1、Line Lean Six Sigma Improvement Process Road Map,Definition Line Balance Model Design Principles Value Definitions Approaches to Line Balance Exercise,RD011202,Line Lean Six Sigma 改善过程路径,定义 线平衡模型 设计原则 价值定义 线平衡方法 练习,RD011202,Line Balance Model,3,Lean Six Sigma Improvement Process Road Map,Analyze,Con
2、trol,Improve,Define Identify Problem Develop List of Customers Develop List of CTQs from Voice of the Customer Finalize Project Focus and Key Metrics Complete PDF,Measure Map Business Process Map Value Stream Develop Data Collection Plan Conduct Measurement System Analysis Collect Data Conduct Proce
3、ss Capability Analysis,Analyze Propose Critical Xs Prioritize Critical Xs Verify Critical Xs Estimate the Impact of Each X on Y Quantify the Opportunity Prioritize Root Causes Conduct Root Cause Analysis on Critical Xs,Improve Critical Xs Confirmed Develop Potential Solutions Select Solution Optimiz
4、e Solution Pilot Solution,Control Implement Process Changes and Controls Write Control Plan Calculate Final Financial/ Process Metrics Transition Project to Future Owners Identify Project Translation Opportunities,Measure,Define,Project ID Tools Project Definition Form Net Present Value Analysis Int
5、ernal Rate of Return Analysis Discounted Cash Flow Analysis PIP Management Process RACI Quad Charts,Process Mapping Value Analysis Brainstorming Multi-Voting Techniques Pareto Charts C&E/Fishbone Diagrams FMEA Check Sheets Run Charts Control Charts Gage R&R,Cp & Cpk SupplyChainAccelerator Analysis M
6、ulti-Vari Box Plots Interaction Plots Regression ANOVA C&E Matrices FMEA,Brainstorming Pull Systems Setup Reduction TPM Process Flow Benchmarking Affinity DOE Hypothesis Testing Force Field Tree Diagrams Gantt Charts,Check Sheets Run Charts Histograms Scatter Diagrams Control Charts Pareto Charts In
7、teractive Reviews Poka-Yoke,Revised 1-12-02,Line Balance Model,4,精益6 过程改善流程,分析,控制,改进,定义 选定题目 列出客户 从顾客之声中列出关建需求 定出项目焦点和重要指标 完成 PDF,测量 绘制业务流程图 绘制价值流程图 制定数据收集计划 测量系统分析 收集数据 过程能力分析,分析 提出关键因子 区分关键因子 验证关键因子 评枯每个关键因子对结果的影响 量化机会 根本原因排序 寻找根本原因针对关键因子,改进 关键因子确认 发掘潜在的解决方法 选择方案 优化方案 实行方案,控制 过程变革和控制 制定控制计划 计算最终财务
8、 过程指标 项目过渡给未来项目管理者 项目鉴 别 转化机会,测量,定义,项目编号工具 项目定义表 净现值分析 内部回报率分析 折算现金流分析 ？（按现值计算的现金流量分析） PIP管理过程 RACI Quad 表,过程图 价值分析 脑力风暴 投票归类法 柏拉图 因果图/鱼骨图 FMEA 查检表 运行图 控制图 量具 R&R,Cp & Cpk 供应链加速器分析 多变动图i 盒状图 交互作用图 回归分析 ANOVA C&E 矩阵图 FMEA,脑力风暴 拉系统 减少设置 TPM 流程图 标杆管理 亲和图 DOE 假设检验 力场分析图 树状图 甘特图,查检表 运行图 柱状图 散布图 控制图 柏拉图 互
9、动回顾 愚巧法,Revised 1-12-02,Line Balance Model,5,Learning Objectives,How to design and implement a process supported by a line balancing model that ensures optimal use of: People Floor space Capital Assets Material Know how to maximize productivity,Line Balance Model,6,学习目标,如何设计和实施由“线平衡模型”支持的一个流程以确保优化配置
10、： 人 地方 固定资产 材料 知道如何使生产率最大化,Line Balance Model,7,Whats in It for Me?,Able to design and implement a balanced process line Understand the issues in a typical process environment and how to impact those issues,Line Balance Model,8,益处,能够设计和实施一个线平衡的生产线 了解典型流程环境中的问题及如何影响那些问题,Line Balance Model,9,Line Bala
11、nce Model,A Line Balancing Model allows the user to view task times across a process to identify bottlenecks and thus calculate output rates (throughput) and Takt Times. In addition, the user will be able to visually see unbalanced areas and where tasks can be shifted to balance the process. The Lin
12、e Balance techniques are applicable in transactional as well as manufacturing, e.g., order entry operations.,Line Balance Model,10,线平衡模型,线平衡模型允许用户在一个流程中确定瓶颈问题，并计算产出比率（产能）和Takt Times 。 除此，用户将能直观地看到不平衡的区域和使流程平衡所做的任务。 线平衡 方法与生产互动一样是可行的，如订单进入生产。,Line Balance Model,11,Primary Issues in Typical Process En
13、vironments,Large or erratic batches Excessive WIP Poor floor space utilization Low employee efficiency Long/erratic cycle times Poor balance of operations and labor across process steps Conveyance, standby and motion waste Disorganized workspace and component/supply storage High variability of deman
14、d on multiple processing centers, e.g., call centers/flow lines,Line Balance Model,12,典型的流程环境 中的主要问题,大批量或 反复无常的批量 过多的 WIP 地方利用的差 较低的员工效率 长的/反复无常的周期时间 流程步骤中差的生产平衡和劳动力 传送、备用和启动浪费 无规则的工作地点和元件/供应存储 对于多重的流程中心，需求变化差异大2，如电话中心/流出线,Line Balance Model,13,Line Balance Design Principles,Minimize Batch Size/Tran
15、sfer Quantity/Work In Process Minimize/Stabilize Cycle Time Maximize Labor Efficiency Optimize number of workstations/process steps Balance tasks/labor across workstations Maximize space utilization Minimize takt variance Minimize NVA (conveyance, standby, and motion wastes) Minimize the need to re-
16、balance as demand requirements change Minimize volume variability (combine product category demand) Maximize flexibility to allow for product introductions and discontinuations,Line Balance Model,14,线平衡 设计原则,使批量规模/转移质量/在制品最小化 将周期时间最小化/稳定化 使劳动效率最大化 优化配置工作站/流程步骤 平衡任务/工作站里的劳动 最大限度利用空间 使 takt 的变化最小化 最小化
17、 NVA (运送、备用和启动浪费) 根据需求的变化使再平衡的需求最小化 使批量差异最小化 (综合产品种类需求) 使柔性最大化以允许产品引入和非持续性,Line Balance Model,15,Value Definitions,Value Add: Adding form, fit, or function to the product. A task or activity for which the customer would be willing to pay. Example Assembler screwing a bolt into a piece of aluminum re
18、quired to hold the window together Example Financial Services employee adding credit history to a credit application Business Value Add: A task that is required to build a window but for which the customer is not willing to pay Example The time it takes for an assembler to grab a part that is at poi
19、nt-of-use and ready it for assembly Example The time it takes for a Financial Services employee to secure a credit application and ready it for processing Non-Value Add: A task that is not required and should be eliminated because it is wasteful Example Assembler having to search around their area t
20、o retrieve a part for assembly Example Financial Services employee having to look for missing information needed to add credit history information,Line Balance Model,16,价值定义,增值: 增加产品的形式、或功能。客户愿意付费的任务或活动。 如 在铝合金中装配螺钉以把窗子固定在一起 如 给员工在应用信用方面 提供信用历史的财务服务 业务增值: 所需的一项任务是一扇窗子，但是客户不愿付费 如 装配商花时间抓住一个零件在使用点上进行装
21、配 如 为员工提供财务服务是花时间确保信用的应用,Line Balance Model,17,Line Balance Approaches,Two Different Approaches: Approach #1 Long Term Planner: Given the inputs of average productivity, assembly/processing time, and forecasted output (demand), and hours per shift, calculate the number of assemblers/processors and a
22、verage takt time it will take to satisfy the demand. Approach #2 Day-to-Day Scheduler: Given the inputs of average productivity, assembly/processing time, number of assemblers/processors, and desired output (demand), calculate the hours per shift and takt rate it will take to satisfy the demand. Wha
23、ts the difference? Long Term Planner allows management to understand staffing increments based upon some forecasted demand on a line by line basis. Day-to-Day scheduler allows line supervision to calculate process parameters (takt rate, hours to work) based on the number of units to process and the
24、number of people who show up to work that day.,Line Balance Model,18,线平衡步骤,两种不同的方法: 方法 #1 长期计划员: 作出平均投入生产率、装配/加工时间、及预计的产量（需求），每班的时间，计算装配工/操作工的数量，及满足需求所花的平均时间。 方法 #2 日常安排员 : 作出平均投入生产率,装配/加工时间，装配工/操作工的数量，理想的产量（需求），计算每班所用的时间和满足需求的takt 比率。 区别是什么? 长期计划员允许管理来了解在以生产线为基础上的需求预测而增加员工。 日常安排员允许生产的监督来计算流程参数（ tak
25、t比率，工时），这个参数是基于 加工单元数量和人员数量。,Approach #1 Long Term Planner,途径 #1 长期计划员,Line Balance Model,21,Input 1. Demand requirements 2. Labor efficiency 3.Assemble/process tasks and times 4. Hours per shift or number of assembler/stations,Output 1. Takt rate 2. Number of Assemblers/Processors OR Number of hour
26、s per shift 3. Staffing levels at varying demand,Process Balance Model (spreadsheet),Process Balance Model: Design process,Or,Line Balance Model,22,投入 1. 需求需要 2. 劳动效率 3.装配/加工任务和时间 4. 每班时间或装配工/工作站数量,产出 1. Takt 比率 2. 装配工/操作工数量或每班时间 3. 在变化基础上的员工水平,过程平衡模型 (spreadsheet),Process Balance Model: 设计流程,Or,Lin
27、e Balance Model,23,Process Balance Model: Steps,Step 1: Understand present state process operation (gather and document data) Step 2: Determine total time required to process unit (value add and business value add) Step 3: Determine maximum operating parameters and plug parameters into yellow cells
28、Step 4: Determine target unit/day output requirement and plot on table to determine number of shift hours to work to achieve requirement Step 5: Plot current operating range to determine labor reduction required to meet operating goals Step 6: Group tasks in logical and efficient manner that does no
29、t violate design principles,Line Balance Model,24,过程平衡模型 步骤,Step 1: 了解目前的生产流程状况 (收集数据并文件化) Step 2: 确定处理单元所需的全部时间（增值和业务增值） Step 3: 确定最大的运行参数并将参数插入黄格中 Step 4: 将目标单元/天所需的产量在桌面上标出以确定达到需要的每班工作时间 Step 5: 标出目前的运行变化以确定满足生产目标所需减少的劳动力 Step 6: 在不影响设计原则的情况下，按逻辑和效率态度将任务分解,Line Balance Model,25,Step 1 Understand
30、present state process operation (gather and document activity time actuals) Note: Time should include customer value add, business value add, and non-value add times for each step/operation/task,Step 2 Determine total (current) time required to process unit. Note: Model should automatically calculat
31、e total time entered in seconds, minutes, and hours,Process Balance Model: Steps 1 and 2,Line Balance Model,26,步骤 1 了解现在过程状况 (收集、记录活动时间) 注意: 时间应该包括 CVA、BVA、与每一步骤、作业、与任务的时间,步骤2 决定全部（目前）需要完成任务的时间。 注意：模型应该可以自动计算时间。,过程平衡模型 步骤 1 和 2,Line Balance Model,27,Step 3 Determine maximum operating parameters and
32、plug parameters into highlighted cells - All other cells are calculated automatically (Example calculations are located at the end of this section.),Process Balance Model: Step 3,Line Balance Model,28,步骤 3 决定最大的作业参数与加乘参数到设定的格位中。其他的格位可自动计算。 (计算案例在本节最后。),过程平衡模型 步骤 3,Line Balance Model,29,Step 4 Determ
33、ine target unit/day output requirement and plot on table to determine # of shift hours to work to achieve requirement,Process Balance Model: Step 4,This line says that I need to work an 8 hour shift with 12 processors to achieve a 400 unit/day output requirement,Line Balance Model,30,步骤 4 决定需要的目标单位/
34、日表，并图示需要完成任务需要的工作时间。,过程平衡模型: 步骤 4,这行说明我需要使用12人，8小时班来完成每天 400 单位的需要,Line Balance Model,31,Model will build the following graph which shows how we should plan to: Staff in equal increments (to limit having to re-balance line) Vary hours worked to get complete coverage of demand requirements,Process Ba
35、lance Model: Step 4 (Cont.),Line Balance Model,32,模型可建立如下图说明: 每一阶段需要的人力 完成任务需要的工作时间,过程平衡模型: 步骤 4 (续.),Line Balance Model,33,Step 5 Plot current operating range to determine labor reduction required to meet operating goals,Process Balance Model: Step 5,The model has calculated that at a rate of 150 u
36、nits/day, the area should be working a 6 hour shift with 7 processors. This is 2 fewer processors than their current environment.,Line Balance Model,34,步骤 5 绘制目前的作业范围来决定完成目标可节约的人力,过程平衡模型: 步骤 5,在 150 单位/天的需求下, 需要每班 6 小时， 7 位作业员. 比目前人力少两人,Line Balance Model,35,Step 6 Group process tasks in logical and
37、 efficient manner that does not violate design principles (eg - (task time takt rate time),Process Balance Model: Step 6,Line Balance Model,36,步骤 6 合乎逻辑与共效率的团队工作不违反设计原则 (例 - (task time takt rate time),过程平衡模型: 步骤 6,Line Balance Model,37,This worksheet provides a summary of inputs used and outputs gen
38、erated for each window category that is run through the model. This worksheet is automatically created and updated by the model.,Model Summary,Line Balance Model,38,这个工作表提供了在本模式运行下的按窗口分类的投入和产出的总结。这份表格是自动生成的并能通过该模式更新。,模型总结,Line Balance Model,39,Approach #1: Calculation Notes (Step 3),Max Labor Effici
39、ency Best in class is 65% Assumption is that labor efficiency declines the more tasks each processor is asked to perform Max hrs per shift Should be set to 11 hours to obtain optimal coverage of requirements Max Demand (units/ hour) = Max Demand Requirement/Max hrs per shift Max Demand (units/minute
40、) = Max Demand (units/hour) / 60 Takt Time (seconds/unit) = 60 / Max Demand (units/minute) This is the amount of time between products exiting - This is also the maximum amount of process time that any one workstation should perform without compromising the line flow Total Assemblers/Processors = (T
41、otal Process Time (hrs) * Max Dmd Req (units/shift) / Max hrs per shift) /Max Labor Efficiency The result is rounded up to the next whole assembler This is the number of assemblers/processors I should have to process the maximum demand requirement at the maximum labor efficiency Workstation Time (se
42、cs/workstation) = Total Process Time (hrs) * 60 * 60 / Total Processors 1 processor = 1 workstation This is the optimal amount of time that tasks should be grouped by to balance the line Labor Productivity (Units/Labor Hour) = Max Demand (units/hour) / Total Processors,Line Balance Model,40,途径 #1: 计
43、算说明 (步骤 3),最高劳动效率 最好是 65% 假设劳动效率下降，需要每个操作工做更多的工作 每班最多工时 应该设为11个小时以最好地满足需要 最大需求 (units/ hour) = 最大需求需要/每班最多工时 最大需求 (units/minute) = 最大需求 (units/hour) / 60 Takt 时间 (seconds/unit) = 60 / 最大需求 (units/minute) 这是现有产品之间的时间量 - 这也是每个工作站的最多的流程时间 全部装配工/操作工 = (Total Process Time (hrs) * 最大需求需要 (units/shift) / M
44、ax hrs per shift) /最高劳动效率 这个结果接近下次的全部操作工 这是在最高劳动效率下的满足了最高需求下的操作工人数 工作站时间 (secs/workstation) = Total Process Time hrs) * 60 * 60 / Total Processors 1 操作工 = 1 工作站 这是将任务分组的最佳时间 劳动生产率 (Units/Labor Hour) = 最大需求 (units/hour) / 全部操作工,Line Balance Model,41,Approach #1: Team Exercise,1. Go to the Virtual Coa
45、ch Exercise Tab and open the file titled: Windows R Us Line Balancing Exercise.doc 2. Read the scenario and complete steps 1 through 4 using the spreadsheet titled: Windows R Us Line Balancing Data.xls 3. Prepare a 5 minute presentation with your team answers. You have 45 minutes to build this part
46、of a line balance model. Detailed instructions are on the next slide.,Line Balance Model,42,Approach #1: 小组练习,1. 看虚拟辅导练习并打开以下抬头的文件: Windows R Us Line Balancing Exercise.doc 2. 读情节并完成第1到第4步，使用有以下抬头的工作表格: Windows R Us Line Balancing Data.xls 准备5分钟的展示 你有45 分钟的时间来建这个线平衡模型部分 具体的指导显示在下一个幻灯片上.,Line Balance
47、 Model,43,Exercise Objectives,Teach the student how to balance a line mathematically Teach the student the method to re-lay out the line to realize the mathematical balance The exercise will develop: Takt Time chart Skill Matrix Proposed time calculation,Line Balance Model,44,练习的目标,教学生怎样用数学方法来平衡一条线
48、教学生对线进行再布局的方法以实现数学上的平衡 这个练习将制作出: Takt 时间图表 技能距阵 拟定时间的计算,Line Balance Model,45,Exercise Instructions,1. Using the Excel spreadsheet, look at the “Current times” tab to complete the “Current Takt Time Chart.” 2. Look at the “Current Staffing” tab to complete the “Skill Matrix” tab. 3. Use the three ta
49、bs and re-divide the tasks to have a balanced number of tasks with the same number of people and same sequence as the original line.Note: A proposed layout is not to be made. Current extrusion data is not to be developed. Improvements tab is not to be completed.,Line Balance Model,46,练习指南,1. 使用 Excel工作表格,看 “目前的时间” 以完成 “Current Takt Time Chart.” 2. 看 “Current Staffing” 完成 “Skill Matrix” 3. 使用这三个表重新分配任务，用同样的认输和程序在原来的生产线上平衡任务数量。Note: 不必做出一个拟定的布局 不用做出目前的数据 不必完成改进表,Line Balance Model,47,Assembly Balance Model: Day-to-Day Scheduler,
