319
Yoshihiro Mizutani et al. / Energy Procedia 89 (2016) 318 – 322
When examining the three most important elements of business, namely Quality, Cost and Delivery, it is apparent that, though quality and cost are equivalent with those of the large companies, small companies can be in a highly advantageous position when it comes to delivery [1-5] ,Q WKLV SDSHU ZH ZLOO GHOLQHDWH WKH ³-SDFNV 3URGXFWLRQ 6\VWHP´ ZKLFK LV DEOH WR UHGXFH GHOLYHU\ WLPH ZLWKRXW H[FHVVLYH SUHVVXUH RQ WKH SURGXFWLRQ FHQWHUHG DURXQG ³ Production method of preferentially proceed of purchase order with multiple processes ´ , ³3URGXFWLRQ0HWKRGZLWK (YHU\3URFHVVHV&RQGXFWHGLQ3DUDOOHO´DQG³6LQJOH8QLW)ORZLQJ3URGXFWLRQ´GHYHORSHGE\-3DFNV 2. Production method of preferentially proceed of purchase order with multiple processes It is a method where arranging purchase orders in the descending order of processes and starting the production from the order ZLWK WKH PRVW VWHSV ZKLFK LV ZK\ LW LV QDPHG ³3UR duction method of preferentially proceed of purchase order ZLWKPXOWLSOHSURFHVVHV´ Normally, in the first process of corrugated cardboard production which is printing, it is common to produce the board with the same color all at once in a large quantity in order to reduce ink loss when changing color. However, the cost of ink loss is very small and negligible in relation to the entire operational cost of the factory. In fact, in the production method of preferentially proceed of purchase order with multiple processes, waiting time of the workers during the 2 nd to the last steps is significantly reduced, hence a major improvement can be expected. The delay in the production process cannot be theoretically regained, and moreover influence all the way to the last process. Therefore, how to reduce the delay in processes is extremely important for L/T shortening. 2.1. Simulation We simulated the common production method (Table 1) and production method of preferentially proceed of purchase order with multiple processes (Table 2) under these conditions. ORWVDUHSURGXFH d per day. W\SHVRIORW s (1 st process, 2 nd process, 3 rd process) are mixed, each of 5 kinds with different colors.
Production method of preferentially proceed of purchase order with multiple processes
Table 2
Common Production Method
Table 1
The 1st Process
The 2nd Process
The 3rd Process
Set Change
Operation Time
The 1st Process
The 2nd Process
The 3rd Process
Set Change
Operation Time
Lot
Lot
10 20 30 10 20 30 10 20 30 10 20 30 10 20 30
5 7 5 7 5 7 5 7 5 7
15 15 15 15 15 10 10 10 10 10
30 30 30 30 30 20 20 20 20 20 10 10 10 10 10
䐟 䕿
䐟 䕿 䕿 䕿 䐠 䕧 䕧 䕧 䐡 䕕 䕕 䕕
䐠 䕿 䕿
12
䐡 䕿 䕿 䕿
×
×
×
䐢 䕧
䐢
䐣 䕧 䕧
䐣 䖂 䖂 䖂
12
䐤 䕧 䕧 䕧
䐤 䕿 䕿 䐥 䕧 䕧 䐦 䕕 䕕
䐥 䕕
䐦 䕕 䕕
12
×
×
䐧 䕕 䕕 䕕
䐧
× × ×
䐨 䐩 䐪
䐨 䖂 䖂
× ×
5 5 5 5 5
䐩 䕿 䐪 䕧 䐫 䕕
×
12
䐫 䖂
×
䐬 䖂 䖂
䐬
12
䐭 䖂 䖂 䖂
䐭 䖂
Measurement Change
15 Times
Measurement Change
15 Times
Color Change Waiting Time
5 Times
Color Change Waiting Time
15 Times
50 100 120
0
0
150
Operation Time Working Time
300
Operation Time Working Time
300
570
450
Unit is minute The gray color in the table is the waiting time
Unit is minute The gray color in the table is the waiting time
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