1、ier A A A A B B Market Area (574 parts) CC C CD D F F F E CC C CD D A A A A B B F F F E PBS 1.PBS pass the production sequence information to the Picking station 2.The operator picks the parts according to production sequence and put in the trolley in sequence 3.The operator deliver the parts with t
2、rolley to the fit of point (1) A A A A B B (2) (3) Benefits: To save line side space and reduce operator workload handling parts complexity (Out-plant: 324 parts) 29 Color Parts Delivery Process 顏色零件之交貨程序 Body Allocation Ford Lio Ho Suppliers Send 1+6 Body Allocation at 3:30 PM E mail Multi frequenc
3、y delivery base on on-to-primer information ILVS delivery for Bumper, side skirt 30 SMART Office A A A A B B F F F E CC C C D D Fill Active Fill Active Fill Active A-01A-03 AA AAAA AAA AAA BBCC B B BBB BBB DDD DDD CCC CCC Part CPart BPart APart D DD Zone Mailbox Kan-Ban Part Process 看板供料看板供料 程序程序 Se
4、rial Number Lineside Mailbox Lineside Mailbox Operator A Operator B Workgroup Leader MH Benefits: To keep line side inventory at a minimum level, improve 5S and reduce emergency delivery 1. The operator picks the kan-ban attached in the container when he uses the first piece of the part. 2. The work
5、group leader collects the kan-ban in Line side Mailboxes and sends them to Zone Mailbox every three hours. 3. MH collects the kan-ban in Zone Mailboxes and sends them to SMART Office for sorting and putting them in different Market Mailbox. 4. The number of the kan-ban sent back to Market Mailbox ar
6、e the number of containers to be delivered to the line side Line Feeder B Market Area (764 parts) Line Feeder AMarket Mailbox A Market Mailbox A 7:20 AM 7:30 AM 7:40 AM 31 Call Parts Process 呼叫供 料 Part Number SMART No Market Address Line Side Address F7C6-5422401-AG 000122 DTL-A-02 E26-N-010 F8C6-54
7、26075-AA 005126 DTL-A-03 E27-S-020 F7C6-5467934-AB 003412 DTL-A-01 E26-N-030 Call light board A B C A B C B Call button Market Area (269 parts) Benefits: To minimize stock levels at line side and spare out spaces for the new parts of new model. 1.The operator pushes the call button to request the pa
8、rt he needs. 2.The light on the call light board for the part will be fleshing indicating the part has being requested 3.The line feeder pushes the reset button on the Reset panel reset 4.The linefeed come to market area to pick the part and deliver to the fit of point (1) (2) OnOff OnOff OnOff A B
9、C Reset panel (3) (4) Call button Call button Total: 269 parts 32 Inventory Control Process 庫存管理程序 Pack Size Confirmation Float Day Parameter Set-up in CMMS Weekly On- Site Review Inventory Objective Set-up Inventory Performance Review Continuous Improvement Form-1121 Confirmation. By Each Analyst M
10、onthly inventory Performance review by Each Analyst Follow up Action Plan Safety Stock/Adv.Job Shipping Frequency Org Review Team 33 Material Control 物料管理物料管理 n福特生產系統小組活動 n倡導每一位員工對物料的新觀念以合乎 同步物流的要求 n防止刮傷人人有責 n紅桌物料檢討 n物料改善會議 n庫存檢討改善會議 n門禁 34 Model B/out Management process 車種結束物料管理程序 Discontinue Parts
11、 List First Cycle Count Second Cycle Count Special Cycle Count Analyst submit the lists Special count for Local- import parts 3 months before balance out Adjust BOH. Special Count one month before Balance out Adjust BOH. Special Count by MSC35 MS-9000 物料管理系統簡介物料管理系統簡介 nMS-9000 物料管理系統為福特汽車事業總部 根據ISO-
12、9000及QS-9000之精神所發展出來的物料 管理系統及評估標準，為最高的物料規劃 標準。 n評分方法：評分方法： 評分依 20要項，每一要項再依 O、M、C及CI（4） 個層級問題來評定，分別給予每一要項03分再以 要項的平均分數乘以50來計算，總分範圍為0150 分。 n基本要求條件基本要求條件 ： n最低必要條件新廠商80分以上，且各 項問題評分不得低於1分。 nQ1獎必要條件最低 100分，且各項問 題評分不可低於 2分。 nTQE獎必要條件符合 Q1必要條件及通 過TQE審核。 36 MS-9000 物料管理系統必要條 件 4.1 管理責 任 4.2 物料管 理系統 4.3 檢討合
13、 約/客接觸面 4.4 時間表 系統 4.5 文件控 制 4.6 採購轉 包商管理 4.8 品驗 證與追蹤 4.9 裝船 4.10 製告彈 性/存貨管理 4.11 檢驗測 量與測試 4.14 糾正與防範 4.15 處理、存放、 包裝和交貨 4.15.2 處理 4.15.3 存放 4.15.4 包裝 4.15.6 交貨 4.16 物料記錄的與 控制 4.17 物料部審核 4.18 訓練 4.20 統計方法 37 Supplier Delivery Performance 協力廠商交貨實績 CriteriaCriteria nASN Achievement:30% nTimeliness:20%
14、nShipping Discrepancy: 20% nOver shipment:5% nPackaging: 15% nProblem Report:10% 38 執行Six Sigma 的現況 n2000年開始推廣Six Sigma黑帶訓 練開始 n2001年計畫開始上課並執行 n2002現況: 黑帶人數: 2人執行專案5個 綠黑人數:53人執行專案14個 節省金額:U$2,000/專案 39 通用物流管理系統通用物流管理系統 40 進口零件來源進口零件來源進口零件來源進口零件來源 ，訂購及包裝訂購及包裝訂購及包裝訂購及包裝 方式方式方式方式 Japan Suzuki Pronto US
15、 IEO U204/J14 14 Direct ship parts 3.0 Engine 2.0/3.0 T/M Mexico Chihuahua Eng. 2.0 Japan Mazada C206 EII U204 Japan Jatco 2.5 Auto T/M Europe IEO CD132 Huppert z H Building CD132 RGL Coughlin PXP Weekly Shipment Transit Time 51 Days (Including 16 Days Float)i PXP Weekly Shipment Transit Time 46 Day
16、s Lot Weekly Shipment Transit Time 10 Days PXP Weekly Shipment Transit Time 10 Days Ford Lo Ho Plant41 Part By Part Part By Part 訂購訂購 ( (MMetrostaretrostar) ) 批量訂購批量訂購 ( (其他車種其他車種 Mazda, Suzuki and Ford Mazda, Suzuki and Ford U204) U204) 以車以車 型車種型車種 別以批量別以批量 訂訂 購購 KD Lot Order By MSC. Lot 國外供應商國外供應商 KD Source 全
