2021年03月16日 14:03
<section style="margin: 0px; padding: 0px; color: rgb(51, 51, 51); font-family: mp-quote, -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; font-size: 17px; text-align: justify; white-space: normal; box-sizing: border-box;"><section powered-by="xiumi.us" style="margin: 10px 0px; padding: 0px; box-sizing: border-box; max-width: 100%; overflow-wrap: break-word; text-align: center;"><section style="margin: 0px; padding: 0px 5px 0px 20px; box-sizing: border-box; display: inline-block; max-width: 100%; min-width: 10%; overflow-wrap: break-word; vertical-align: top;"><section powered-by="xiumi.us" style="margin: 0px; padding: 0px; box-sizing: border-box; max-width: 100%; overflow-wrap: break-word;"><section style="margin: 0px; padding: 0px; border-color: rgb(29, 29, 29) rgb(29, 29, 29) rgb(182, 182, 182) rgb(182, 182, 182); border-radius: 0px; border-style: dashed; border-width: 2px; box-shadow: rgb(0, 0, 0) 0px 0px 0px; 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margin-bottom: 0px; padding: 0px; clear: both; min-height: 1em; max-width: 100%; box-sizing: border-box; overflow-wrap: break-word;"><span style="margin: 0px; padding: 0px; box-sizing: border-box; max-width: 100%; overflow-wrap: break-word; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"><strong style="margin: 0px; padding: 0px; box-sizing: border-box; max-width: 100%; overflow-wrap: break-word;">010:</strong><strong style="margin: 0px; padding: 0px; box-sizing: border-box; max-width: 100%; overflow-wrap: break-word;">『线平衡』</strong></span></p></section></section></section></section></section></section></section></section></section><p></p><section powered-by="xiumi.us" style="margin: 0px; padding: 0px; color: rgb(51, 51, 51); text-align: justify; white-space: normal; max-width: 100%; box-sizing: border-box; font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; 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margin: 0px; padding: 0px; max-width: 100%; color: black; font-size: 17px; letter-spacing: 2px; text-align: justify; box-sizing: border-box !important; overflow-wrap: break-word !important;"></span><span style="margin: 0px; padding: 0px; max-width: 100%; color: black; font-family: 微软雅黑, sans-serif; font-size: 17px; letter-spacing: 2px; text-align: justify; box-sizing: border-box !important; overflow-wrap: break-word !important;"></span></span></p><p style="margin-top: 0px; margin-bottom: 0.1px; padding: 0px; clear: both; max-width: 100%; min-height: 1em; letter-spacing: 1.8px; background-image: initial; background-position: initial; background-size: initial; background-repeat: initial; background-attachment: initial; background-origin: initial; background-clip: initial; color: rgb(240, 176, 121); text-indent: 43px; box-sizing: border-box !important; overflow-wrap: break-word !important;"><span style="color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"><span style="font-size: 18px; font-family: arial, helvetica, sans-serif; text-indent: 35px; letter-spacing: 1.8px; color: rgb(51, 51, 51);">在上一讲当中,Tonii老师提到了生产线柔性,并强调柔性是生产线设计核心能力指标之一,线平衡则是另外一个核心能力指标。</span><span style="font-size: 18px; font-family: arial, helvetica, sans-serif; margin: 0px; padding: 0px; color: rgb(0, 0, 0); letter-spacing: 2px;"></span></span></p><p style="margin-top: 0px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 36px;"><span style="color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"><strong style="margin: 0px; padding: 0px;">什么是线平衡?</strong></span></p><p style="margin-top: 0px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 36px;"><span style="color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"><strong style="margin: 0px; padding: 0px;">它指构成生产线各道工序所需要的时间处于平衡状态,作业人员的作业时间尽可能的保持一致,从而消除各道工序间的时间浪费,进而取得生产线平衡。</strong></span></p><p style="margin-top: 0px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;">生产线平衡非常好理解,一道工序,一个流程或者是一条生产线,从原材料到成品,中间可能经历很多工序,每一道工序在设计的时候,让它的作业时间尽量的保持一致,比如说都是5分钟左右。</span></p><p style="margin-top: 0px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 36px;"><span style="color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"><strong style="margin: 0px; padding: 0px;">线平衡有哪些好处呢?</strong></span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="color: rgb(0, 0, 0); margin: 0px; padding: 0px; font-family: arial, helvetica, sans-serif; font-size: 18px;">真正意义上的线平衡,能够大幅的降低工序之间的在制品,能够实现真正意义上的单件流。单件流的好处就是线平衡的好处。另外一个,线平衡能够提升作业及设备工装的工作效率,能提高整体的效率。还记得Tonii老师在利特尔法则当中举的那几个例子吗?对于一个线平衡很差的流程,稍微给它做一下线平衡,它的产出率和提前期就会有大幅度的提升,所以说做线平衡能够提升整体效率。</span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-align: center; text-indent: 35px;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"></span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;">有一个指标来衡量线平衡的水平,就叫做平衡率。</span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 36px;"><span style="color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"><strong style="margin: 0px; padding: 0px;">平衡率等于各道工序的作业时间总和,除以时间陷阱岗位时间乘以人数,再乘以百分比</strong><span style="font-size: 18px; font-family: arial, helvetica, sans-serif; color: rgb(0, 0, 0); margin: 0px; padding: 0px;">。在上面的例子中,就是6道工序的作业时间总和,除以(6道工序中时间陷阱工序所用的时间乘以6),再乘以100%,算出来就是这个流程的平衡率。通常来讲,一个流程的平衡率应该大于85%,如果低于85%,就说明线平衡还有改善的空间。</span></span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;">接下来Tonii老师带着大家一起看几个状态。</span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-align: center;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"></span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="color: rgb(0, 0, 0); margin: 0px; padding: 0px; font-family: arial, helvetica, sans-serif; font-size: 18px;">第一个状态就是很多没有做精益的生产线流程。上图中有10道工序,节拍时间大约是55秒,结果第一道工序就要用70秒。虽然有10道工序,但是非增值时间充斥在每一个工序间,最后还是完不成客户的需求。(每一道工序都有增值时间、必要非增值的时间和非增值时间, 浅黄色就是非增值时间)</span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"></span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="color: rgb(0, 0, 0); margin: 0px; padding: 0px; font-family: arial, helvetica, sans-serif; font-size: 18px;">第二个是线平衡的理想状态,把所有的非增值活动全部剔除掉,同时优化了必要非增值时间,留下来增值时间,然后再进行绝对意义上的平衡,结果发现只需要4个工位就可以满足客户需求,效率得到了极大的提升。</span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;">但是现实状态是要比这残酷的,因为没法百分之百消除非增值活动,也没法大量的消除必要非增值活动,只能优化它。因此现实状态当中线平衡的结果一般是下图的状态:</span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-align: center;"><span style="margin: 0px; padding: 0px; color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"></span></p><p style="margin-top: 16px; margin-bottom: 16px; padding: 0px; clear: both; text-indent: 35px;"><span style="color: rgb(0, 0, 0); font-family: arial, helvetica, sans-serif; font-size: 18px;"><span style="font-size: 18px; font-family: arial, helvetica, sans-serif; color: rgb(0, 0, 0); margin: 0px; padding: 0px;">可能要用6道工序,每一道工序都有一定的非增值活动,或者是 必要非增值活动,但是它们的比例已经很小了。另外每一个工序的时间尽量是在</span><span style="font-size: 18px; font-family: arial, helvetica, sans-serif; color: rgb(0, 0, 0); margin: 0px; padding: 0px; background-image: initial; background-position: initial; background-size: initial; background-repeat: initial; background-attachment: initial; background-origin: initial; background-clip: initial;">Takt time</span><span style="font-size: 18px; font-family: arial, helvetica, sans-serif; color: rgb(0, 0, 0); margin: 0px; padding: 0px;">下面。这就是现实状态。这里要强调的是很多人都做过线平衡,但有可能进入一个误区,就是做线平衡只是把以前的工位重新排一下,就像搭积木一样重新的组装,这是不对的。在做线平衡之前,一定要识别各个工序当中有哪些是非增值的活动,一定要先消除非增值活动,把剩下的活动再进行平衡。</span></span></p></section></section></section></section><section style="margin: 0px; padding: 0px; color: rgb(51, 51, 51); font-family: mp-quote, -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; 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