CN1189228A - Method and apparatus for cycle time costing - Google Patents
Method and apparatus for cycle time costing Download PDFInfo
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- CN1189228A CN1189228A CN96194813A CN96194813A CN1189228A CN 1189228 A CN1189228 A CN 1189228A CN 96194813 A CN96194813 A CN 96194813A CN 96194813 A CN96194813 A CN 96194813A CN 1189228 A CN1189228 A CN 1189228A
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Abstract
A cycle time costing method and apparatus is provided to obtain cost, efficiency, bottleneck and value creation information in a manufacturing facility. The manufacturing facility includes a plurality of production lines with each production line including a plurality of process steps. A work cell which includes a plurality of workers is responsible for each process step. Each work cell has an associated local processing apparatus for inputting process step quantity and time information. The local processing apparatus is coupled to a central processing apparatus via local area network. The central processing apparatus then calculates cycle time costing information regarding each work cell in the manufacturing facility. The cycle time costing information may include, among other information, gross cycle time, net cycle time, bottleneck costs and scrap information for each process step and/or a product manufactured by a plurality of process steps. The cycle time cost information is then transferred to a printer or projection display nearby a work cell.
Description
The present invention relates to obtain cost information.Especially, the present invention relates to a kind of method and apparatus, be used for determining the cost of product, thereby improve efficient and benefit in manufacturing a product at production equipment.
Production equipment is extremely complicated, and must adapt to: 1) a large amount of operation; 2) various products; And 3) the far-ranging product number of packages of every part of customers order.For example, the manufacturing equipment of producing the lead frame that is used for semiconductor devices may be produced the lead frame of 750 kinds of different models.A lead frame can have 8 to 208 lead-in wires.The lead frame of some type may require to use better simply production process, and other lead frame may require to use many complicated step.The size of order of customer order can be from 1,000,000 of 10,000 to every part meters of every part of order form manifest.
Based on customer order, send work order and draw up to produce what type, how many products satisfy the requirement that the client orders goods.A work order will comprise that identification will be processed into the lot number of the raw material quantity of manufactured goods.In producing the example of lead frame, one batch is to be used for a volume metal of a plurality of lead frames of processing.Usually, show the explanation of the packing of product of work order and out of Memory or paper and marked batch (lot) or the volume in the production run.
Production plant generally includes a large amount of production lines of the combination of producing a large amount of different products.Every production line can be included in many operations of making in the final products.In the makers' example of lead frame, when production supply client's lead frame product, in a large amount of other operations, operation can comprise that one dry ecthing operation is with electroplating work procedure.In each procedure, wherein have parts just by machining or time cycle of in production line, moving.When parts did not move in production line, parts may be queuings or wait another procedure.
Each procedure can be finished certain working procedure one by a collection of workman who forms teams and groups.Workman in different teams and groups was assigned in the given working day of working on the production line of a certain working procedure, and a plurality of break tour order of classes or grades at school or different time cycles also can be arranged.In most modern production factory, there is a class to be called the system that the resources of production calculate (" MRP "), be used for the work order of trace flow through production procedure.For example, by the McDonnell Donglas Information Systems company supply of material that is positioned at California, USA Long Beach, be called a kind of MRP system of CHESS, attempt using coming the optimization production process in conjunction with the method for various software modules.Typically, a kind of module of MRP system is the pricing module.
Carry out the cost Calculation and Study from the parts of production typical amounts under the typical plant condition, can determine " standard cost " each parts.These standard cost comprise two parts cost: the 1) cost of raw material of each parts; With 2) the expense cost shared of each parts.Standard cost are input to one can be by the pricing module database of MRP system access.When product flow through production run, these standard cost can be distributed to specific customer order, determined that it is to be less than or greater than the price to client's charge that these parts are given client's total cost.
, these MRP software packages can not provide the real-time details of related manufacturing process exactly.Especially, these MRP software packages can not provide the details about certain working procedure, or the data of the practical production experience when obtaining each or every part of work order and flowing through factory.The MRP system can not obtain real-time or the cost information when product is made on certain working procedure.The MRP system depends on the standard cost in the database, and it may inaccurately reflect at that time the component count produced or the condition of factory at that time.For cost information accurately can be obtained, need the fringe cost research of a large amount of affairs and managerial cost in the MRP system.Because do not obtain the full information of certain working procedure, how to know that by improving the accurate information that certain working procedure and their interaction improve specific product production be impossible.
For example, in a certain working procedure or cycle period, unless actual processing can not known the time of using in this operation or machine are set.In addition, do not have following full information, promptly in certain certain working procedure, have how many stocks waiting, and wait full information how long through before the production line.Equally, during this operation itself in, may not possess following accurate information, i.e. the speed of production line machine and whether technological innovation or improved machine can make the efficient of production final finished higher.In addition, do not possess the full information that waits next process about the stock who finishes the operation processing component.Do not have following sufficient information, promptly when related manufacturing process should be finished, so that meet the working ability of next process.
Similarly, can not get the efficient of relevant certain certain working procedure or the full information of qualification rate.For example, do not consider the relevant waste product (scrap) or the disabled enough information of finishing the number of components of operation that should be assigned to certain certain working procedure.The waste product that generates in a procedure just can identify after waiting until several procedures possibly.So it seems that some operation be high efficiency, and the waste product that they produce possibly can't identify exactly.
In addition, the typical method of cost accounting is called standard cost and calculates or " based on the pricing of effect ", it only determines the time that the typical products work order spends on the per pass operation, and is used for multiply by this time with a time charge that is used for equipment and labor service relevant with the per pass operation.Then, by being added, the cost of per pass operation determines the total cost that manufactures a product together.Yet these methods can not determine that in a series of production processes which procedure is the bottleneck of specific products type and work order quantity.
Also have, must identify the information of the creation of value in a procedure.One procedure should and the efficient of the production line of front comparison component processing aspect output, flow efficiency and efficiency how.
Therefore, in manufacturing a product, people wish to have a kind of method and apparatus, and it can be provided at the information of relevant cost in the certain working procedure, efficient, bottleneck, waste product and the creation of value.In addition, also wish not only will to obtain information, and need to obtain this information of all products in having the production equipment of customers order quantity on a large scale about cost, efficient, bottleneck, waste product and the creation of value of certain certain working procedure in manufacturing a product.This information should obtain with actual production information real-time continuous ground, and does not need the research of the pricing of priori.
Consult the following drawings, can understand other aspects and advantages of the present invention after detailed description and the claim.
According to the present invention, provide a kind of use to obtain cost information in the production equipment from the T/A data of work area (work cell).The data storage of T/A is in storer.Cost information about this work area calculates by the information of this T/A.Then, cost information outputs on the display.
Automatic acquisition time and quantity data in the current production cycle of this new method all parts in production equipment.The real cost of every part of work order and each product component is to calculate in real time.The method makes no longer to be needed pricing research and sets up standard cost.In addition, the present invention has removed a large amount of affairs and managerial cost, and produced real-time accurately with continuous cost information.
In another aspect of this invention, production process is finished in described work area one.
Of the present invention aspect another, the data of T/A comprise that parts check and accept (acceptance) and (set-up) time of preparation, parts examination amount, production process operation starting time, the quantity of finishing working time and finishing.
In another aspect of the present invention, cost information comprises a mao cycling time, clean cycling time and quantity scrapped.
In still another aspect of the invention, provide a kind of improvement to comprise to be used to the device of the work area production equipment of finishing a procedure.Be used for being connected to the device of computation cycles time cost data from the device of work area acquisition number of components and time data.Then, the device of output work area cost data cycling time is connected to calculation element.The data of number of components and time comprise parts examination quantity, parts examination and setup time, operation starting time, parts quantity performed and parts deadline.
Of the present invention again aspect another in, the described device that is used to obtain data comprises the bar code scanner that connects computing machine.The described device that is used to calculate comprises the computing machine that connects network.The device that is used to export comprises printer, projection screen or display screen.
In another aspect of this invention, provide a kind of system that improves factory's benefit.Factory comprises many production lines, and every production line comprises a plurality of work areas.The device that is used for obtaining from work area of production line component information is connected to local treating apparatus and is used for memory unit information.The central processing unit that is used for computation cycles time cost computational data is connected to this this locality treating apparatus.Then, be used to export the device of pricing cycling time data, receive this central processing unit.In out of Memory, pricing cycling time data in work area comprise a mao cycling time, clean cycling time, thruput, qualification rate and bottleneck information.
In another aspect of the present invention, the device that is used to obtain data comprises the keyboard that is connected to computing machine.Described local treating apparatus comprises, is connected to the computing machine of CPU (central processing unit) by network, and it comprises the server that connects computing machine.Central processing unit comprises, a work area operation (workcell activity) module, a work area value creating module, manager's reporting modules, a bottleneck pricing module and a waste product (chargeback) module of withholing.
Followingly embodiments of the invention are described, wherein with reference to accompanying drawing
Fig. 1 explanation is according to production equipment of the present invention, and it has many production lines and multiple working procedure;
Fig. 2 explanation is shown in the part producing equipment of Fig. 1, comprising according to work area of the present invention;
Fig. 3 explanation is from the information of a work area output block quantity, comprises according to the present invention finishing qualified parts and waste product behind the procedure;
Fig. 4 illustrates the output clocking information in a work area, comprises according to the present invention finishing one examination behind the typical process in a work area chronometric data of beginning and completion;
Fig. 5 explanation is according to work area of the present invention hair cycling time and clean cycling time;
The waste product that Fig. 6 explanation is produced according to work area of the present invention;
Fig. 7 explanation is according to the logic flow of pricing cycling time of the present invention;
Fig. 8 explanation according to of the present invention cycling time cost calculating system and resources of production calculate interface between (" MRP ") module;
Fig. 9 explanation is according to a work area operation module logic of the present invention;
Figure 10 explanation is according to a work area qualification rate report output of work area operation module logic of the present invention;
Figure 11 explanation is from a work area thruput report according to work area operation module logic output of the present invention;
Figure 12 explanation is according to manager's reporting modules logic of the present invention;
Figure 13 explanation gathers from actual production every day according to manager's reporting modules logic output of the present invention;
Figure 14 explanation is from a work order final report according to work area operation module logic output of the present invention;
Figure 15 explanation is according to a bottleneck pricing module logic of the present invention;
Figure 16 explanation is from a stock number bottleneck report according to bottleneck pricing module logic output of the present invention;
Figure 17 explanation is according to a work area value creating module logic of the present invention;
Figure 18 explanation is from a value creating report according to value creating module logic output of the present invention;
Figure 19 explanation is according to a waste product of the present invention (chargeback) module logic of withholing.
Fig. 1 explanation is according to a cover production equipment 15 of the present invention.In one embodiment, production equipment 15 comprises production line 1-4.The production line 1-4 A-D that manufactures a product.Article one, the top of production line is represented by label 16, and the terminal of production line is by label 17 expressions.In each bar production line, there are a plurality of operation A-D.In another embodiment, may have more or less production line and operation far away.Also have, various production lines can be positioned at the position of different production equipments.
In an embodiment of the present invention, a cover lead frame production equipment is produced polytype lead frame that is used for different semiconductor devices.Product A is a kind of lead frame that only has 8 lead-in wires, and product B is a kind of lead frame with 208 lead-in wires.Produce among the embodiment of equipment at this lead frame, operation A can comprise the dry ecthing operation one, wet etching operation or one stamping procedure.Process B can comprise electroplating work procedure one, and operation C and D can comprise cutting/band envelope (cut/tape) and letter sorting/packing (sort/pack) operation respectively.
In a further embodiment, product A may be the like products with identical stock number (stocknumber) with product B.In addition, some has finished each parts of operation A in production line 1, can experience process B in production line 1, or experience process B in production line 2.And the present invention is described at production line of above usefulness, and the present invention also can implement in a kind of environment of job shop, here each parts processed from a job shop position or the work area be sent to another job shop position or work area.
Each bar production line and/or operation may have a relevant bottleneck.For example, the bottleneck of 2 explanations of the production line in work area 14 in the manufacturing of product B.Bottleneck is defined as the operation in given production line, and this operation is because a variety of causes has limited the ability of final production product.The bottleneck operation is the operation of per minute production process time minimal components.Bottleneck on the image height speed highway, or the rate-limiting step in chemical reaction is the same, and the production bottleneck operation has determined that a kind of product type in a particular process order scope can flow through the speed of whole factory.To carry out detailed especially discussion to bottleneck below.
As shown in fig. 1, Fig. 2 illustrates the part of production equipment 15.Particularly, Fig. 2 explanation according to of the present invention one cycling time cost calculating system 26.For example, work area 12 and 13 communicates by bus 11 and central processing unit 10.In a preferred embodiment, central processing unit 10 comprises one by Hewlett Packard 9000 servers of the Hewlett-Packard's supply of material that is positioned at California, USA Santa Clara with by being positioned at New York, the personal computer of IBM Corporation's supply of material of Armonk.In one embodiment, bus 11 is LAN (Local Area Network).
In one embodiment, work area 13 and work area 12 comprise local treating apparatus 20 and 23 respectively, and they are connected to bus 11.In one embodiment, local treating apparatus 20 and 23 is the personal computers by the IBM supply.Local treating apparatus 20 or 23 has relevant keyboard and display.Keyboard can be used to import work area T/A data.Local treating apparatus 20 also is connected bar code scanner 21 and 24 with 23, so that input work area T/A data.Bar code scanner can directly be wired to local treating apparatus, or uses radio communication, as radiofrequency signal communication.Bar code scanner can obtain work area T/A information from the bar code on the packing of shop.
In one embodiment, bar code scanner is by the Intermec.Inc company supply of material that is positioned at Washington, DC Everett.Work area T/A data are sent to CPU (central processing unit) 10 by with bar code scanner 21 and 24 and/or be connected the keyboard of local treating apparatus 20 and 23 by bus 11.
From the pricing cycling time data of work area T/A data computation, outputing on the bus 11 on local processing unit 20,23 and/or display 22 and 25.In addition, can print pricing cycling time data.And each work area can have a local treating apparatus, bar code scanner and display, and in a further embodiment, the local treating apparatus that is connected to bus 11, bar code scanner, and display can be shared in each work area.
In one embodiment, the present invention calculates the cost of producing a product cost of raw material with expense cycling time (" CTC ").Cycling time, expense reflected the real cost of producing by the factory's spending that is absorbed on factory's bottleneck productive capacity, and the bottleneck productive capacity of factory is determined effective productive capacity of factory.
Cycling time, expense was defined as:
CTC=operates spending/operation the number of minutes (1)
The operation spending is the cost-record summary of factory, comprises wage and depreciation, but does not comprise starting material.Operation the number of minutes is determined by the bottleneck of factory, by getting the fate that can be used for producing, deducts the fate of shut-down, multiply by the hourage in a day that produces, and per hour multiply by 60 minutes, multiply by the number of production line in the bottleneck.
When cycling time expense be applied to clean cycling time during rate, as described below, can determine the cost of every product.
In typical MRP system and the product cost related of a completion can be definite like this, the final cost that the cost of raw material by adding the various operations of each parts and possible labour cost obtain a finished product.The method of this acquisition cost information does not count the contribution of factory's fund of the time relevant with the per pass operation or each parts.The MRP system can not obtain the quantity relevant with each work area and temporal information is determined cost and efficiency information more accurately.For example, the MRP system can not determine at the machine of preparing (setting-up) procedure or how long prepares the actual employing of parts to be processed, and processes the relevant real time with actual.In addition, these MRP systems can not calculate the quantity scrapped relevant with the per pass operation exactly, or identify which work area and be responsible for generating waste product.For example, operation A may generate waste product, and C just checks out up to operation.Therefore, waste product should be remembered on the account of operation A.
Fig. 3 and 4 explanations, T/A data are how to obtain from each work area.By input examination amount (" AQ ") number to local treating apparatus, the workman in a work area begin to prepare (set-up) with process a work order/batch.So in Fig. 4, local treating apparatus adds time mark (time stamp) for when checking and accepting and preparing for 50 times (" ATD ") AQ quantity.Similarly, when the production run of a procedure starts in a work area, when production run starts and finishes, workman must be respectively operation starting time 40 (" BTD ") with finish working time 41 (" CTD ") and import a local treating apparatus.Adjacent before finishing a procedure, a workman will import qualified number of components 42 (" CQ ").When the workman imports the number of components of processing with bar code scanner or keyboard, the local treating apparatus date of timing automatically or identification BTD time and CTD time.When the workman imports the ATD time directly or indirectly with local treating apparatus time mark, the BTD time, the CTD time, when AQ incremental data and CQ incremental data, also to import workman's marker number, order of classes or grades at school numbering and production position.
Next then work area, for example, work area 13 will have a workman to import AQ quantity and ATD time in a playscript with stage directions ground treating apparatus in work area 13 equally, and they also are next one examination (" the NAQ ") quantity and next reception time (" NATD ") 50 (a) in work area 12.For example, when the workman in work area 13 imports an AQ quantity and ATD during the time, CPU (central processing unit) 10 is automatically distributed AQ quantity in the work area 13 and ATD time NAQ quantity and the NATD time as work area 12.
Because a number of components is responsible in each work area and temporal information is imported a playscript with stage directions ground treating apparatus, and is as discussed above, CPU (central processing unit) 10 can be calculated the pricing cycling time information in each work area.For example, can obtain for specific work area and the particular job order and batch in the hair cycling time 60, as shown in Figure 5.A work order/batch how long have is responsible in work area of this information representation.This comprises preparation (set-up) time, and production run time and if required is at the queuing time (stand-by period) of next procedure.Cost information cycling time that given work order of formula 2 to 10 expressions is every batch.Hair is defined as cycling time 60:
WWGCT=NATD w
jl
tc
yp
z-ATDw
jl
tc
yp
z(2) wherein:
WWGCT is work area/work order/batch hair cycling time;
NATD is next reception time/date;
ATD is the reception time date;
w
jIt is work order/job number;
c
yBe teams and groups (for example, y=1 to 5);
p
zBe operation (for example, z=A to D); With
l
tBe a work order batch or part
Because the work area hair is calculated cycling time, work order hair rate cycling time is calculated as:
WWGCTR=WWGCTw
jl
tc
yp
z/ NAQw
jl
tc
yp
z(3) wherein
WWGCTR is work area/work order/batch hair rate cycling time; With
NAQ is the next quantity of checking and accepting.
Equally, can obtain clean cycling time 61.Represent a particular job order clean cycling time, or in a work order batch for finishing an operation will with how long, for example, from checking and accepting and preparing 50 and move 41 time durations to finishing.Be defined as clean cycling time:
WWNCT=CTDw
jl
tc
yp
z-ATDw
jl
tc
yp
z(4) wherein:
WWNCT is work area/work order/batch clean cycling time;
CTD is deadline/date;
ATD is reception time/date;
w
jIt is work order/job number;
l
tBe a work order batch or a part
c
yBe teams and groups (for example, y=1 to 5); With
p
zBe operation (for example, z=A to E).
The same with hair rate cycling time in each work area, clean cycling time of the rate in each work area is defined as:
WWNCTR=WWNCTw
jl
tc
yp
z/ NAQw
jl
tc
yp
z(5) wherein:
WWNCTR is work area/work order/batch clean rate cycling time; Know
NAQ is the next quantity of checking and accepting.
CPU (central processing unit) 10 also can obtain to finish in the work order of a plurality of operations in a production line, is used for the pricing cycling time information of a work order or one batch.This information representation is consumed time altogether, i.e. beginning to by finished goods inventory or by the used time of final user's work order/when batch checking and accepting from the preliminary work that is used for first procedure.
WGCT=NATDw
jl
tc
yp
5-ATDw
jl
tc
yp
1(6) wherein:
WGCT is work order/batch hair cycling time; With this product requirement with 5 procedures (A to E).
Equally, in a production line, finish work order or batch used clean cycling time in the work order of multiple working procedure, be defined as the order that is used to deal with the work/batch the summation of clean cycling time in all work areas:
WNCT=∑ CTDw
jl
tc
yp
z-ATDw
jl
tc
yp
z(for example, Z=1 to 5) wherein:
WNCT is work order/batch clean cycling time; With
This product requirement is with 5 procedures (A to E).
The hair streams rate (gross flow rate) and the net flow rate (netflow rate) that are used for one batch of a work order are defined as follows.
WGFR＝NAQw
jl
t/GCTw
jl
t (8)
WNFR=NAQw
jl
t/ NCTw
jl
t(9) wherein:
WGFR is the hair streams rate; With
WNFR is the net flow rate.
The hair streams rate and the net flow rate that are used for a work area can be done similar calculating.
At last, each work order batch qualification rate and flow efficiency also may be defined as:
WY＝NAQw
jl
t/AQw
jl
t (10)
FE=WNCT/WGCT (11) is wherein:
WY is qualification rate (yield); With
FE is flow efficiency (flow efficiency)
Work area qualification rate and flow efficiency also can calculate equally.
In the production line of a processed finished products,, obtain the chance that a large amount of pricing cycling time information seek to be used to improve production run by top to each work area with to all work area computation cycles time cost information.For example: 1) work well afoot (WIP) can remove; 2) setup time that is used for processing machine can shorten; 3) can improve in processing or the machine speed, as if possible; 4) innovation of the processing in a specific work area can more effectively be assessed; 5) the output quantity in specific work area can be come regularly by user's the request or the request in next work area, and can improve to the delivery rate in next work area.
Equally, Fig. 6 illustrates that how the present invention is from a work area identification waste product.The whole waste products 70 of identification in Fig. 6, it comprises from the waste product 71 of newspaper and the waste product 72 of user report, has also created the chance that is used to improve production run.If will pay for its waste product spare in each work area, the workpeople will be more prone to: the article of 1) checking input; 2) precision of raising machine; 3) seek the process technology innovation that can reduce waste product; With 4) user's request is reacted so that reduce the waste product 72 of user report.
Fig. 7 explanation is according to the present invention, cycling time cost calculating system logic flow 80.Separately work area among quantity and temporal information input logic square frame Figure 81.As mentioned above, quantity and temporal information or available bar code scanner, keyboard, the combination of the two, or other input equipment device is imported.Each work area in the production equipment 15 of cost calculating system 26 cycling time from logic block Figure 82 obtains work area data then.As mentioned above, be connected the HP9000 server of LAN (Local Area Network) with one, obtain production work area data in the cost calculating system 26 cycling time by adopting MRP CHESS software package.Database from logical block 83 extracts relevant work area data then.In one embodiment, adopt the CHESS data extract file of fixed width form to extract relevant work area data.At last, then can adopt different pricing cycling time application modules 84, so that calculate the data of selecting.Pricing cycling time application module 84 comprises: 1) work area operation module 85; 2) work area value creating module 86; 3) manager's reporting modules 87; 4) bottleneck pricing module 88; With 5) the work order waste product module 89 of withholing.In one embodiment, above-mentioned module is the software application of being supplied by the Microsoft company that is positioned at Washington, DC Redmond on the personal computer of central processor equipment 10.In a further embodiment, pricing cycling time is used and can be designed in the hardware that adopts various hardware logics.
Fig. 8 explanation interface between cycling time cost calculating system logic 80 and MRP module 90.In one embodiment, MRP module 90 is CHESS systems, comprises a work order (workorder) module, a stock model, pricing (costing) module and engineering module.Pricing cycling time logic 80 obtains the work area data from a common data base 91.In a preferred embodiment, this database is the database by the Oracle company supply that is positioned at California, USA Long Beach.
Fig. 9 explanation is in the logic flow of work area operation module 85 illustrated in fig. 7.Work area operation module logic 85 was identified in the cycle of a selection, the work order of being finished by the work area of selecting.Logical block 100 is selected a work area and time cycle.Then, in logical block 101, work area that collection is used to select and the work area data of the time cycle of selection.Pricing cycling time variable with stock number (stocknumber) expression calculates in logical block 101.The pricing cycling time variable that calculates in logical block 102 comprises: 1) mao cycling time; 2) clean cycling time; 3) net flow rate; 4) hair rate cycling time (time rate); 5) clean cycling time rate; With 6) qualification rate (yield).Then, pricing cycling time variable outputs to a reporting format in the logical block 102.At last, reporting format or printing perhaps show on the screen of logical block 104.
Figure 10 and 11 is the example of reporting format.Reporting format exportable: 1) at the screen or the printer of CPU (central processing unit) 10; 2) local printer or screen 20 and 23 of handling, as shown in Figure 2; Or 3) be projected on the giant- screen 22 or 25 among Fig. 2.So the work area has the instant information as pricing cycling time variable, so that discern bottleneck and raise the efficiency.Equally, the managers in CPU (central processing unit) 10 also have pricing cycling time information.
The reporting format that Figure 10 explanation is exported from work area operation module 85 in Fig. 9.Figure 10 explanation is used for the work area qualification rate report that cutting/band envelope (cut/tape) operation is finished in a work area.Teams and groups are yellow, and break tour order of classes or grades at school (shift) is for working in three shifts.The March of selecting 25 March 19 time cycle from nineteen ninety-five to nineteen ninety-five.As can be seen, relevant with given product stock number complete list is listed in first hurdle.The examination of each stock number and completion quantity column are in the 3rd and the 4th hurdle.Single through-put rate and the rejection rate relevant with each product also calculate and list in the 5th and the 6th hurdle.At last, the qualification rate hurdle of getting the last place.
For example, in first row, from March 25 March 19 nineteen ninety-five to nineteen ninety-five, yellow teams and groups check and accept 13.38k parts of stock number 50802 in cutting/band envelope work area.Then, in the time cycle of this selection, cutting/band envelope operation has been finished 13.25k parts of stock number 50802.This product has the thruput of 13.25k and the rejection number of 0.13k.This causes qualification rate is 99%.
Equally, Figure 11 explanation from March 19 nineteen ninety-five to the time cycle in March 25 nineteen ninety-five, in the time, yellow teams and groups cutting/band seals the work area thruput in work area and reports at three-shift operation.With the same in Figure 10, single stock number is listed in one hurdle, left side, and the qualification rate of thruput and single stock number is listed in the 3rd and the 4th hurdle.Average hair cycling time of each batch and average clean cycling time also exported at a kind of day: hour: and minute form in.At last, the net flow rate is got the last place in the hurdle too.
Manager's reporting modules logic 87 that Figure 12 explanation is mentioned in Fig. 7.140 select time cycles of logical block and the production equipment position that will analyze.Logical block 141 is collected in the work order number that select time was finished in the cycle then.Logical block 142 is gathered into the relevant work area data of finishing of work order.Then, logical block 143 is pressed work order computation cycles time cost and is calculated variable.The pricing cycling time variable that calculates in the logical block 143 can gather by work order with the reasonable time increment in logical block 144 then, or separates by relevant product section in logical block 146.Be imported into logical block 147 from the output of logical block 146, it gathers pricing cycling time variable with an appropriate time increment by the product section.Logical block 147 and 144 output are respectively in the pricing cycling time reporting format of input logic piece 148 and logical block 145.
The reporting format that Figure 13 explanation is exported from logical block 145 in Figure 12.Figure 13 explanation gathers (dailyreel production summary) from volume production every day in the cycle that select April 1 March 26 nineteen ninety-five to nineteen ninety-five.In other pricing cycling time variable, show hair cycling time and clean cycling time.Equally, are also gathered the hair cycling time of every volume and clean cycling time.From April 1 March 26 nineteen ninety-five to nineteen ninety-five, on the basis of every day, try to achieve each pricing cycling time variable.For example, in March 27 nineteen ninety-five, completion 10 volumes are produced 74k parts.Hair cycling time and clean cycling time are respectively 46.62 hours/K and 16.92 hours/K.Qualification rate is 64%, has 36% flow efficiency.The clean cost of raw material is 3,388 dollars, and cost of spoiled goods is 1,782 dollar, has 5,170 dollars of total costs.
Figure 14 also illustrates a cycling time of the costing exercise order summary report from work area operation module logic 85 output.The work order summary report is at work order 6211, and be specially under the 3rd (" OK ") hurdle, identify batch 1.This work order has identified that in work area separately by dry ecthing, wet etching is electroplated, band envelope (taping), the A58447 of the material code of cutting and letter sorting/packaging process.The employee-name of the various number of components that enter each work area is checked and accepted in expression, also expresses with date and time information.
The bottleneck pricing module logic of mentioning in Figure 15 key diagram 7 88.In logical block 160, select a time cycle and stock number.Then, in logical block 161, collect relevant work area data.The pricing cycling time variable of representing by stock number that is used for per pass operation and work area calculates at logical block 162.Then, in logical block 163, determine the average net flow rate of per pass operation.Determine bottleneck with the minimum average net flow rate in the average net flow rate of per pass operation calculating.Stock number bottleneck cost cycling time calculates in logical block 164, and outputs in the logical block 165 that generates a reporting format.By determining the relation of bottleneck operation clean cycling time of rate, in logical block 164, calculate stock number bottleneck cost cycling time to the specification product quantity of production.The linear regression of employing standard (standard linearregression) technology is set up this relational expression.Not linear relation,, can set up or adopt yet as the relation of index or logarithm.
Stock number/batch the cost of raw material (" RMCs
x") calculate and divided by the average clean qualification rate of this stock number, shown in following formula 15 with the unit starting material of specific stock number.
So, total bottleneck stock number cost be defined as for bottleneck cost cycling time add stock number/batch cost of raw material and.
TBC
x=BCTCs
x+ RMCs
x(12) and
Bs
x=have a minimum (WNFRs
xp
z) operation (13)
BCTs
x=WWNCTRs
x(for Bs
x) * CTC*NAQp
5(14)
RMCs
x=RMs
x/ average WYs
x(15) wherein:
Bs
xIt is the stock number bottleneck;
BCTCs
xIt is the bottleneck cost; With
RMCs
xIt is the cost of raw material.
Figure 16 illustrates a reporting format of logical block 165.The time cycle of selecting is from February 15 February 10 nineteen ninety-five to nineteen ninety-five.In this example, analyze bottleneck by the work area, by having the per hour flow rate of 33 parts, judge that letter sorting/packaging process is a bottleneck.And then, to analyze by the work area, letter sorting/packaging process per hour has the average net flow rate of 10 parts.The output explanation of this part report in order to improve average net flow rate and bottom line, must improve letter sorting/packaging efficiency.Although there are a large amount of reasons, be illustrated as the letter sorting of what yellow teams and groups/bag and cultivate operation and have lower average net flow rate, report clearly illustrated that should focal attention in the neutralization of production run resource the place.
The work area value creating module logic 86 that Figure 17 explanation is mentioned in Fig. 7.This logic module determines that how many specific work areas produces and be worth.A selected work area and time cycle in logical block 180.The relevant work area data aggregation in time cycle that is used for selecting and work area is at logical block 181.Then, the value that each work order is created is calculated in logical block 182, and the value creating variable was gathered for the time cycle of selecting in logical block 183.At last, the output of pricing cycling time variable is in a reporting format of logical block 184.The a value creating reporting format of explanation in Figure 18.
The value that create in the work area is determined by following formula:
VC=WR*WAY*WFE*WLE (16) is wherein:
VC is the value of creating;
WR is the work area income;
WAY is the work area average qualification rate;
WFE is the work area flow efficiency;
WLE is the work area efficiency.The work area income is remembered the sales value of the specification product that this work area in cycle seclected time produces on the account in this work area.The work area income is defined as:
WR=∑ NAQw
jl
tc
yp
z* ASPs
x(17) the work area average qualification rate is measured the overall yield of work area in the selected cycle.The work area average qualification rate is defined as:
WAY=∑ NAQw
jl
tc
yp
z/ ∑ AQw
jl
tc
yp
z(18) the work area flow efficiency is remembered effective use of process time on the account in work area.The work area flow efficiency is defined as:
WFE=∑ WWNCTw
jl
tc
yp
z/ ∑ WWGCTw
jl
tc
yp
z(19) the work area flow efficiency also can be the mean value by stock number or the weighting of work order batch.The work area efficiency is remembered the effective recruitment in the component processing process on the account in work area.The work area efficiency is defined as:
WLE=budget labour cost c
yp
z/ actual labour cost c
yp
z(20)
By the total sales value of product is added three efficiency factors, can determine the value that create in the work area.In service efficiency factor (WAY, WFE and WLE), how the work area increases value if can directly being seen.Can make comparisons the index in its index and other work area in a work area.In addition, can be weighted the relative value of adjusting each factor and they influence to efficiency factor, or provide further stimulation means to improve a specific efficient the creation of value.
The waste product that Figure 19 explanation is mentioned in Fig. 7 module logic 89 of withholing.Each work area and work order are identified in logical block 190.By using the input of waste product code and the quantity in logical block 191, distribute waste product for each work area.According to the specific work area of waste product code and this waste product of report, adjust qualification rate.For example, electroplate mistake if the part of step D in one batch detects one, the workman in the step D imports the waste product code of these quantity scrappeds and expression plating problem in the work area.Then, central processor equipment 10 is attributed to suitable plating work area with the waste product 72 of user report, as shown in Figure 6.Yet if step D detects a punching press mistake in a part of one batch, with different waste product code of input, and central processor equipment 10 will specify a waste product to withhold to a specific stamping procedure work area.So waste product is withholdd and is determined by the input waste product code of the work area of report and use.Waste product is withholdd and is gathered by the operation in the logical block 192.In logical block 193, check and accept quantity AQ by each work area and work order and adjust by withholing of particular job order with completion quantity CQ, then, in logical block 194, AQ that use is adjusted by withholing and CQ measure and calculate work area and work order qualification rate.
The above-mentioned illustrative purposes of the preferred embodiment of the present invention is explanation and describes that it is not to be used for being exhaustive or to limit the invention to disclosed precise forms.Obviously, those skilled in the art can make many changes.These embodiment are selected and describe so that principle of the present invention and practical application thereof are made best interpretations, thereby other it will be appreciated by those skilled in the art that various embodiment of the present invention and to the various corrections of suitable special-purpose.For example, can be with other embodiment that does not comprise network or central processor equipment.The user can be work area quantity and treating apparatus of time data input, a device internal storage position of particularly calculating and exporting pricing cycling time data.Pricing cycling time data can output to a display screen, printer, or by other communication medium transmission.Scope of the present invention is limited by claims and equivalent thereof.
Claims (39)
1. method that is used for obtaining at production equipment cost information may further comprise the steps:
Will be in memory location from the T/A data storage in a work area;
Cost information in response to relevant this work area of described T/A data computation; With
Export this cost information.
2. the method for claim 1, production process is finished in wherein said work area one.
3. the method for claim 1, wherein said T/A data comprise that a parts reception time and parts check and accept quantity.
4. method as claimed in claim 2, wherein said T/A data comprise an operation starting time of described production process.
5. method as claimed in claim 2, wherein said T/A data comprise that one of described production process is finished working time.
6. method as claimed in claim 2, wherein said T/A data comprise a quantity performed of described production process.
7. the method for claim 1, wherein said cost information comprises a mao cycling time.
8. the method for claim 1, wherein said cost information comprises clean cycling time.
9. method as claimed in claim 2, wherein said cost information comprises the quantity scrapped of described production process.
10. the method for claim 1, the output of wherein said cost information comprises that this information of being output into is to a display.
11. a device that is used to improve production run, wherein said production run comprises the work area that is used to finish a procedure, and this device comprises:
Be used for obtaining the device of number of components and time data from described work area; With
Be connected to described acquisition device, be used for device in response to described number of components and time data computation cycles time cost computational data; With
Be connected to described calculation element, be used to export the device of pricing cycling time data.
12. device as claimed in claim 11, wherein said acquisition device comprises a bar code scanner that is connected to a computing machine.
13. device as claimed in claim 11, wherein said number of components and time data comprise parts examination quantity and parts reception time.
14. device as claimed in claim 11, wherein said number of components and time data comprise operation starting time.
Finish operation quantity and finish working time 15. device as claimed in claim 11, wherein said number of components and time data comprise.
16. device as claimed in claim 11, wherein said calculation element comprises a computing machine.
17. device as claimed in claim 16, wherein said computing machine is connected to a network, and this network is connected to described acquisition device.
18. device as claimed in claim 11, wherein said output unit comprises a printer.
19. device as claimed in claim 11, wherein said output unit comprises a display.
20. device as claimed in claim 11, wherein said output unit comprise a projection display in contiguous work area.
21. a device that is used to improve factory's benefit, wherein this factory comprises many production lines that are used to produce a kind of product, and a production line comprises a plurality of work areas; This device comprises:
Be used for obtaining from a work area of described production line the device of component information, this information comprises T/A information;
Local treating apparatus is connected to described acquisition device, is used for memory unit information;
Central processing unit is connected to described local treating apparatus, is used for computation cycles time cost computational data; With
Be connected to described central processing unit, be used to export the device of pricing cycling time data.
22. device as claimed in claim 21, wherein said cycling time or pricing data comprise bottleneck information.
23. device as claimed in claim 21, wherein said pricing cycling time data are included in the hair cycling time and the clean cycling time in a work area in the described production line.
24. device as claimed in claim 21, wherein said pricing cycling time data are included in the hair cycling time and the clean cycling time of the product of making in the described production line.
25. device as claimed in claim 21, wherein said pricing cycling time data comprise rejection rate.
26. device as claimed in claim 21, wherein said output unit comprises a printer.
27. device as claimed in claim 21, wherein said output unit comprise a projection display in contiguous work area.
28. device as claimed in claim 21, wherein said acquisition device comprises a bar code scanner.
29. device as claimed in claim 21, wherein said acquisition device comprises a keyboard that is connected to a computing machine.
30. device as claimed in claim 21, wherein said local treating apparatus comprises a computing machine.
31. device as claimed in claim 21, wherein said central processing unit comprise a server that is connected to a computing machine.
32. device as claimed in claim 31, wherein said central processing unit comprise a work area operation module.
33. device as claimed in claim 31, wherein said central processing unit comprise a work area value creating module.
34. device as claimed in claim 31, wherein said central processing unit comprise manager's reporting modules.
35. device as claimed in claim 31, wherein said central processing unit comprise a bottleneck pricing module.
36. device as claimed in claim 31, wherein said central processing unit comprise the waste product module of withholing.
37. one kind is used for obtaining the device of information from having many Production Line equipment, one first production line has a plurality of work areas; This device comprises:
One first local device is used for first work area input time and the quantity information from described a plurality of work areas;
One central processing unit is connected to described first local device, be used in response to coming computation cycles time cost computational data from the T/A information in described first work area, it comprise mao cycling time and clean cycling time and
One output unit is connected to described central processing unit, is used to export the hair cycling time and the clean cycling time in described first work area.
38. device as claimed in claim 37 also comprises one second local device, it is connected to described central processing unit, is used for second work area input time and the quantity information from described a plurality of work areas.
39. device as claimed in claim 38, wherein said central processing unit is in response to coming computation cycles pricing data from the T/A information in described first and second work areas, and it is included in the hair cycling time and the clean cycling time of the product that is used to make on described first production line.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN96194813A CN1189228A (en) | 1995-05-02 | 1996-04-24 | Method and apparatus for cycle time costing |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/431,679 | 1995-05-02 | ||
| CN96194813A CN1189228A (en) | 1995-05-02 | 1996-04-24 | Method and apparatus for cycle time costing |
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| Publication Number | Publication Date |
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| CN1189228A true CN1189228A (en) | 1998-07-29 |
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|---|---|---|---|
| CN96194813A Pending CN1189228A (en) | 1995-05-02 | 1996-04-24 | Method and apparatus for cycle time costing |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7346588B2 (en) | 2001-08-07 | 2008-03-18 | Ricoh Company Limited | Cost estimation method and system, and computer readable medium for the method |
| CN105388876A (en) * | 2015-12-22 | 2016-03-09 | 蓝星（北京）技术中心有限公司 | Method and device for obtaining team-based intermittent-type chemical production process conformity |
| CN105549559A (en) * | 2015-12-22 | 2016-05-04 | 蓝星（北京）技术中心有限公司 | Method used for acquiring continuous chemical industry production technology conformity based on team and group and apparatus thereof |
| CN108713176A (en) * | 2015-10-01 | 2018-10-26 | 莱克斯诺弗莱托普欧洲有限公司 | The planning system and method for circulation time are maintained in automobile plant |
-
1996
- 1996-04-24 CN CN96194813A patent/CN1189228A/en active Pending
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7346588B2 (en) | 2001-08-07 | 2008-03-18 | Ricoh Company Limited | Cost estimation method and system, and computer readable medium for the method |
| CN108713176A (en) * | 2015-10-01 | 2018-10-26 | 莱克斯诺弗莱托普欧洲有限公司 | The planning system and method for circulation time are maintained in automobile plant |
| US10969769B2 (en) | 2015-10-01 | 2021-04-06 | Rexnord Flattop Europe B.V. | Planning system and method for maintaining a cycle time in an automobile factory |
| CN108713176B (en) * | 2015-10-01 | 2021-06-29 | 莱克斯诺弗莱托普欧洲有限公司 | System and method for maintaining cycle time planning in automotive plant |
| CN105388876A (en) * | 2015-12-22 | 2016-03-09 | 蓝星（北京）技术中心有限公司 | Method and device for obtaining team-based intermittent-type chemical production process conformity |
| CN105549559A (en) * | 2015-12-22 | 2016-05-04 | 蓝星（北京）技术中心有限公司 | Method used for acquiring continuous chemical industry production technology conformity based on team and group and apparatus thereof |
| CN105388876B (en) * | 2015-12-22 | 2017-11-10 | 蓝星（北京）技术中心有限公司 | Obtain the method and device of the batch-type chemical production technology degree of conformity based on teams and groups |
| CN105549559B (en) * | 2015-12-22 | 2017-11-10 | 蓝星（北京）技术中心有限公司 | For obtaining the method and device of the continuous type chemical production technology degree of conformity based on teams and groups |
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