1、,Standard Work Workshop 標(biāo)準(zhǔn)化工作訓(xùn)練營,Standardized Work 標(biāo)準(zhǔn)化作業(yè),Terms to know: 你需知道的術(shù)語 Takt time 客戶需求節(jié)拍 Target cycle time 目標(biāo)加工周期 Actual cycle time 實(shí)際加工周期 Manual time 手工時(shí)間 Walk time 行走時(shí)間 Wait time 等待時(shí)間 Unassigned time 未分配時(shí)間 Machine cycle time 機(jī)器加工周期,Standardized Work 標(biāo)準(zhǔn)化作業(yè),Takt Time Calculation:客戶需求節(jié)拍的計(jì)算 Av

2、ailable Daily Operating Time (Seconds)每天可用工作時(shí)間(秒)_ Total Average Daily Production Requirements (Pieces)總的平均日生產(chǎn)需求(件),Standardized Work 標(biāo)準(zhǔn)化作業(yè),Takt Time Calculation Example: 客戶需求節(jié)拍的計(jì)算舉例 Cell 3000 (Two shift operation) 單元3000(兩班) Customer demand = 1504 / per day 客戶需求-1504/天 Available work time = 16 hour

3、s 可用工作時(shí)間16h = 960 min/day Less 4 breaks per day 10 min. each 減 4次休息 = 40 min Total Available Time 總可用時(shí)間 = 920 min 920 minutes X 60 seconds = 55,200 seconds Takt Time = 55,200sec / 1504 units = 36.7 seconds We need to net 1 unit every 36.7 seconds 我們每36.7秒需要加工一件零件,Target Cycle Time 目標(biāo)加工周期,Target Cycl

4、e Time = Takt Time - Special Allowances 目標(biāo)加工周期=客戶需求節(jié)拍-允許的特殊耗時(shí),Target Cycle Time may include planned, repetitive operations 目標(biāo)加工周期包括計(jì)劃的、重復(fù)的操作,- Examples of Special Allowances允許的特殊耗時(shí)例子,Team Meetings 小組會(huì)議 PM 預(yù)防性保養(yǎng) Changeover 換裝,Target Cycle Time 目標(biāo)加工周期,Planned, repetitive allowances will be determined

5、by each Business Unit 計(jì)劃的，重復(fù)的所允許的耗時(shí)由每個(gè)業(yè)務(wù)單元決定。,Target Cycle Time Example 目標(biāo)加工周期舉例,Production Requirement: 1504 parts per day 生產(chǎn)需求 每天1504件部件 P.M.保養(yǎng) 15 minutes X 2 shifts = 30 min. EI Meeting EI會(huì)議 12 minutes X 2 shifts = 24 min. 54 min. 54 minutes X 60 seconds = 3240 seconds 3240/ 1504 = 2.15 seconds l

6、ost for Special Allowances Target Cycle Time = 36.7(Takt) 2.15(SPA) = 34.55 sec. 目標(biāo)加工周期,Standardized Work 標(biāo)準(zhǔn)化作業(yè),Actual Cycle Time實(shí)際加工周期= Manual time + Walk Time + Wait Time 手工時(shí)間+行走時(shí)間+等待時(shí)間,Standardized Work 標(biāo)準(zhǔn)化作業(yè),Actual Cycle Time = Manual time +Walk time +Wait time 實(shí)際加工周期=手工時(shí)間+行走時(shí)間+等待時(shí)間 Longest oper

7、ators actual cycle time tells us how many parts the cell is capable of running 最長的加工周期告訴我們單元有能力加工多少件零件,Actual Cycle Time is the time it takes an operator to complete one cycle of his/her standard work 實(shí)際加工周期是指一位操作員完成其標(biāo)準(zhǔn)作業(yè)的周期,Standardized Work 標(biāo)準(zhǔn)化作業(yè),Manual Time:手工時(shí)間 The time required for an operator

8、to perform the physical tasks for one cycle of operation (Inspecting, loading / unloading, and gauging) 操作工在一個(gè)周期的操作中為完成手工任務(wù)所需的時(shí)間(如檢驗(yàn)，裝載，卸載，測(cè)量),Standardized Work 標(biāo)準(zhǔn)化作業(yè),Walk Time:行走時(shí)間 The time required for the physical movement from one point to another, with or without a part 從一點(diǎn)移動(dòng)到另一點(diǎn)所需的時(shí)間，持有或無零件,St

9、andardized Work 標(biāo)準(zhǔn)化作業(yè),Wait Time:等待時(shí)間 The time the operator waits while the machine completes its function 操作工等待機(jī)器完成其操作的時(shí)間,Standardized Work 標(biāo)準(zhǔn)化作業(yè),Standardized Work 標(biāo)準(zhǔn)化作業(yè),Machine Cycle Time: 機(jī)器周期 The time required by a machine to complete one cycle of operation 機(jī)器完成一個(gè)操作循環(huán)所需的時(shí)間 *Machine cycle time may

10、 also be referred to as Auto Time機(jī)器周期也被稱為自動(dòng)時(shí)間,Target Cell Manning 目標(biāo)單元人員配備,# Of Members =,Total Manual Time+ Total Walk Time Target Cycle Time目標(biāo)周期,員工數(shù) 總的手工時(shí)間 總行走時(shí)間,GOAL: actual cycle time target cycle time takt time,Target Cycle Time目標(biāo)周期 = Takt time- special allowances特殊耗時(shí),Actual Cycle Time = The ti

11、me it takes an operator to complete one cycle of standard work. The longest operators actual cycle time tells us how many parts the cell is capable of running 實(shí)際周期=一位操作員完成標(biāo)準(zhǔn)作業(yè)的整個(gè)周期的時(shí)間。操作員實(shí)際最長耗時(shí)告訴我們這個(gè)單元可以生產(chǎn)的部件數(shù)。,Takt Time Calculation:計(jì)算,每日可得操作時(shí)間(秒),總平均每日生產(chǎn)要求(件數(shù)),目標(biāo)： 實(shí)際周期 目標(biāo)周期 TAKT時(shí)間,Labor Efficiency

12、勞動(dòng)效率,Labor Efficiency =,Standard Direct Labor Hours,Actual Spent Hours,Standard Labor x Standard Cycle Time (In Hours) x Output,Actual Labor x Actual Hours,=,Productivity Benchmark 生產(chǎn)力參照值,Cell F1 單元F1 Average Manual Time (MT) - 36.0 seconds 平均手工時(shí)間-36.0秒 Manual time is the time required for an operat

13、or to perform the physical tasks for one cycle of operation.(Inspecting, loading/unloading, and gauging) 手工時(shí)間是一操作工完成一個(gè)操作周期所花在手工操作上的時(shí)間(檢驗(yàn)，裝卸，檢測(cè)等) Takt - 48.7 seconds 理論周期-48.7秒 Manual (MT) % of Takt - 73.9% 手工時(shí)間占理論周期的比例-73.9%,MT,TAKT,=,36,48.7,=,73.9%,PRODUCT MIX 混流生產(chǎn),Product Mix Example 產(chǎn)品混合例子,Total

14、 Available Time總共可用時(shí): 8 hours X 60= 480-20(2-10 breaks)=460X60”=27,600” 27600”/876 daily units required = 31.5” Takt Time,Total Daily Available Time總每日可用時(shí) Avg. Daily Units Required(A,B,C) 平均每天所需求的件數(shù),TAKT =,Target Cycle Time Calculation 目標(biāo)周期的計(jì)算,Target Cycle Time = Takt Time - Special Allowances 目標(biāo)周期

15、= TAKE 時(shí)間- 特殊耗時(shí) Takt Time = 31.5” Special Allowances特殊耗時(shí)= 10 ATPM + 12 Team Meeting 小組會(huì)議 Special Allowances特殊耗時(shí)= 22 X 60” = 1320” Special Allowance per cycle = 1320”/876 units = 1.5” 每個(gè)循環(huán)的特殊耗時(shí) 31.5”(Takt Time) - 1.5”(Special Allowance) = 30.0” TCT,Product Mix Example 產(chǎn)品混合例子,Part A 356” x .25 = 89” P

16、art B 300” x .35 = 105” Part C 240” x .40 = 96” 290” Weighted Average 加權(quán)平均的全部工作內(nèi)容,Calculation of Avg. Target Manning 平均目標(biāo)人力的計(jì)算,Target Manning Example 目標(biāo)人力配備舉例,290” 30.0”,Target Cycle Time 目標(biāo)周期,Total Manual Time + Total Walk Time 總手動(dòng)時(shí)間 + 總走動(dòng)時(shí)間,Target Manning 目標(biāo)人力,=,=,=,9.6,We round to the next full p

17、erson and use 10 people 我們?nèi)≌麛?shù)，用10人。,Fixed Manning/Flex TCT 固定人力/ 可變的目標(biāo)周期,Product產(chǎn)品 A B C,Manual人力 306” 260” 200”,Walk走動(dòng) 50” 40” 40”,Total總共 356” 300” 240”,% Mix混合 25% 35% 40%,Part A 356”/9.6 = 37.08” Target Cycle Time Part B 300”/9.6 = 31.26” Target Cycle Time Part C 240”/9.6 = 25.00” Target Cycle T

18、ime,Fixed TCT/Flex Manning 固定的目標(biāo)周期/可變的人力,356”/30.0” = 11.8 Target Manning目標(biāo)人力 300”/30.0” = 10.0 Target Manning目標(biāo)人力 240”/30.0” = 8.0 Target Manning目標(biāo)人力,Product Mix Example 產(chǎn)品混合例子,Fixed Manning 固定人力,Fixed TCT固定目標(biāo)周期,Target Manning 目標(biāo)人力,Target Cycle 目標(biāo)周期,Target Manning 目標(biāo)人力,Target Cycle 目標(biāo)周期,A 30.0” 11.

19、8 37.0” 9.6 B 30.0” 10.0 31.2” 9.6 C 30.0” 8.0 25.0” 9.6 Gross 30.0” 9.6 30.0” 9.6,9 Continuous Improvement Process Steps 持續(xù)改進(jìn)的9個(gè)步驟,1. Observe current method 觀察目前的方法 2. Document current method 記錄目前的方法 3. Identify improvements (steps to eliminate) 識(shí)別改進(jìn)(需消除的步驟) 4. Implement improvements 實(shí)施改進(jìn) 5. Valida

20、te quality and productivity of new method 驗(yàn)證新方法的質(zhì)量及生產(chǎn)力 6. Standardize new method 將新方法標(biāo)準(zhǔn)化 7. Document “Before” and “After” conditions 記錄改進(jìn)前后的情況 8. Recognize achievements 認(rèn)可取得的成績 9. Look for next improvement 尋求下一次改進(jìn),Implementing Standard Work 實(shí)施標(biāo)準(zhǔn)作業(yè),Train the cell members in Standard Work & Takt Time Production. 給每個(gè)單元的成員就標(biāo)準(zhǔn)作業(yè)和理論時(shí)間生產(chǎn)進(jìn)行培訓(xùn) Calculate Takt and Target Cycle Time 計(jì)算需求節(jié)拍和目標(biāo)周期 Develop standard work charts with flex manning, plus and minus one operator 做出的標(biāo)準(zhǔn)作業(yè)圖表要體現(xiàn)靈活的人力配置，加1減1模式 Create Standard Work Combination Tables 建立標(biāo)準(zhǔn)作業(yè)組合表(SWCT) Create a Balance Bo