PQ & PR 分析.ppt
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1、7.1Version 5.1(6/30)“Lean”Tools7.2Version 5.1(6/30)7.3Version 5.1(6/30)PQ Analysis7.4Version 5.1(6/30)7.5Version 5.1(6/30)P-Q AnalysisThe best way to begin an effort to build a U-shaped“Flow”cell for wide variety small lot production is to study the current production conditions that exist in the fa
2、ctory.This is done through the use of a P-Q analysis.In a P-Q analysis,the P stands for product and the Q stands for quantify(no consideration to dollar value).Step 1:Obtain at least 6 months of data on products made and production output quantities.(If known,future production quantities would be be
3、tter.)Step 2:List the products in order of highest quantity output and their associated percentage output of the total and tabulate on a P-Q list(see table 1).P-Q Analysis ListNo.P/NQuantityTotal%Cumulative%ABBCCDEFEFFG15,90012,50011,7009,4509,4009,00015,90028,40040,10049.55058,95067,95017.513.712.9
4、10.410.39.917.531.543.754.565.274.7Table 17.6Version 5.1(6/30)7.7Version 5.1(6/30)P-Q AnalysisStep 3:Create a P-Q Analysis table(see table 2),with the left vertical axis representing the output quantity and the horizontal axis representing the product.The graph is a Pareto chart,listing the products
5、 and their quantities in descending order,and a cumulative percentage line(right vertical axis).Note:Technically,in a wide variety small lot production shop,40%of the product accounts for approximately 60%of the volume(or less).In the above example 40%of 14 total part numbers is approximately.6.Draw
6、 a vertical line through the 6th product until you hit the cumulative%line,and draw a horizontal line over until you intersect the right axis.In this example it intersects around 70%,and approximates a true wide variety small lot factory.Table 2ABBCCDDEEFFGGHHIIJJKKLLMMNNO16,00014,00012,00010,000 8,
7、000 6,000 4,000 2,000Qty.100%80%60%40%20%.7.8Version 5.1(6/30)Table 2ABBCCDDEEFFGGHHIIJJKKLLMMNNO16,00014,00012,00010,000 8,000 6,000 4,000 2,000Qty.100%80%60%40%20%.7.9Version 5.1(6/30)P-Q AnalysisStep 4:Design a line of processes based on the P-Q Analysis list.If the P-Q Analysis shows that 20%of
8、the parts represent 80%of the volume;then each product should be investigated for a single product cell(the relative volume probably already requires dedicated equipment).7.10Version 5.1(6/30)7.11Version 5.1(6/30)P-Q AnalysisIn a wide variety small lot factory depicted below(see table 3),Group Techn
9、ology or families must be identified through the use of a Process-Route(PR)Analysis(described in the next section).In the diagram below of a wide variety factory,Group A parts typically represent about 70%of the volume and can warrant a specialized single product line.Products falling into groups B&
10、C represent the remaining 30-39%,and will be reviewed for a group or family.Table 3Wide VarietySmall Lot ProductionA group:about 70%B group:About 70%to 95%C group:about 95%to 99%Specialized line“Quantity building line”Group Technology lineProduct modelbuilding lineQPABCNo line7.12Version 5.1(6/30)Ta
11、ble 3Wide VarietySmall Lot ProductionA group:about 70%B group:About 70%to 95%C group:about 95%to 99%Specialized line“Quantity building line”Group Technology lineProduct modelbuilding lineQPABCNo line7.13Version 5.1(6/30)PR AnalysisThe next step is to analyze the flow of product in group A(as a start
12、ing point),to determine if other products follow a similar process path and could be considered a family.When considering families via a process-route(PR)analysis,do not consider differences in product shape,size,or material as different varieties of parts,but rather parts that follow the same basic
13、 process flow sequence.Most factories have no more than 5 such process families.When grouping several different parts together into a family(Group Technology),the key factor becomes changeover,which must be drastically reduced.Typically Group B&C parts fall into this category,comprising different pr
14、oducts that have similar process paths and can therefore use the same line/cell configuration.Process Path Table Location:Fabrication-Plant 1 Date:9/4/00ProcessMachine No.No.ItemPressPressPunchDrillTurnBendCleanMarkInspectShip123451997M451997M441997M491997M341997M1061997M14P1P2P3P4P5P6BenchBenchDock
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