles,1:4:2,“Period”,周期,In one day,在一天内,“Frequency”,频率,Make four deliveries,4,次交付,“Lag”,迟延,And these parts must come back two deliveries after supplier kanban is sent,这些零件在看板卡发出后的,2,次交货后返回,Supplier Kanban Cycles,供应商看板循环,Customer,客户,Supplier,供应商,Supplier Kanban Cyc