标准化(PPT-79页)课件.ppt

1、GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 1 GMS标准化(PPT 79页)GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 2 GMSManufacturingProcess ValidationIn-ProcessControl &VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualMana

2、gementWork-placeOrganizationAndonConceptProblemSolvingContinuousImprovementProcessBusiness PlanDeploymentTotal ProductiveMaintenanceScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowTemporaryMaterialStorage Fixed Period Ordering Syst

3、em/ Order PartsHealth andSafety PriorityTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesStandardization标准化标准化Vision/MissionManagementby TAKT TimeShop FloorManagementQualified PeopleProductQualityStandardsQualitySystemManagementLean Design of Facilities, Equipment,Tooling and LayoutEarly M

4、fg. and DesignIntegration (DFM / DFA)Small LotPackagingControlledExternal TransportationGMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 3 GMSWhat is it? 是什么？ Group Discussion小组讨论GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 4 GMSSta

5、ndardization is a dynamic process by which we set standards of terminology, principles, methods, and processes within our organization.标准化是指在我们的组织内部标准化是指在我们的组织内部对各种术语、原则、方法及工对各种术语、原则、方法及工艺建立标准的动态过程。艺建立标准的动态过程。Definition of Standardization标准化的定义标准化的定义GMS OrientationStandardizationGMDAT/DIMC Confident

6、ialVersion Date 2003.2.22Slide 5 GMSThe purpose of standardization is to reduce variation and stabilize, so as to achieve a base from which to grow and improve.标准化的目的是减少变化与维标准化的目的是减少变化与维持稳定，在此基础上进步与提持稳定，在此基础上进步与提高。高。Purpose of Standardization标准化的目的标准化的目的GMS OrientationStandardizationGMDAT/DIMC Confi

7、dentialVersion Date 2003.2.22Slide 6 GMSWhy Is Standardization Important? 为什么标准化很重要？为什么标准化很重要？SAFETY 安全QUALITY质量COMMON DIRECTION共同方向JD Powers#1PRODUCTIVITY产量GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 7 GMSWhat Happens When We Do Not Have Good, Clear Standards?若没

8、有良好、明晰的标准会怎样？若没有良好、明晰的标准会怎样？Example: 2000 U.S. Presidential Elections: Variation in Voting Machines & Methods Caused Major Election Controversy事例：事例：2000年美国总统大选：年美国总统大选： 投票机器与方式的不一致导致重大选举投票机器与方式的不一致导致重大选举纷争纷争GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 8 GMSStanda

9、rdization 标准化标准化“THE WEDGE” TO STABILIZE BEST PRACTICE“楔子楔子”楔牢最优方法楔牢最优方法 Continuous Improvement不断改进不断改进Change改变改变WorldClass世界领世界领先水平先水平GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 9 GMSA Standard Is The Best Current Practice Based On Many Peoples Experience & Less

10、ons Learned, so标准是基于多数人的经验教训得来最优现行方法，所以标准是基于多数人的经验教训得来最优现行方法，所以DONT SHORTCUT THE STANDARD!切勿缩短标准！切勿缩短标准！BAD THINGS COULD HAPPEN, ESPECIALLY SAFETY & QUALITY PROBLEMS不良的事故会发生，尤其是安全不良的事故会发生，尤其是安全及质量问题。及质量问题。IF YOU DONT LIKE THE STANDARD, TRY TO CHANGE IT, BUT NEVER SHORTCUT IT.若你不满意这个标准，试着改变它，切勿走捷径。St

11、andardShortcutGMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 10 GMSWhat Happens When We Do Not Follow Standards?如果不遵照标准会怎样？如果不遵照标准会怎样？EVERY YEAR PEOPLE DIE FROM NOT FOLLOWING LOCK-OUT PROCEDUREU.S SUBMARINE HITS JAPANESE FISHING BOAT - SURFACING PROCEDURE NOT FOLLOW

12、EDEXXON VALDEZ OIL SPILL CAPTAIN DID NOT FOLLOW STANDARDSGERMAN PLANE CRASHES IN SWITZERLAND AIR TRAFFIC CONTROL PROCEDURES IGNORED每年都有人死于不每年都有人死于不遵循关阀规定遵循关阀规定美国潜艇击沉不遵守美国潜艇击沉不遵守海面规定的日本渔船海面规定的日本渔船德国忽视空中飞行条德国忽视空中飞行条例在瑞士坠毁例在瑞士坠毁船长不遵循标准导致船长不遵循标准导致EXXON 瓦尔迪瓦尔迪兹兹石石油泄露油泄露GMS OrientationStandardizationGMDAT

13、/DIMC ConfidentialVersion Date 2003.2.22Slide 11 GMSSTANDARDIZATION EXERCISE标准化练习 Think of any example inside or outside work where standards not being followed led to a bad situation 想想工作中或其它不遵守标准导致不良事件想想工作中或其它不遵守标准导致不良事件发生的例子。发生的例子。 Discuss as a team and report Take 5 minutes 小组讨论、汇报小组讨论、汇报-5分钟分钟G

14、MS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 12 GMSAlways Remember The Priorities牢记的重点牢记的重点Safety 安全安全People 员工员工Quality 质量质量Responsiveness 响应响应Cost 成本成本Importance重要For Example, Sometimes We Have To Sacrifice Efficiency To Achieve Safety例如：有时我们必须为了安全而牺牲效率GMS Orient

15、ationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 13 GMSMAKE RULE 制订条例制订条例TEACH RULE 讲授条例讲授条例KEEP RULE 遵守条例遵守条例DO THE RIGHT THING!做合理的事情LEAD BY EXAMPLE!榜样领导GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 14 GMSStandardization On A Broader Scale L

16、eads to Communization 更大范围的标准化以达到共有化更大范围的标准化以达到共有化w One “Language” 同一语言w Common Principles 通用原则w Common Methods 通用方法w Common Processes 通用程序GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 15 GMSStandardization vs. Commonization标准化与共有化标准化与共有化 If one family made a recip

17、e for their Kimchi, then it would be Standardized. 如果一个家庭为其如果一个家庭为其泡菜定个菜谱，就是标准化。泡菜定个菜谱，就是标准化。 But all families are still different so we are not Commonized (sometimes common is not appropriate).但是每个家庭做法不一样则没有达到共有化。（有时共同的并但是每个家庭做法不一样则没有达到共有化。（有时共同的并非是正确的）非是正确的）GMS OrientationStandardizationGMDAT/DIMC

18、 ConfidentialVersion Date 2003.2.22Slide 16 GMSManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementIn-ProcessControl &VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingContinuousImpro

19、vementProcessBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualif

20、ied PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementStandardization 标准化标准化Early Mfg. and DesignIntegration (DFM / DFA)Lean Design of Facilities, Equipment,Tooling and LayoutScheduledShipping /ReceivingWorkplaceOrganization工作场地布置工作场地布置GMS Orientation

21、StandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 17 GMSWorkplace Organization工作场地布置工作场地布置What is it? 指什么？指什么？Group Discussion 小组讨论小组讨论GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 18 GMSGMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion D

22、ate 2003.2.22Slide 19 GMSWorkplace Organization, 5S工作场地布置工作场地布置, 5SPut order to the workplace by making Standards that allow “out-of-standard” conditions to be visible!制定标准使工作场地井井有序，制定标准使工作场地井井有序，并使非标准的东西暴露出来。并使非标准的东西暴露出来。GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Sli

23、de 20 GMSWhere is Workplace Organization Important? 哪些工作场地布置重要？哪些工作场地布置重要？On the shop floor. . . 车间地面车间地面. . . in the office!办公地点办公地点GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 21 GMSHow is workplace organization done?怎样布置工作场地？怎样布置工作场地？Workplace Organization工作场地布

24、置工作场地布置5S5 Self Discipline/ Cont. Improvement不断改进不断改进4 Sustain/Maintain 维护维护2 Sort/Standardize 整顿整顿1 Sift/Clear 整理整理3 Sweep/Clean 清扫清扫/清洁清洁GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 22 GMSSift/Clear 整理整理uDivide the needed and not needed items at the job site, an

25、d quickly remove the unneeded items. 区分开工作场所中必要和不必要的东西，迅速将不必要的东西清除。区分开工作场所中必要和不必要的东西，迅速将不必要的东西清除。uAreas of Focus 重点区域重点区域Tools 工具工具2) Inventory/Storage 库存库存/储存储存 3) Equipment 设备设备Keep neededItems保留必要东西保留必要东西Remove unneededItems (waste)清除不必要东西（废清除不必要东西（废料）料）The Most Difficult thing for us to do 这是最难做

26、到的1 Sift/Clear ()GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 23 GMSRed Label CampaignHammerObsoletePliersRustedSift/Clear 整理整理1 Sift/Clear ()If In Doubt Throw It Out! 毫不毫不犹豫扔掉犹豫扔掉GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 24

27、GMSSort/Standardize 整顿整顿 A Place for everything . . . and everything in its place 所有工作的场地，所有工作井所有工作的场地，所有工作井井有序。井有序。FThe location of equipment, tooling and material should be clearly defined, displayed and maintained.F各种设备、工具、材料明确区分，放置，维护。L850Hose30 pcs.SmallBolts小螺栓小螺栓700 pcsMed.Bolts中等中等螺栓螺栓500 pc

28、.LargeBolts大螺大螺栓栓300 pcs.L850RubberHose 橡胶管橡胶管2 Sort/Standardize ()1 Sift/Clear ()GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 25 GMSSort/Standardize 整顿整顿 Make A Standard! 制定标准制定标准3. Mark the Location 标明位置标明位置2. Determine a Location 确定放置地点确定放置地点Where is the best p

29、lace?哪里是最恰当的？1. Categorize 分类分类How often do I use this? 经常使用吗？2 Sort/Standardize ()1 Sift/Clear ()GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 26 GMSSweep / Clean 清扫清扫/清洁清洁3 Sweep ()2 Sort ()1 Sift ()“ “Sweeping” is checking!清扫既是检查！清扫既是检查！CheckGMS OrientationStand

30、ardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 27 GMSResponsibility ChartKimLeeParkSeoChoTarget: Major 5S 1/qtr.WhoTask12345Sustain/Maintain 维护维护uIdentify Tasks 确定任务确定任务uAssign Responsibility 划分责任划分责任uSet Targets 设定目标设定目标3 Sweep()2 Sort()1 Sift()4Sustain()Safety/5S Checks Must Be Perfo

31、rmed Everywhere and At Every Level Of The Organization!安全安全/5/5S S检查应该人人处处开展！检查应该人人处处开展！Standards areworthless if there is no systemto check!如果没有系统检查，标准即毫无用处。GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 28 GMSSelf-Discipline/Continuous Improvement 自律自律/不断改进不断改进5 S

32、elf Discipline/ Cont. Improvement自律自律/不断改进不断改进4 Sustain/Maintain 维护维护2 Sort/Standardize 整顿整顿/标准标准1 Sift/Clear 整理整理3 Sweep/Clean 清扫清扫/清洁清洁It is everyones responsibility!这是每个人的职责！这是每个人的职责！GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 29 GMS5S EXERCISE5S练习 How would y

33、ou use the 5S process to improve the situation below?你怎样用你怎样用5S程序来改善下图的情形？程序来改善下图的情形？ Utilize ALL 5Ss 利用所有利用所有5S程序程序 Discuss as a team and report Take 10 minutes 小组讨论、汇报小组讨论、汇报10分钟分钟GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 30 GMS5S EXERCISE INSERT WORKSHEET 插入

34、工作表插入工作表GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 31 GMSAnything outside the standard is WASTE!所有标准外的东西都是浪费！WPO is a key means of visualizing and eliminating waste WPO WPO是暴露及消除浪费的主要途径是暴露及消除浪费的主要途径Why workplace organization?为什么要场地布置？为什么要场地布置？GMS OrientationStan

35、dardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 32 GMSWhy workplace organization?为什么要场地布置？为什么要场地布置？Good 5S Leads to Good Safety! Good 5S Leads to Good Safety! No trip, slip hazards, etc. No trip, slip hazards, etc. 做好做好5 5S S等于安等于安全！就没有跌倒滑倒等的危险。全！就没有跌倒滑倒等的危险。SAFETYQUALITYItems always i

36、n same place means less Items always in same place means less likely to make mistakes likely to make mistakes 事物特定放置意事物特定放置意味着少犯错误。味着少犯错误。EFFICIENCYItems always in same place means less Items always in same place means less wasteful and more repeatable motions wasteful and more repeatable motions 事物

37、特定放置就是减少多余重复的动作。事物特定放置就是减少多余重复的动作。GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 33 GMSExample of Cabinet 5S 橱柜橱柜5S范例范例Cabinet “Before 5S”5S之前的橱柜之前的橱柜Cabinet “After 5S”5S后的橱柜后的橱柜GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 34 GMSE

38、xample of 5S GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 35 GMSManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementIn-ProcessControl &VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-place

39、OrganizationAndonConceptProblemSolvingContinuousImprovementProcessBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMateria

40、lStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementStandardizedWork 标准化工作标准化工作Standardization 标准化标准化Lean Design of Facilities, Equipment,Tooling and LayoutEarly Mfg. a

41、nd DesignIntegration (DFM / DFA)GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 36 GMSStandardized Work 标准化工作标准化工作The documented, current best method to Safely and Efficiently perform work that meets the necessary level of Quality.为了达到一定的质量标准，以为了达到一定的质量标准，以文件化文件化及最可行

42、的方法来安全有效地开展工作及最可行的方法来安全有效地开展工作GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 37 GMSWithout Standardization 没有标准化没有标准化With Standardization 有了标准化有了标准化Standardized Work 标准化工作标准化工作GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 38 GMSMat

43、erials物料物料Standardized Work 标准化工作标准化工作Standardized work is used when there is a definable, repeatable process.当工序明确可重复时，采用标准化工作当工序明确可重复时，采用标准化工作Production生生产产Office办办公室公室Standardized Work Can Be Performed Everywhere!随处随处都可以都可以开开展展标标准化工作准化工作!GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersio

44、n Date 2003.2.22Slide 39 GMSTeam Leaders班班长长Team Members班班组组成成员员Group Leaders工段工段长长Everyone can perform standardized work!每每个个人都可以人都可以进进行行标标准化工作！准化工作！Managers主任主任Engineers工程工程师师Employees Should Be Involved In Developing Standardized Work They Know The Job The Best! 员工应该加入标准化工作开展因为他们最了解工艺！GMS Orienta

45、tionStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 40 GMSStandardization标标准化准化Improvement改改进进Standardized Work (标标准化工作准化工作)Standardized Work Is A Baseline for Continuous Improvement!标标准化工作是不准化工作是不断断改改进进的基的基线线！Standardization标准化标准化Standardization标准化标准化Standardization标准化标准化Improveme

46、nt改改进进Improvement改改进进GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 41 GMSEach Individual Has Good Ideas If We Do Not Document The Best Methods Then We Are Not Fully Utilizing The Teams Brainpower and We Will Never Improve Or We May Actually Get Worse!每每个个人都有好主意人都有好

47、主意如果我如果我们们不把最好方法文件化，不把最好方法文件化，则则不可能充分利用不可能充分利用团队团队的智能，的智能，不但不能取得不但不能取得进进步，甚至步，甚至会会越越来来越糟糕！越糟糕！SAFETY, QUALITY, EFFICIENCY安全、质量、效率GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 42 GMSWould You Want To Get Into A Plane Where The Crew Did Not Exactly Follow A Standardi

48、zed Check Process? Even Though They Have Performed It Hundreds Of Times! 你会你会不不会会乘坐乘乘坐乘务员务员不不履行履行标标准准检查检查程序的程序的检查的检查的飞飞机机？-即使他即使他们们重复操作过重复操作过无无数数遍。遍。Check Fuel (检查汽油)Check Tires (检查轮胎)Check Instruments (检查仪表盘)GMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 43 GMSCont

49、inuous ImprovementStandardizationThere Is a Real Balance Between Standardization and Continuous Improvement. 标标准化准化与与不不断断改改进进之之间间有有个个天平。天平。We Must Control The Balance to Be Sure That We Are Neither to Strict With Standardization, Nor Too Flexible. 我我们们必必须须控制控制这个这个天平以确保天平以确保既既不要不要死死守守也不也不要要脱脱离离标标准化准化

50、BUTGMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 44 GMSLego ExerciseGMS OrientationStandardizationGMDAT/DIMC ConfidentialVersion Date 2003.2.22Slide 45 GMSStandardized Work BasicsWHY What will happen if standard is not followed 若不遵守若不遵守标标准准会怎样会怎样？Why is it importan