Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,Title of Presentation,*,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,Title of Presentation,*,精益生产之仓库模拟游戏,精益生产之仓库模拟游戏,1,Warehouse Simulation Game,*,2,During the Warehouse Simulation Game the principles of Lean are shown and we ask you to apply them on the spot,The game makes you think about what is value add for the customer,what is the employees role and value add in the process,and to let go of traditional roles and seemingly independent tasks,The goal is to make Lean more concrete and easier to apply,It is an interactive way to get you acquainted with the Lean principles.,Warehouse Simulation Game*2Dur,2,To understand the opportunity to improve quality,cost,and delivery performance in traditional warehousing,To gain an awareness of how JIT warehousing differs from traditional warehousing,To gain an appreciation of the following LEAN terms:,Eight types of waste,Continuous flow processing,Takt time,Objectives,*,3,To understand the opportunity,3,Agenda,Case introduction,Practice round,Round 1“Waste”,Round 2“Flow”,Round 3“Takt”,Summary,*,4,AgendaCase introduction*4,4,Run,(do),Redesign&,Prepare,(plan),Analyze,(check),LEAN,theory&examples,(act),Structure of simulation rounds,“Set up new round”,“Design improved warehouse system”,“Simulate operation”,“Measure performance and identify issues”,*,5,RunRedesign&AnalyzeLEANStruc,5,Agenda,Case introduction,Practice round,Round 1“Waste”,Round 2“Flow”,Round 3“Takt”,Summary,*,6,AgendaCase introduction*6,6,Context,*,7,You are 6,12,18,or 24 employees in a warehouse that produces kits for the consumer industry,The packing for these products requires special treatment,but has a similar setup,The company is currently unable to deliver the quality,cost,and delivery promises made to its customers,Context*7You are 6,12,18,or,7,Operation,Each order is made from sheet of A4,1 photo film tube and 2 to 12 paperclips,Each operator has a workstation with 1 work instruction,*,8,1,Receive and check packing,2,Cut packing into quarter sheets,3,Prepare box,add pick list,4,Pick pack items required for order,QC,Ship,&,5,Check quality,seal order,6,Material handler,OperationEach order is made fr,8,Units,Goal,Number of good orders delivered,Percent wrong picked/packed items from total number of items,Good orders delivered/number of employees,Number of 1/4 paper sheets in production area,Average throughput time(minutes),Indexed against round 1(=100%),Tracking key performance indicators,KPI,Description,Cost or Revenue,Comment,1.,Quantity,#of correct orders delivered,Revenue,100,2.,Late penalty,#of orders late,Cost,-50,3.,Quality penalty,#of incorrect orders delivered,Cost,-50,4.,WIP,Number of 1/4 paper sheets in production area,Cost,-10,5.,Space,#tables used,Cost,-100,6.,Personnel,#employees,Cost,-200,7.,Overhead,Cost,-300,Fixed,8.,Productivity,#orders delivered/#employees,9.,Lead Time,Time it takes to finish first order,*,9,UnitsGoalNumber of good orders,9,Agenda,Case introduction,Practice round,Round 1“Waste”,Round 2“Flow”,Round 3“Takt”,Summary,*,10,AgendaCase introduction*10,10,Agenda,Case introduction,Practice round,Round 1“Waste”,Round 2“Flow”,Round 3“Takt”,Summary,*,11,AgendaCase introduction*11,11,Round 1:Traditional manufacturing,Every process has a batch size of 4,Every batch must be prepared together and the material handler must be,requested,to deliver the complete batch to the next process(material handler can only take one batch at a time),Every operator should work as fast as possible,1.Receipt,5.Inspect/ship,4.Pick packing,3.Preparation,2.Cutting,Layout is by process,2m,6.Material handler,*,12,Round 1:Traditional manufactu,12,Simulation round 1,Customers demand:,24 orders in 10 minutes,*,13,Simulation round 1 Customers d,13,Time,*,14,Time*14,14,Units,Goal,Number of good orders delivered,Percent wrong picked/packed items from total number of items,Good orders delivered/number of employees,Number of 1/4 paper sheets in production area,Average throughput time(minutes),Indexed against round 1(=100%),Round 1 analysis:,Tracking key performance indicators,KPI,Description,Cost or Revenue,Comment,1.,Quantity,#of correct orders delivered,Revenue,100,2.,Late penalty,#of orders late,Cost,-50,3.,Quality penalty,#of incorrect orders delivered,Cost,-50,4.,WIP,Number of 1/4 paper sheets in production area,Cost,-10,5.,Space,#tables used,Cost,-100,6.,Personnel,#employees,Cost,-200,7.,Overhead,Cost,-300,Fixed,8.,Productivity,#orders delivered/#employees,9.,Lead Time,Time it takes to finish first order,*,15,UnitsGoalNumber of good orders,15,Round 1 analysis:,Learning points,What went well?,What were the most significant problems?,WIP levels,Bottlenecks,Waiting time,Worker stress/boredom,Team interaction,Defect rate,What were the root causes of these problems?,How can these be resolved?,Quality,First pass yield,Cost。