SGM-GMS-CONCEPT通用汽车精益生产系统概览课件.ppt

1、全球制造体系全球制造体系1Welcome！An Overview to GMS全球制造体系全球制造体系2A Lean Manufacturing Management System是一个精益制造管理体系Like An Atom We Need All The Pieces Working Together!全球制造体系全球制造体系3Background背景介绍背景介绍全球制造体系全球制造体系4 New Plant 新工厂+New Product 新产品+New Process新工艺=Quality Problems 质量问题Not True with GMS !GMS决不会这样！Vehicle

2、 Launch Concerns新车型启动关注点新车型启动关注点During a Typical Launch一次典型的启动:Why Global Manufacturing Systems?为什么要为什么要采用采用GMS(通用全球制造体系通用全球制造体系)?全球制造体系全球制造体系5 New Plant 新工厂 +New Product新产品+New Process新工艺=Quality Problems 质量问题J.D.Power,Initial Quality StudyJ.D.Power,初始质量调查初始质量调查1999Mercedes-Benz2002Cadillac CTSYESN

3、O Mercedes-Benz 235 problems per 100 near the bottom of the survey 每100辆车235个问题 在调查中排名靠近末尾 Cadillac CTS88 problems per 100 Ranked SILVER!每100辆车88个问题 排名第二！全球制造体系全球制造体系6Quote from J.Smith(Former Chairman):引自：引自：J.史密斯（主席）史密斯（主席）All GM plants are part of the same company and must operate with one produc

4、tion system with common elements“所有通用工厂同属于同一个公司并且必须在共同的环境中在同一个生产体系下运作所有通用工厂同属于同一个公司并且必须在共同的环境中在同一个生产体系下运作”Assignment任务任务:Summer 96 年夏年夏Develop a Common Global Production System建立一个共同的全球生产体系建立一个共同的全球生产体系Background背景背景全球制造体系全球制造体系7The GM/Toyota Joint Venture GM/Toyota合资公司合资公司 New United Motors Manufac

5、turing Inc.新的联合汽车制造公司 Est.February 1984 in Fremont,California 1984年2月在加利弗尼亚，弗里蒙特成立 GM wanted to learn the Toyota Production System(TPS)GM想学丰田生产体系（TPS)Toyota wanted to learn about manufacturing in the U.S.丰田想学如何在美国造车 Each GM unit was free to study TPS and implement as they saw fit 每个GM的工厂都可以学习TPS,并按需

6、实施全球制造体系全球制造体系8GM-GMSNUMMISATURNCAMI QNPSEisenachNAOGreen Book全球制造体系全球制造体系9Five GM-GMS Principles五项原则五项原则人员参与人员参与不断改进不断改进缩短制造缩短制造周期周期标准化标准化制造质量制造质量全球制造体系全球制造体系10Thinking Way精益概念精益概念全球制造体系全球制造体系11Traditional WayGMS WayqPeople are hired handsqCurrent State is embracedqFunction-driven organisationqGo t

7、o Office&GuessqKnowing OrganisationqQuality seen as a functionqHide MistakesqEgo-driven leadersqComplex Sense-wastefulqSpend time figuring out itselfqPeople are investment in mindsqCurrent State is challengedqCustomer-driven organisationqGo To See&UnderstandqLearning OrganisationqQuality seen as a c

8、ultureqLearn from MistakesqProcess-driven leadersqCommon Sense-simpleqSpend time figuring out enemy Purpose of GMS is to make lean-thinking People&lean Processes to deliver lean Results for the Customer全球制造体系全球制造体系12System Position系统所在的位置系统所在的位置全球制造体系全球制造体系13 Safety安全People人员发展Quality质量 Responsivene

9、ss响应 Cost成本Plant Performance Score Card工厂绩效考核卡工厂绩效考核卡全球制造体系全球制造体系15Goals目标目标=Method方法方法=People Involvement人员参与-People Company人员参与的公司 Continuous Improvement Company持续改进的公司Standard-ization 标准化Built In Quality 制造质量ShortLeadtime缩短制 造周期GMS Supports Attaining Our Goals GMS 支持我们达到目标支持我们达到目标uSafety安全安全u Peo

10、ple人员人员 uQuality质量质量 uResponsiveness响应响应 uCost成本成本PeopleInvolvementStandardizationContinuousImprovementGM-GMSBuilt-In QualityGM-GMS全球制造体系全球制造体系16GMS StructureGoals目标目标NAAPOPrinciples原则原则Core Requirements核心要素核心要素(calibration statements)Tools工具工具Tools工具工具Elements原理原理LAAMGMEMethodsTools工具工具Tools工具工具Glo

11、balMust be Global Common to Have ONE GM-GMS必须是全球共同的必须是全球共同的一个一个GM-GMS全球制造体系全球制造体系17Goals目标Principles 原则Elements 要素CoreRequirements 核心要求Tools 工具Describe the primary state which thecorporation strives to achieve.Reaching thesegoals leads to the complete success of ourcompany 目标：描述公司努力要达到的状态。达到这些目标可引导公

12、司走向成功The leading concepts/philosophyof the company which guide our activities inthe pursuit of success for our company.原则：公司的主导理念，可指导我们的行为，追求公司的成功。Main strategies within each Principle,which must be implemented to ensure successof each principle.要素：每个原则的主要策略，实施策略是每个原则成功的保证。Details which must befollo

13、wed to ensure the success of eachElement 核心要求：实现每个要素成功必须要遵循的细节Methods,activities and systemswhich are used to support the CoreRequirements.They may be used to support multiple Core Requirements.工具：方法，行动和体系用来支持核心要求，也可能用来支持多重的核心要求。Be the Safety Benchmark 确定安全基准PeopleInvolvement人员参与Health and Safety Pr

14、iority 健康和安全第一24 Hr.Incidentfollow up 24小时事故跟踪Green Cross 绿十字全球制造体系全球制造体系18GMS Principle and ElementGMS 原则与要素原则与要素全球制造体系全球制造体系19Each of the 5 GMS Principles is supported by key elements.There are 33 GM-GMS Elements.GMS Principles GMS ElementsGlobal Manufacturing Goals of Safety,People,Quality,Respon

15、siveness&Cost are supported by the GMS Principles.There are 5 GMS Principles:People Involvement 1.Vision/Mission5.Team Concept2.Values6.People Involvement3.Health&Safety Process 7.Open Communication4.Qualified People8.Shop Floor ManagementStandardization9.Workplace Organization10.Management By Takt

16、Time11.Standardized Work12.Visual Management Built-In Quality13.Product Quality Standards 17.Quality System Management14.Manufacturing Process Validation16.Quality Control&15.In-Process Verification Feedback/Feedforward Short Lead Time18.Simple Process Flow 23.Temporary Material 19.Small Lot Packagi

17、ng Storage-CMA 20.Fixed Period Ordering 24.Pull Systems System/Order Parts 25.Level Vehicle Order Schedules 21.Controlled External Trans.26.Supply Chain Management22.Scheduled Shipping/ReceivingContinuous Improvement27.Problem Solving31.Early DFM/DFA28.Business Plan Deployment32.Total Maintenance Sy

18、stem29.Andon Concept 33.Continuous Improvement30.Lean Design of Facilities,Equipment,Tooling and Layout全球制造体系全球制造体系20 F People Involvement Elements人员参与原理人员参与原理 Vision，Value and Culture Priority愿景，价值观与企业文化愿景，价值观与企业文化 Mission 使命使命 Health&Safety Priority 健康与安全第一健康与安全第一 Qualified People合格的人员合格的人员 People

19、 Support System/Team Concept 人员支持体系人员支持体系/团队精神团队精神 People Involvement人员参与人员参与 Open Communication Process开放式沟通流程开放式沟通流程 Shop Floor Management车间现场管理车间现场管理F Definition:The process whereby our employees are engaged as enthusiastic participants and valued contributors to our success.F定义：员工凭之热情工作的程序和评估贡献的

20、程序FPurpose:People are our Companys most valuable asset.Our people and our company culture represent the healthy roots and trunk which support the methods and tools of our plant.Without involved people,the methods and tools will not be successful.F目的：人员是我们公司最宝贵的资产资产。我们的人员和我们的公司文化代表的是健康的根和树干，可以用来支持我们这

21、颗大树的方法和工具。没有人员的参与，就不会有方法和工具Leaves=ToolsSOSStandardized WorkTrunk=PeopleProblem SolvingTPMRoots=CultureOne Pc.Flow5SBranches=Methods全球制造体系全球制造体系21Green cross SheetManufacturing Safety Performance WallBPD-Group Information Board Nerve Center-Group Leader MeetingArea BPD Visualization 全球制造体系全球制造体系22Saf

22、ety Lockout ProcedureGroup AreaOpen Office Flexibility Chart全球制造体系全球制造体系23F Definition:Standardization is a dynamic process by which we set standards of terminology,principles,methods,and processes within our organization.定义：标准化是我们在自己的组织中建立术语、原则、方法和程序标准的动态动态的程序F Purpose:The purpose of standardizatio

23、n is to stabilize,so as to achieve a base from which to grow and improve.F 目的：标准化的目的是为了达到稳定以完成可以用来发展和改进的基础Standardization标准化标准化WorldClass世界级世界级Continuous Improvement不断改进不断改进Change改变改变F Standardization Elements标准化原理标准化原理 Management by Takt Time时间管理时间管理 Workplace Organization工作现场管理工作现场管理 Standardized

24、Work标准化作业标准化作业 Visual Management目视化管理目视化管理全球制造体系全球制造体系24Safety VisualizationVisual Management-Air,water flowTeam member operation certification boardWorkplace organization-5S 全球制造体系全球制造体系25 Fixed Position Stop(Marked On Shop Floor)Trim Line Final Process AreaCode 1 Control Process全球制造体系全球制造体系26F Bui

25、lt-In Quality Elements制造质量原理制造质量原理Product Quality Standards产品质量标准产品质量标准Manufacturing Process Validation 制造工艺验证制造工艺验证In-Process Control&Verification 流程中控制和验证流程中控制和验证Quality Feedback/Feedforward质量反馈质量反馈/前馈前馈Quality System Management质量体系管理质量体系管理F Definition:The methods by which quality is built into th

26、e manufacturing process,in a way that defects are prevented,detected,and countermeasures are implemented to prevent recurrence.定义：在制造过程制造过程中制造质量、防止缺陷、检测和实施防止问题再次发生的对策的方法F Purpose:To ensure that defects are not passed to the customer.3F 目的：确保有缺陷的产品不会达到客户手中Accept允许Build制造Ship传递The Built-In-Quality Mot

27、to制造质量格言全球制造体系全球制造体系27In house stamping panel inspection Boundary Sample-Visualization CARE Line Quality CheckError Proofing全球制造体系全球制造体系28QCOS Trend Control SheetANDON-Quality CallFinal Process Area Code 1 Control ProcessQCOS Sheet全球制造体系全球制造体系29FDefinition:The movement of product or material in the

28、right quantity,at the right time,to the right location,with the right equipment,using the shortest lead time and the lowest possible cost for both the supplier and the customer.定义：让供应商和客户在最短的制造周期内用尽可能低的成本，在正在正确的地点使用正确的设备生产出正确的数量的产品或物料的运作确的地点使用正确的设备生产出正确的数量的产品或物料的运作FPurpose:To achieve customer enthus

29、iasm by delivering the customer his/her product more quickly,while maintaining good quality.Ultimately,our Company benefits through cost reduction and increased customer loyalty.目的：保证优质质量的同时，通过更快传递客户产品来获得客户热诚。最终，我们的公司会受益于降低的成本和提升的客户忠诚。F Short Lead Time Elements 缩短制造周期要素缩短制造周期要素Small Lot Packaging小包装

30、小包装Fixed Period Ordering System 固定周期订单体系固定周期订单体系Controlled External Transportation受到控制的外部交通受到控制的外部交通Simple Process Flow简单的流程简单的流程Scheduled Shipping/Receiving有计划的运送有计划的运送/接收接收Temporary Material Storage临时物料储存临时物料储存Internal Pull/Delivery内部拉动内部拉动/运送运送Level Vehicle Order Schedules水平车辆订单计划水平车辆订单计划Supply C

31、hain Management供应链管理供应链管理long lead-timeshort lead-timeJ L 全球制造体系全球制造体系30Material Andon Light BoardKANBAN PostKanbanMaterial ANDON全球制造体系全球制造体系31The Continuous Im provem ent CycleStandardizationIm provem entStandardizationStandardizationStandardizationIm provem entIm provem entFDefinition:A process ba

32、sed on standardization,whereby improvement is made,through a series of small improvements.定义：一个基于标准化，通过一系列小的一系列小的改进来达到改进的程序。FPurpose:To always advance ahead towards an ever more challenging target and make progress in Safety,People Involvement,Quality,Responsiveness,and Cost through the elimination

33、of waste.目的:不断向前挑战更多的目标并且通过减少浪费在安全、人员参与、质量、响应和成本方面取得进步F Continuous Improvement Elements不断改进要素不断改进要素Problem Solving 问题解决问题解决Business Plan Deployment 业务计划部署业务计划部署Andon Concept 暗灯原理暗灯原理Lean Design of Facilities,Equipment,Tooling and Layout 设施、设备、工具和平面布置的精益设施、设备、工具和平面布置的精益设计设计Early Manufacturing and Des

34、ign Integration(DFM/DFA)制造和设计的早期结合（制造能力设制造和设计的早期结合（制造能力设计、装配设计计、装配设计）Total Maintenance System/Total Productive Maintenance 全员维护体系全员维护体系/全员生产性维修全员生产性维修Continuous Improvement Process 持续改进流持续改进流程程FThe diagram above shows how each time an improvement is implemented,it creates temporary instability.There

35、 will be a short period of instability until new standards are set,and applied.Only once the situation is truly stable,can new improvements be implemented.上面这张图表显示出每次改进之后，都会带来暂时的稳定。而后会有一段短时间的不稳定，直到建立并应用新的标准。只有当情况真正稳定了，新的标准才能实施。改进改进改进标准化标准化标准化标准化全球制造体系全球制造体系32ANDON BoardSGM Line Balance Wall Pilot Ar

36、ea(Building Line Balance Wall)Creform Assembly Aid全球制造体系全球制造体系33GMS In SGM全球制造体系在上海通用汽车全球制造体系在上海通用汽车全球制造体系全球制造体系34 My Understanding of GMS Experience Share Q&A全球制造体系全球制造体系35 Thanks!全球制造体系全球制造体系36上海通用汽车的宗旨上海通用汽车的宗旨 依靠一支训练有素、富有使命感和团队精神的员工队伍，贯彻精益管理原则，注重不断学习和积极创新。安全地为顾客提供高质量的产品和服务，使上海通用汽车成为面向二十一世纪，国内领先、

37、在国际上有竞争力的汽车公司”。愿景：使上海通用汽车成为面向二十一世纪，国内领先、在国际上有竞争力的汽车公司使命：安全地为顾客提供高质量的产品和服务方法：依靠一支训练有素、富有使命感和团队精神的员工队伍，贯彻精益管理原则，注重不断学习和积极创新。全球制造体系全球制造体系37Shanghai General Motors Core Values 上海通用汽车的核心价值上海通用汽车的核心价值以客户为中心 Customer Focus以满足客户需求的程度作为衡量工作成效的标准 We will measure our performance by determining whether it has m

38、et customers satisfaction安全 Safety充分关注人的安全和健康以及环境安全 We will pay full attention to peoples safety and health as well as the safety of environment充分授权的团队合作 Empowered Teamwork创造良好氛围，积极发挥员工与合作伙伴特点、长处 We will promote an environment in which the unique qualities of each employee and partner can be employe

39、d to win.诚信正直 Integrity成为值得信赖的公司和员工 We will be a trustworthy organization and employee持续改进与创新 Continuous Improvement&Innovation更好、更快、更有效，更多运用新思维 We will do things better,faster,more effective and implement more new ideas全球制造体系全球制造体系38People Involvement Elements 1Corporate Vision,Values,&Cultural Pri

40、oritiesDefinition:The Corporations desired state as well as attitudes,mindsets,beliefs,and behaviors each of which is critical to the success of the organization.Purpose:To guide individual behavior and organizational decisions,creating a process and results focused culture.MissionDefinition:A local

41、 statement that conveys a mental image of the goal or desired state for a specific plant or function.Purpose:To motivate/inspire people to act and help the entire workforce visualize,understand,and relate to the organizations competitive goals and objectives.全球制造体系全球制造体系39People Involvement Elements

42、 2Health and Safety PriorityDefinition:Implementation of behaviors,actions,policies,and practices that help our employees realize a healthy,injury free environment.Purpose:To ensure we protect the well being of our people through actions consistent with the belief that safety is our overriding prior

43、ity and all accidents are preventable.Qualified PeopleDefinition:People at all levels of the organization that possess the required profile and skills to perform,thrive,and grow within a competitive manufacturing environment.Purpose:To ensure the best possible fit of peoples abilities with the expec

44、tations of the competitive manufacturing roles and responsibilities.全球制造体系全球制造体系40People Involvement Elements 3People Support System/Team ConceptDefinition:Small groups of employees that are empowered to function as the owners and basic work unit who share common tasks,support each other,and achieve

45、 common goals through continuous improvement.Purpose:To involve employees in the work process to continuously improve performance,product quality,and working conditions through teamwork.To develop employee pride,job satisfaction,and personal growth.People InvolvementDefinition:Systems,procedures,pra

46、ctices,and programs that involve all employees as active participants in continuous improvement activities.Purpose:Create and maintain an environment which fosters a spirit of pride.“全球制造体系全球制造体系41People Involvement Elements 4Open Communication ProcessDefinition:Behaviors and practices that create a

47、n environment that fosters a free and open flow of communication at all levels.Purpose:To exchange information that helps people at all levels make informed decisions and improve organizational performance.Shop Floor ManagementDefinition:The behavior of management and support groups to go to where the work is performed,to understand,support,and manage the operations.Purpose:To ensure that decisions are made at the work site by utilizing relevant,factual,accurate,and first-hand information.