精益生产管理手册(中英文版)课件.ppt

1、12 Defect : X 1/10缺陷缺陷降低降低90% Inventory : X 库库存减半存减半 Productivity : X 2生生产产效率翻倍效率翻倍 Lead Time : X 生生产产周期减半周期减半 Scrap : X 1/10报废报废降低降低90% Space : X 面面积积减半减半Goal : Add Value & Eliminate Waste Relentlessly for Our Customers目目标标: 减少浪减少浪费费&创创造价造价值值 全心全意全心全意为为客客户户服服务务ETE (End to End) Productivity Improvem

2、ent 端到端端到端( (从头到尾从头到尾) )产能提高产能提高ETE Zero Defect (Quality, TPM, OEE & etc.) 端到端端到端(从从头头到尾到尾)零缺陷（零缺陷（质质量，全面生量，全面生产维护产维护，全局，全局设备设备利用率等）利用率等）Inventory Reductions 降低降低库存库存Lead Time Reductions 缩短缩短生产前置期生产前置期Crew Size Optimization 优化优化人员数量人员数量Space Reduction 减少减少使用使用面积面积No Money 不投入更多金钱不投入更多金钱No Space 不占用更

3、多面积不占用更多面积No Manpower 不使用更多人力不使用更多人力3Standard Work & Standard Combination Sheet标准化作业标准化作业 & 标准作业合并表标准作业合并表1) Standard work defined 标准作业定义 a) Takt time defined 节拍时间的定义节拍时间的定义 b) Work sequence defined 工序的定义工序的定义 c) Standard WIP defined 标准在线库存定义标准在线库存定义d) Cycle time defined 周期时间定义 e) No of operators de

4、fined 操作员数量的定义 f) Safety 安全性 g) Multi skill多技能 2) Standard work combination sheet defined 标准作业合并表定义a) Manual time手动时间b) Auto time机器(自动)时间c) Walking time走动时间d) Waiting time等待时间3) Is the Quality check legend defined on each process on std work sheet?标准作业合并表上，有定义每个流程中的品质管控的关键点吗？3 Key Elements3项项关关键键要素要

5、素43 Types of Standard Works3种标准作业种标准作业53 Types of Standard Works3种标准作业种标准作业Type 1 : Standard Work to support machine (90%) & man (10%) combination task.类型1：标准作业适用于90%的机器作业和10%的手动作业的组合作业方式。Type 2 : Standard Work to support man (90%) & machine (10%) combination task. 类型2：标准作业适用于90%手动作业和10%机器作业的组合作业方式。

6、Type 3 : Standard Work (also called as Work Standard) to support task carried out once signal is triggered.类型3：标准作业（也叫做作业标准）适用于当信号产生时才去执行相应任务的作业方式。No Std Work means no Kaizen Std Work is the Mother of all Kaizen没有标准作业就没有改善标准作业是改善之母6How to start the Takt Time CalculationBased On Customer Demand 怎样根据客

7、户需求计算节拍时间 Step 1: Calculate Takt time Based on Customer Demand 第一步：根据客户需求计算节拍时间 Example 例如:Customer Demand per Month 792K. Working hour per day is 22 hours, 20 days a month. 客户每月需求量是792K。每天工作小时是22小时，一个月20天。Takt Time calculation shall display all the variable and units to make clarity to all. 计算节拍时间时

8、要显示所有变量及单位，便于大家理解。计算节拍时间时要显示所有变量及单位，便于大家理解。sec 2792,0001,584,000pcs 792,000s 3600 x days 20 x Hours 22 Demand Customer Time AvailableTime Takt客户需求有效时间7How to start the Takt Time CalculationBased On Product and Process Design怎样根据产品和制程设计计算节拍时间Step 2: Calculate Process Takt time Based on Product and Pr

9、ocess Design 第二步：根据产品和制程设计计算节拍时间Based on Step 1, Takt Time is 2 second to produce 1 pcs.根据步骤1，节拍时间是每 2 秒生产 1 件产品。8How to start the Takt Time CalculationBased On Product and Process Design怎样根据产品和制程设计计算节拍时间Scenario 1: Product design is 6 pcs per one PCB panel. The Process Takt Time will be every 12 se

10、cond a panel. Besides, your process design is using a pallet to place 4 panels, then your Process Takt Time is 48 second a pallet. If 2 line running, process Takt time will be 96 sec.情节1：产品设计为每块PCB板由 6 块小板组成，节拍时间是每块PCB板 12 秒; 制程设计治具同时放置 4 块PCB板，则制程的节拍时间是 48 秒/治具。如果同时有 2 条生产线生产，制程的节拍时间则为 96 秒。Scenari

11、o 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec情节情节2 2：如果正反面产品同时在一条生产线生产，节拍时间则为一半，：如果正反面产品同时在一条生产线生产，节拍时间则为一半，4848秒。秒。As such the Process Takt Time Calculation as following: 制程节拍时间计算如下：= Takt Time X Product Up x Process Up X Number of Line = 2 se

12、c X 6 products per panel X 4 Panel per pallet X 2 Lines= 96 sec 9What is Standard WIP什么是标准WIPVarious types of WIP in our manufacturing process 生产过程中存在各种类型的WIP1.Standard WIP 标准WIP2.Process WIP制程WIP3.Process To Process WIP制程与制程间WIP4.Station To Station WIP工位与工位间WIP10What is Standard WIP什么是标准WIP WIP mea

13、ns INVENTORY. INVENTORY is Basically bad. WIP就是库存。库存从根本上说是就是库存。库存从根本上说是“不好不好”的。的。 Standard WIP is the Ideal or Should be conditions for WIP标准WIP是理想WIP或者是WIP的应有状态。 However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and

14、 bottle neck然而，在完全达到标准WIP数量前，你需要经过不同的阶段了解制程中的浪费和瓶颈。Key Note from Sensei: 老师的重要提示：老师的重要提示： To understand the above WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解要理解WIP定义，你需要去到现场在工作中实

15、践正确的定义，你需要去到现场在工作中实践正确的WIP数量。数量。这是让你理解这个定义的唯一方法。这是让你理解这个定义的唯一方法。11What is Standard WIP什么是标准WIPThe purpose of Standard WIP is:标准WIP的目的：1.Separation between machine job and man job 区分机器作业和手动作业2.Ensures quality requirements确保质量要求3.Ensures smooth flow based on Takt time确保基于节拍时间的连续流Example 1: 例子1WIP in t

16、he reflow oven for curing with process time 6 min and Takt time 30 sec.在回流焊炉中固化的WIP，制程时间 6 min，节拍时间 30 sec.Standard WIP in the curing oven = Process Time / Takt Time 回流焊炉的标准WIP = 6 min / 30 sec = 12 Pcs12What is Standard WIP什么是标准WIPExample 2: 例子2WIP in the tester at backend assembly with process tim

17、e 60 sec and Takt Time 30 sec.后段组装线测试机的WIP，制程时间 60 sec，节拍时间 30 sec.Standard WIP in the Test station = 60 sec/ 30 sec测试工位的标准WIP = 2 pcsIn other words, Standard WIP in order to fulfill the above 1), 2), 3) functions, It is the compulsory WIP in the machine / process before establish standard work for

18、the process. 换句话说，标准WIP能够确保上述1),2),3)达成，在建立标准作业前，标准WIP是机器和制程强制的WIP。13What is Standard WIP什么是标准WIPProcess WIP 制程WIPWIP within same process with low variation of cycle time同一个制程中的WIP，周期时间CT变化很小It is all that WIP in the same process, not categorized as Standard WIP or PTP WIP. 所有在同一个制程中的WIP，不是标准WIP或制程间

19、WIP.Example:- 例如例如Before Kaizen, Manual Insert (MI) Line Process WIP =9 pcs. After Kaizen MI Process WIP is 3. Standard WIP for each station is 1pc. 改善前，插件拉的制程WIP=9 pcs。改善后插件拉制程WIP=3pcs。每个工位的标准WIP为1pcs.T.T60 sec51455843PersonTimeABCDT.T60 sec60606012PersonTimeABCDvarianceAfterBeforeProcess WIP = 3,

20、Standard WIP = 1 Process WIP = 9, No standard WIP 14What is Standard WIP什么是标准WIPProcess To Process WIP (PTP WIP) 制程间WIPWIP between 2 different processes with big gap cycle time两个周期时间相差很大的不同制程间的WIP.PTP WIP Is needed due to changeover in upstream line. 上游制程需要转拉，则需设定制程间WIP. Not All line need PTP WIP.不是

21、所有产线都需要制程间WIP.If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期时间小于下游制程的周期时间Example 1:- SMT Cycle time (30 sec) Less then Manual Insertion (60 sec)例1：SMT周期时间(30 sec)小于MI插件周期时间 (60 sec)CT (Upstream process) Need PTP WIP 需要制程间WIP If Cycle time Upstream process is Equal or gr

22、eater then Down stream process, No PTP WIP required. 如果上游制程的周期时间大于或等于下游制程的周期时间，不需要制程间WIP.节拍时间前工序机器转拉时间制程间Time Takt Machine Previous of Changeover WIP WIPProcess to Process15What is Standard WIP什么是标准WIPProcess To Process WIP制程间WIP节拍时间前工序机器转拉时间程间制Time Takt Machine Previous of Changeover WIP WIPProcess

23、 to ProcessExample 2:- Process A cycle time 15 sec. It is faster then Process B cycle time 25sec. Process A is running 2 product models as capacity requirement. In order to Keep Process line running, process to process WIP is required between Process A and B. The calculation as below:-例2：制程A周期时间是15s

24、ec，比制程周期时间25sec快。制程A根据生产能力需求，需要生产2种产品。为了保证产线正常运作，需要在制程A和制程B之间设定制程间WIP。计算如下：Takt Time = 30secChangeover Time = 5 min30secProcess AProcess Bpcs 10sec 3060sec x 5min WIPPTP16Takt Time 节拍时间节拍时间Cycle time Takt time ( 1 Station Process )C/T than takt for single process (2 same stations needed)C/TTakt (需要2

25、个相同工位)TAKT Time = 20s10203040Machine/Process A : St. #1Machine/Process A : St. #2Note注: CT TT : Additional Machine/Man needed 需要额外的机器/人员It can be used to calculate 节节拍拍时间时间可以可以计计算算 Total Operators needed员工需求数量 Total machines needed机器需求数量 Standard WIP needed & Etc标准WIP需求数量，等171)Is the Takt time visib

26、le (with counter and triggering point)? 节拍时间可以直观地看出来吗？有没有借助工具(计数器和触发机制) 。2) Is the Takt board defined (on the board)? 节拍时间确定了吗？(把节拍时间写在白板上) 3) Are the Standard WIP defined? 标准WIP有定义吗? 4) Do you know how to separate manual (persons) from auto (the machines) work? 你知道如何区分手动作业和自动作业吗? 5) Is the Work loa

27、d leveling defined for man，machine and C/O? 人工,机器以及换线使用工作负荷均衡表分析了吗？ 6) Is the H/C calculated based on Takt time? 人力的多少是根据节拍时间计算出来的吗? 7) Is the Std work (front page) SWCS (back page) posted in front of each operator? 每个工站前都有标准作业(前页)和标准作业合并表SWCS(背页)吗? Operations操作操作 18Operations ( continue )操作操作(续页续页)

28、8) Is the std work being followed by the operator? 操作员有没有按照标准作业流程作业? 9) Is the std work defined for water strider? 有没有定义物料员的标准作业? 10) Is the operator idle at the station? 在作业过程中,操作员是否有等待? 11) Does the operator search for components or tools? - Locate all tools and parts within easy access or reach (

29、Doctor & Nurse). 在作业中,操作员有没有寻找物料或工具的动作? 工具或物料应该放置在易于获取的位置,定点定位.(遵循医生和护士概念：Doctor医生,指直接作业的人员,nurse护士,指辅助作业人员,如物料员) 12) Do you have std work for inspection station? 检查工站有没有标准作业书? 13) Do you have shortest cycle time for inspection? 对于检查工站,有没有定义最短周期时间? 19Operations ( continue )操作操作(续页续页)14) At the hand

30、load station, do you apply doctor and nurse concept? 在手工作业工站,有没有运用医生和护士理念? 15) Do you meet the target of 3 sec per component during insertion at hand load? 在手插工站,有没有达到每3 秒一颗零件的插件速度? 16) SIC less at hand load station (with template). 手插工站不需要SIC(用模板来显示需要插件的位置)? 17)Hand load manual CT Takt time nurse n

31、ot required. Are there system in place to stop work when abnormal conditions arise? 当手动作业的周期时间小于节拍时间时，不需要”护士”(护士nurse:辅助作业人员) 当异常情况出现时，有没有系统来控制停止作业? 18 ) Does the supervisor respond in a quick/crude manner? 当异常发生时，管理人员的反映是快速还是迟钝? 19) Do you have 6S implemented on your line? 线上有实行6S吗 ?(6S=5S+Safety)

32、20Operations ( continue )操作操作(续页续页)20) Is the production qty for the day defined? 日产量有没有定义? 21) Is the Multi skill charts visible and available? 有没有显示和使用多技能培训表？22) Do you allow banana peeling on the line? 允许在线拆卸物料包装吗? 23) Are you able to detect bottleneck station at a glance? 瓶颈工站能一眼看出来吗? 24) The op

33、erator must not re-orient the part 操作员不允许重新调整零件方向,防止零件极性弄错.(这里操作员指辅助作业人员,即nurse) 25) Change over : 快速换型a) Internal time 内部时间d) Adjustment time调整校准时间b) External time 外部时间e) Clean清洁c) Trial run试运行21Operations ( continue )操作操作(续页续页)26) ETE Operation criteria: 端到端运行标准a)The line should run based on Takt

34、time 生产线必须按照客户需求节拍合理安排生产b)The H/C should be loaded based on Takt time 生产线应按客户需求节拍时间合理安排人员c)Material should be loaded based on Takt time 按客户需求节拍时间备置原材料d)The line should be configured to zero defects 配置生产线时需满足零缺陷e)Supermarket should meet all the 15 criteria 超市必须符合15个设置准则27) ETE consists of : 端到端包括: a)

35、 Productivity improvement (MLT,H/C, WIP, Space) 提高生产效率(生产前置期,科学的人员配置,适当的在线库存,有效的空间利用)b) Material replenishment (Water strider, Min- Max, Supermarket) 灵活精益的原材料供给方式(水蜘蛛补货原则，设置最低最高库存，超市)c) Quality improvement (Zero defects) 提高质量(零缺陷)d) C/O (if the time more than 10 minutes) 换型时间(如果时间超过10分钟)22Operations

36、 ( continue ) 操作操作(续页续页)28) 4 functions of Conveyor, Say NO to Conveyor if below criterias not meet“传送带”的4个功能， 如果不符合以下条件则不能使用“传送带”Function as a Pace Setter ( Takt Manufacturing ) 节拍调节器（节拍生产）b)Function as a Value adding work station ( Value being added as it moves)增值工位（传送带移动时产品可以增值，如在传送带上作业） c)Functi

37、on as a Jidoka ( Stop every abnormal ) 自働化（异常时停止作业）d)Function as a transportation mode ( 5% of the function ) 传送作用（只占（只占5%的功能）的功能）23Layout 布局布局1) Insure the short walking distance. 确保产线行走距离短. 2) Do you have 3 TEI implemented on your line? 产线有没有对物品实施三定原则? a) Fix place 定点b) Fix things 定位/定物 c) Fix qty

38、 定量3) Is the safety aisle easily accessed by the operator? 安全通道是否易于员工通过? 4) Are there trash bins inside the cell? 单元生产线内有没有垃圾箱? 5) Do you have cell concept implemented on your line? 有没有在生产线上应用单元生产的概念.24Layout ( continue ) 布局布局(续页续页)6) The operator movement in a cell : is it counter clock wise(1) or

39、clockwise(0). Counter clock wise is recommended 操作员在单元内的移动是逆时针还是顺时针(逆时针为佳) 7) The gap in a cell : is it wider(0) or narrower(1) (narrower recommended). 单元内工站间的间距合适的吗?宽(0) 还是窄(1) (推荐用窄).8) Is the station made of crefoam material and is it on the wheel for flexible movement? 工作台是由复合管做成的吗 ?是否有滑轮易于移动呢?

40、9) The flow of a layout must be like a single stroke, no zigzag. 产线布局的流向必须是单行程的，而不是弯曲交错的。10) Do you use 7 ways when designing tools, jigs, fixtures, layout or process? 在设计工具,夹具,治具,工厂布局和流程时有没有采用7种方法(7 ways)? 11) Do you use Pugh matrix to evaluate 7ways? 有没有使用Pugh matrix来评估7种方法? .25Layout ( continue )

41、 布局布局(续页续页)12) Hand load station should meet the below requirements :手动作业工站应该满足以下要求: a) Part presentation 物料摆放方式 b) Zero defect 物料品质零缺陷 c) Layout /Ergonomic, 插件的顺序/根据人机工程学来安排d) Both hands of operator have to be used during insertion 插件时要双手作业 13) Are the cables, wires and network using the overhead d

42、rop point for flexibility?电线,网线,信号线是否架设在线体上端并连接到产线，易于灵活使用? 14) Do you use the Spaghetti Chart to do the layout, process, movement? 在设计layout，流程,行走路线时有没有使用到Spaghetti Chart(意大利面条图)工具,清晰的画出人流、物流及产品流路线? 15) Is the line visibility clear for the supervisor? (boarder post defined for clear visibility) 对于管理

43、者来说，产线可视化吗?(定义看板使其清晰可视化) 16) Do you use mock-up layout? 有没有模拟layout实施后的情况吗? 17) Tree and Branch connecting sub assembly & main assembly 主干和枝条 主装配线和辅助装配线的合理衔接26Layout ( continue ) 布局布局(续页续页)18) Short Takt time 1minute, multiply takt time by (x) factor and duplicate the backend cell accordingly客户节拍时间太

44、短小于 1 分钟时，增大节拍时间 X 倍并建立相应数量的相同的单元产线。19) Do your work stations are in same height ?工作台都是同一个高度吗？20) Do you carry out “rope test” to validate the continuous value flow ?有实施“绳子测试”验证连续价值流吗？27Zero Defect 零缺陷零缺陷1)Can normal and abnormal be visually differentiated? 正常和异常现象易于区分吗 ? 2) Are the escalation paths

45、 well defined if abnormality occurs? 针对异常的发生,有没有制定出逐级上报的流程? 3) Are the defects allowed to escape to down stream? 有没有不良流入下一工站? a) Do not pass defect ( Downstream Internal or To End Customer ) 不流出不良品不流出不良品 (内部下游客户或终端客户) b) Do not make defect( In Own Process ) 不制造不良品不制造不良品（自己的工位）c) Do not accept defect

46、 ( From Upstream) 不接收不良品不接收不良品（从上游工序） d) Do not rework ( Not Build Product Via Rework ) 不允许返工不允许返工（不通过返工生产产品）4) Do you have a common area to view the defect (fish market)? 有没有特定的地点来检讨不良?(fish market 鱼市场) 28Zero Defect ( continue ) 零缺陷零缺陷(续页续页)5) Do you apply 3 Gens? 有没有做到三 现? a) Genba - Actual place

47、 现场 b) Genbutsu - Actual product 现物 c) Genjitsu - Actual fact 现实6) Do you use 5 W ( who, what , where, when, why)+1H (how) where rule and regulation applied? 规章制度的制定有没有运用5W+1H的方法? 7) Do you have hand free inspection station? 视检工站,有没有不需要用手的? 8) Do you have template with navigation or pointer to guide

48、 inspection operators? 有没有模板来辅助视检作业？ 29Zero Defect ( continue ) 零缺陷零缺陷(续页续页)9) Do you apply SDCA,PDCA? and for defects do you apply PDCA? (Problem,Display,Clear & acknowledge) SDCA ( Standardize, Do, Check & Action ) 工作中有没有运用 SDCA、PDCA方法？针对不良现象，有没有运用PDCA的方法？ 10) Do you have Kaizen Newspaper displaye

49、d? 改善活动的海报有没有展示出来? 11) Do you have 1hr, 2hr, 4hr, 8hr tracking system on the floor? (lead to zero defect) 产线有没有跟踪系统，随时了解每1小时，每2小时，每4小时，每8小时的状况？(向零缺陷靠近) 12) Identify POO & POD to solve the problem 当问题发生时,鉴别出问题的起源(POO)和问题的发现点(POD)来解决问题. POO=point of origin (where is the first point are the cause probl

50、em) POD=point of detection (where the point the problem been captured) 13) Learn how to make the defect to understand root cause 研究如何会产生不良, 从而了解根本原因。 30Zero Defect ( continue )零缺陷零缺陷(续页续页)14) Do you have Auto Jidoka implemented in your line? 产线有没有运用自働化系统？ 15) Talk to the defect to understand the roo