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1、KAIZENROADMAPTAKT/CustomerDemandCapacity/TOCAnalysisLoad/LineBalanceAnalysisValueStreamMappingSpaghettiMapCellDesign/DevelopNewLayoutDevelopContinuousFlowOn-goingContinuousImprovement(As-is&Tobe)(As-is&Tobe)(Tobe)(As-is)(As-is)Understandcurrentsituation/Base
2、lineUnderstandcurrentsituation/BaselineUnderstandVOCUnderstandcurrentProcessWasteeliminationCostdownKAIZENROADMAP1.VOC-TakttimeTaktTime=DemandRateTaktTime=AvailabletimeRequestedQtyＡＢ①KAIZENROADMAP2.CapacityanalysisEXAMPLEMachineB(3pc)540(Capacity)MachineA(3p
3、c)MachineC(2pc)242(Capacity)360(Capacity)360(Load)180(Load)135(Load)3.Load/LineBalanceLoad/CapacitycumulativeA、FormachineBloadexceeditscapacity(242-180=62H);B、TokeepOTDitshouldarrangeoverworktime62HformachineB(Load/capacityadjustment)KAIZENROADMAPEXAMPLE3.Lo
4、ad/LinebalanceKAIZENROADMAPT.T=33TOC=29.2UtilizationlossBalancelossLinebalance(%)=(∑C.T/∑29.2*n)×100%=89.5%Linebalanceloss(%)=1-Linebalance(%)=10.5%EXAMPLE5.4KnittingDipping2ndWashing/dryingHeattransfermarkingPackingBottleneckOver-WIPandwastewillgeneratedifl
5、inenotbalanced9.75.49.7Linebalance(%)=(Capability5.4*n/∑capability)×100%=52.7%Linebalanceloss(%)=1-Linebalance(%)=47.3%Productionloss=Averagecapability-currentcapability=8.3-5.4=2.93.Load/Linebalance7.09.7BottleneckEOLRKAIZENROADMAPEXAMPLECapacitycalculation
6、---EOLR產(chǎn)能計(jì)算ProcessProcess1Process2Process3Process4Process5Capacity100pc/H75pc/H110pc/H80pc/H125pc/HKAIZENROADMAPEXAMPLEEXAMPLEProductionControlMRPDailyShipScheduleWeeklyScheduleDailyOrderWeeklyFAXForecast(2months)CuttingsewingFormingFINISHEDGOODSRAWMATERIALC
7、ustomerSupplierVSM-CurrentC/T=?(TCT1)People:?Uptime=?C/O=?minBatchsize=?FTY=?Shift:1(8H)?Monthlydemand:11000pr?Dailydemand:500pr?Packing10days?80sec?3days?1day?58sec?2days?10days?30sec?140sec?DTD=26day?MCT=308sec(25person?)PcsC/T=?secDTD=26days?VA=308sec?VAR
8、%=VA/DTD*100%=?EOLR?EOLR?EOLR?EOLR?C/T=?(TCT2)People:?Uptime=?C/O=?minBatchsize=?FTY=?Shift:1(8H)?C/T=?(TCT3)People:?Uptime=?C/O=?Batchsize=?FTY=?Shift:1(8H)?C/T=?(TCT4)People:?Uptime=?C/O=?Batc
