12 Heijunka Esp

HeijunkaSistema de Manufactura de Johnson Controls

Capacity Planning rev 2.ppt

ObjetivosUsted podr definir qu es Heijunka

Entender dnde utilizar Heijunka y las diferentes formas de aplicarlo en produccin

Aprender los elementos de Heijunka y cmo son utilizados

Har algunas simulaciones de Heijunka


HeijunkaCul es la definicin de Heijunka?

Dnde debe ser aplicado en Produccin?

Quin es responsable de que la herramienta heijunka tenga impacto?


HeijunkaCales son los beneficios visuales que Heijunka le puede traer al rea de produccin?


Heijunka : Elementos VisualesElementos Visuales de Heijunka:Nmeros de parte horizontalmenteTiempo Takt / Tiempo PitchTiempo de ruta verticalmente (usualmente en incrementos de pitch)Retrasos / Stock de Seguridad Construccin del Buffer / Jalar el BufferBarra de ritmo de trabajo Secuencia de Manufactura (Frecuencia de ciclo)Instrucciones de produccin / Kanban de retiro


Heijunka : Tiempo de rutaLa Ruta -

Cuando se carga Heijunka el # of pitches por ruta se determina por el tiempo elemental requerido para retirar material y reabastecer la lnea.

Entre ms cercana la ruta de reabastecimiento, el menor nmero de pitches requeridos para cada ruta.

Ejemplo: Si la ruta tiene 11 minutos de recorrido y el pitch es de 6 minutos. En cunto tiempo se tiene que establecer la ruta?


Heijunka : EjemploDado el siguiente ejemplo, cmo cargara el tablero de Heijunka si usted tiene una frecuencia de ciclo de 1 (o manufacturar cada parte una vez por da)?



Question

Assmuptions:

Takt Time Matrix

Planning Cycle:2weeks (Mon - Fri)Takt TimeCalc Op On LineAct Op On Line*Act Op Off LineTotal # Ops Required

Normal # of Shifts:2shifts137.340

Hours / Shift:8hours146.820

Finshed Pack:10pcs156.360

Forecast:27,100pcs165.970

175.61628

185.300

Planned Downtime195.020

Stretches10Daily each shift204.770

Break 115Daily each shift214.55527


Clean Up12Daily each shift234.150

TPM50Once per week243.980

Wed Update20Wednesdays 1st and 2nd shift253.820

263.67426

*Assume any OT added has 0 planned downtime273.540

283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:

What would be the finalized level load plan with the given assumptions.

Provide the info below for your production review meeting with the team.

Finalized takt time:

Total Operators Required:

Total Hours per shift:

Pitch Time:

= Avail Time / Cust Demand

(Dem Sec per Pc + 15%)------------------------------ Takt Time

Direct Operators on line used in the elemental time studies

*Off Line Ops include Line Support / Route Person / etc.

Act Op on Line + Act Op Off Line

Dem Cycle + 15% to be used to determine cycle times teams are held accountable to.

Answer

Assmuptions:

Takt Time Matrix



Hours / Shift:7.5hours146.820


Total Demand:27,100pcs165.970

175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:



2 Possible Answers:

Finalized takt time:21or17

Total Operators Required:78

Total Hours per shift:97.5

Pitch Time:3.22.8

Data needed:

Total Sec648000540000

Total Planned DT7920079200

Total Avail Prod Sec568800460800

Takt Time21.017.0







Quiz Questions

1.What is the Takt Time?

Weekly Avail Time =105hrs

Weeks Demand =40000pcs

Takt Time =9.45sec


Two 8 hour Shifts / day

7 hrs avail prod time / shft

Weekly Demand =20000

Takt Time =0

Sheet3

Hoja de Clculo para construccin del programa de Heijunka

Determine el programa de Heijunka para el da:

Cantidad a embarcar

Nivel Total a producir:20 ContenedoresHoy

Piezas Por Contenedor:24 PiezasV110

Tiempo Takt:1 MinV25

Tiempo Pitch:24 minV33

Frecuencia de ciclo:1V42

ContenedoresContenedores+ Buffer-Buffer

Parte%ProgramadosEmbarcadosDentroFuera

V150%-=o

V225%-=o

V315%-=o

V410%-=o

Parte #Porc %7:00 AM7:24 AM7:48 AM8:12 AM8:36 AM9:00 AM9:24 AM9:48 AM10:12 AM10:36 AM11:00 AM11:24 AM11:48 AMComida12:36 PM1:00 PM1:24 PM1:48 PM2:12 PM2:36 PM3:00 PMJalar del Buffer

V150%

V225%

V315%

V410%


Question

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:






Pitch Time:







Answer

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:



2 Possible Answers:




Pitch Time:3.22.8

Data needed:

Total Sec648000540000



Takt Time21.017.0







Quiz Questions




Takt Time =9.45sec





Takt Time =0

Sheet3



Cantidad a embarcar








V150%10-10=0o0

V225%5-5=0o0

V315%3-3=0o0

V410%2-2=0o0


V150%XXXXXXXXXX

V225%XXXXX

V315%XXX

V410%XX

Heijunka : EjemploAhora intente el mismo ejemplo con un cambio de programacin para algunas partes y una frecuencia de ciclo que se incremente a 2.



Question

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:






Pitch Time:







Answer

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:



2 Possible Answers:




Pitch Time:3.22.8

Data needed:

Total Sec648000540000



Takt Time21.017.0







Quiz Questions




Takt Time =9.45sec





Takt Time =0

Sheet3



Cantidad a embarcar








V150%-=o

V225%-=o

V315%-=o

V410%-=o


V150%

V225%

V315%

V410%


Question

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:






Pitch Time:







Answer

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:



2 Possible Answers:




Pitch Time:3.22.8

Data needed:

Total Sec648000540000



Takt Time21.017.0







Quiz Questions




Takt Time =9.45sec





Takt Time =0

Sheet3



Cantidad a embarcar








V150%10-13=0o3

V225%5-4=1o0

V315%3-3=0o0

V410%2-3=0o1


V150%XXXXXXXXXX3

V225%XXXXX

V315%XXX

V410%XX1

Heijunka : EjemploDebido a que esta lnea obviamente no cambia con las restricciones dadas vamos a cambiar tantas veces como sea posible. Cmo cargara el heijunka en este escenario?



Question

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:






Pitch Time:







Answer

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:



2 Possible Answers:




Pitch Time:3.22.8

Data needed:

Total Sec648000540000



Takt Time21.017.0







Quiz Questions




Takt Time =9.45sec





Takt Time =0

Sheet3



Cantidad a embarcar








V150%-=o

V225%-=o

V315%-=o

V410%-=o


V150%

V225%

V315%

V410%


Question

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:






Pitch Time:







Answer

Assmuptions:

Takt Time Matrix






175.61628

185.300








263.67426


283.410

293.290

Assumptions:

Dem Sec / Pc:83

Dem Sec / Pc + 15%:95.45

Question:



2 Possible Answers:




Pitch Time:3.22.8

Data needed:

Total Sec648000540000



Takt Time21.017.0







Quiz Questions




Takt Time =9.45sec





Takt Time =0

Sheet3



Cantidad a embarcar








V150%10-10=0o0

V225%5-5=0o0

V315%3-3=0o0

V410%2-2=0o0


V150%XXXXXXXXXX

V225%XXXXX

V315%XXX

V410%XX

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