Lean Manufacturing

精益生产

Ford Motor China Sourcing Office

福特汽车中国采购中心
 First Time Through Calculation (FTT)
Definition:
First Time Through is the percentage of units that complete a process and meet
quality guidelines the first time without being scraped, rerun, retested, diverted for off-
line repair, or returned. It is a measure of the quality of the manufacturing process.

定义 :
首次通过率是指一次性完成一个生产过程并且满足质量要求的零件的百分率， 不包括
报废，返工，再测试，下线修理或返回。 FTT 用于衡量制造过程的质量。

FTT=

Units entering process-(scrap+reruns+retests+repaired off-line+returns)

Units entering process
 First Time Through Calculation (FTT)
单工序：

进入数量 = 1000
报废 = 10
返工 = 15
测试 = 5
下线修理 = 0
FTT% = 1000 - （ 10+ 15+ 5+ 0 ）
1000
FTT% = 97.0%

多工序：

FTT ( 工序 1) = 92.87%
FTT ( 工序 2) = 87.65%
FTT ( 工序 3) = 82.34%
最终检验 ( 工序 4) = 82.34%
总 FTT% = 92.87% X 87.65% X 82.34% X 82.34%

Total FTT% = 44.22%

 Total Dock To Dock Calculation (DTD)
Definition:
Dock to Dock is the elapsed time between the unloading of raw materials and the release of finished
goods for shipment. DTD measures how fast raw materials are converted to finished goods and shipped. It
is a measure of the speed of material through the plant, not the speed of the processes.

定义 :
DTD 指从原材料到发运产品之间的总运转时间间隔。 DTD 用于测量原材料转化成成品发运的速度。也就是
指材料通过工厂的速度，而不是加工工艺的速度。

DTD (Single Operation) = Total Units of Control Part

End of line Rate

DTD (Multiple Operation)= DTD(OP 1)+DTD(OP 2)+…

End of line Rate
 Total Dock To Dock Calculation (DTD)
The End of Line Rate is calculated off the last operation in the manufacturing line for a product:
总产量 = 730 （最终工位）
生产时间 = 12 小时 （正常生产时间 10 小时 + 加班时间 2 小时）

End of Line Rate = 730/12 =60.83

各区域数量 = 原材料 + 半成品 + 最终产品
原材料 = 300
工序 1 = 181
工序 2 = 3
工序 3 = 3
最终产品 = 200

DTD （原材料 ) = 300/60.83 =4.93 小时

DTD ( 工序 1) = 181/60.83 =2.98 小时
DTD ( 工序 2) = 3/60.83 =0.05 小时
DTD ( 工序 3) = 3/60.83 =0.05 小时
DTD ( 最终产品 ) = 200/60.83 =3.29 小时

Total DTD= 4.93+ 2.98+ 0.05+ 0.05+ 3.29 =11.3 小时

 Overall Equipment Effectiveness (OEE)
Definition:
OEE is a combination of three different calculations. It is a measure of the availability, performance efficiency,
and quality rate of a given piece of equipment.
OEE data will help identify several wastes caused by machine/process inefficiencies.
Stretch objective: 85%
定义： OEE 是三个不同计算值的乘积，用于测量指定设备的利用率，性能效率和质量率。 OEE 数据可以帮助
识别由设备 / 过程不足引起的不同的浪费。
接受标准： 85%

OEE = Availability X Performance Efficiency X Quality

Availability = Operation Time

Net Available Time
Performance = Ideal cycle time X Total parts run
Efficiency Operating Time
Quality = Total parts run – Total defects
Total parts run
 Overall Equipment Effectiveness (OEE)
利用率：

总计划时间（包括加班） = 720 分钟
计划停线时间（ 30 分钟午饭 +30 分钟休息） = 30+30 = 60 分钟
净利用时间 = 720-60 = 660 分钟
其它停线时间 = 45+45 = 90 分钟
作业时间 = 660-90 = 570 分钟

利用率 = 570/660 =86.3%

性能效率 :

理想循环时间 = 0.33 分钟 / 件
总零件数 = 1440
作业时间 = 570 分钟

性能效率 = 0.33 X 1440 =83.4%

570
 Overall Equipment Effectiveness (OEE)
质量率：

总零件数 = 1440
返工数 = 50
报废数 = 40

质量率 = 1440 – (50+ 40) = 93.8%

1440

总设备利用率：

利用率 = 86.3%
性能效率 = 83.4%
质量率 = 93.8%
总设备利用率 = 86.3% X 83.4% X 93.8%

OEE = 67.5%
 Build to Schedule (BTS)
Definition:
Build to schedule is the percentage of products scheduled for a given day that are produced on that day, in the
correct sequence. BTS reflects the plant’s ability to produce what its customers want, when its customers want it, and
in the order the customers use the product.

BTS% = Volume% X Mix% X Sequence%

Volume Performance:
Volume Performance, is the traditional measure that manufacturing has used to monitor their performance to
schedule.

Mix Performance:
The Mix component of BTS measures the percentage of product derivatives/models/types that a plant builds on the
right day.

Sequence Performance:
The sequence component of BTS measures the percentage of those products built on the right day that were also
built in the right sequence.

Process with a sequenced ‘batch of many’ schedule

 Build to Schedule (BTS)
定义 :
BTS 是指在指定的生产日按照正确的生产顺序完成生产计划的比例情况。 BTS 反映了工厂能
够按照客户的要求完成生产的能力 , 客户需何种产品 , 何时需要和客户使用产品的顺序。

BTS% = Volume% X Mix% X Sequence%

Volume Performance:
产量性能用于监控生产计划完成情况。

Mix Performance:
BTS 的混线性能用于测量在厂内制造的产品系 / 型号 / 类型等在适当的生产日的完成比率。

Sequence Performance:
BTS 的顺序性能用于测量在适当的生产日按照正确的生产顺序完成生产任务的比率。
Process with a sequenced ‘batch of many’ schedule
 Build to Schedule (BTS-1)
FOCUS/COUGAR/JAGUAR CONDENSER
生产计划 实际生产
批序 型 数量 批序 型号 数量
号 号 号

1 Cougar
200 1 Cougar
190
2 Focus
100 2 Focus
40
3 Cougar
200 N/A Jaguar
60
4 Focus
150 4 Focus
300
5 Cougar
160 3 Cougar
100
810 690
Process with a sequenced ‘batch of many’ schedule
 Build to Schedule (BTS-1)
冷凝器类 计划产 实际产 混线生
型 量 量 产
Cougar 560 290 290
Focus 250 340 250
Jaguar 0 60 0
810 690 540
计划批次 实际批次顺 混线批 按顺序生产批
顺序 序 次 次
1 1 Yes Yes
2 2 Yes Yes
3 N/A No N/A
4 4 Yes Yes
5 3 Yes No
4 批 3 批
Process with a sequenced ‘batch of many’ schedul
 Build to Schedule (BTS-1)
Volume = 690 x 100 = 85.2%
Performance 810

Mix = 540 X 100 = 78.3%

Performance 690

Sequence = 3 X 100 = 75.0%

Performance 4

Build to Schedule =85.2%X 78.3%X 75.0%

= 50%
Process with a sequenced ‘batch of many’ schedule
 Build to Schedule (BTS-2)

冲压 计划生产的零 计划产量 实际生产 生产数量 混线生产 按序生产

线 件和生产序号 的零件序 数量 数量
号
10 A 1000 A 1000 1000 1000
B 2000 B 500 500 500
20 C 4000 C 7000 4000 4000
30 D 1000 E 1000 1000 1000
E 1000 D 2000 1000 0
F 1000 F 0 0 0
总共 10000 11500 7500 6500

Several non-serialized products made on different production lines within an area

of a plant
 Build to Schedule (BTS-2)
Volume = 11,500 = 100%
Performance 10,000

Mix = 7500 = 75%

Performance 10,000

Sequence = 6500 = 87%

Performance 7500

Build to Schedule =100%X 75%X 87%

= 65%

Several non-serialized products made on different production lines within an area

of a plant
 Build to Schedule (Roll-ups )

星期一 星期二 星期一和星期

二总和
计划产量 2100 3000 5100
实际产量 2045 2300 4345
混线产量 2015 2150 4165
按序生产产量 1850 1725 3575
Volume Performance 97.4% 76.7% 85.2%
Mix Performance 98.5% 93.5% 95.9%
Sequence Performance 91.8% 80.2% 85.8%
BTS 88.1% 57.5% 70.1%
 Build to Schedule (Roll-ups )
Volume = (2045+2300) = 100%
Performance (2100+3000)

Mix = (2015+2150) = 75%

Performance (2045+2300)

Sequence = (1850+1725) = 87%

Performance (2015+2150)

Build to Schedule =85.2%X 95.9%X 85.8%

= 65%
 Build to Schedule (Roll-ups )

星期一 星期一 星期一总和

（ 1 班） （ 2 班）
计划产量 1000 1000 2000
实际产量 1000 1000 2000
混线产量 0 0 2000
按序生产产量 N/A N/A N/A
Volume Performance 100% 100% 100%
Mix Performance 0% 0% 100%
Sequence Performance N/A N/A N/A
BTS 0% 0% 100%
 Build to Schedule (Roll-ups )

星期一 星期二 星期一，二

（ 1 班） （ 1 班） 总和（ 1 班）
计划产量 2100 3000 5100
实际产量 2045 2300 4345
混线产量 2015 2150 4165
按序生产产量 1850 1725 3575
Volume Performance 97.4% 76.7% 85.2%
Mix Performance 98.5% 93.5% 95.9%
Sequence Performance 91.8% 80.2% 85.8%
BTS 88.1% 57.5% 70.1%