LeanManufacturing4精益生产4英文课件.ppt

1、2023-2-11LeanManufacturing4精益生产4英文LeanManufacturing4精精益生产益生产4英文英文LeanManufacturing4精益生产4英文TPS 全程生产管理目视化管理稳定标准化过程标准生产(Heijunka)及时正确的零件,数量,时间生产节拍持续流程拉动体系快速切换完备物流 Jidoka(现场质量)问题可见性自动停止暂停人与机器分离防错现场质量控制解决根本原因(5 Whys)高品质高品质 低成本低成本 短周期短周期 更安全更安全 高士气高士气简化生产流程排除浪费 lean manufacturing foundations 个人&团队*选择*快速决定

2、*共同目标*交叉培训 减少浪费*Genchi Genbutsu*聚焦浪费*5 为什么*问题解决 持续改进持续改进LeanManufacturing4精益生产4英文line balance adjusting the spread of work evenly between operators to the rate of customer demandremember:TAKT time available work time/customer demandcycle time actual time to complete the tasksLeanManufacturing4精益生产4英

3、文line balancebenefits:improve throughput of assembly lineencourage one-piece flowincrease labour utilisationreduce costLeanManufacturing4精益生产4英文line balanceYamazumi Japanese word literally meaning to stack upstacked bar chart that shows the balance of cycle time workloads between a number of operato

4、rs typically in an assembly line or work cellLeanManufacturing4精益生产4英文line balanceeffects of imbalanceexcess inventoryidle equipmentidle peopleteam dissensionindividual frustrationLeanManufacturing4精益生产4英文line balanceLine Balance ExerciseLeanManufacturing4精益生产4英文problem solvingwithin all organisatio

5、ns there are an endless supply of problemsthe inverse of a problem is an opportunity problems often classed as failures and thus hidden rather than addressed“every problem is an improvement opportunity”LeanManufacturing4精益生产4英文problem solvingtraditional method of correcting problemscorrect problems

6、off line in rework areas/baysadded layers of inspectionreluctance to identify problems&solutions not exploredproblems continue,added cost to correct laterapplication of 6 sigma and SPC to solve problemsLeanManufacturing4精益生产4英文problem solvingnew approach stopping line to fix problems(Jidoka)principl

7、e“get quality right the first time”stop to fix problems do not allow defects to pass through to next processurgency to fix problems challenges people to thinkAndon,Jidoka,Poke Yoke,Standard Work,Problem Solving,Trainingmotivation to identify and solve problemsLeanManufacturing4精益生产4英文problem solving

8、Problem Solving Process1.Define Problem2.Complete root cause analysis3.Consider solutions through consensus4.PDCA5.Reflect and learnLeanManufacturing4精益生产4英文problem solving1.Define the problem go to where the problem is and observe the situation without preconceptioncompare the actual situation to t

9、he standarduse Pareto Analysis to prioritise a number of different problemsset targets for improvement“Carefully aim before firing”LeanManufacturing4精益生产4英文problem solvingPareto Chart(80/20 Rule 80 percent of the problems stem from 20 percent of the causes)LeanManufacturing4精益生产4英文problem solving2.C

10、omplete root cause analysisAnalysis not clouded no preconceived ideas of source of problemAnalysis continued until true“root”cause of problem are discoveredMultiple causes for problems complete comprehensive analysisVarious problem solving tools availableLeanManufacturing4精益生产4英文problem solving5 why

11、s ask“why?”five timesexample:WHY is the press leaking?There is a crack in the oil filterWHY is the filter cracked?Because it gets too hot during useWHY does it get hot?Because cooling system not workingWHY doesnt the cooling system work?Too much dust on coilsWHY is there too much dust on coils?The a

12、ir intake filter is missing!SOLUTION:Replace air intake filterLeanManufacturing4精益生产4英文problem solvingCause and effect(aka Fishbone diagram)Generate a comprehensive list of possible causesLead to greater understanding of the problem4Ms Man,Machine,Materials,Methods(additional Ms include M-environmen

13、t and Measurement)easier identification and analysisLeanManufacturing4精益生产4英文problem solvingLeanManufacturing4精益生产4英文problem solvingHow to draw cause and effect diagramThis is a three step process.Step 1Write down the effect to be investigated and draw the backbone arrow to it.In the example shown b

14、elow the effect is Incorrect deliveries.LeanManufacturing4精益生产4英文problem solvingStep 2Identify all the broad areas of enquiry in which the causes of the effect being investigated may lie.For incorrect deliveries the diagram may then become:LeanManufacturing4精益生产4英文problem solvingStep 3write in detai

15、led possible causes in each of the broad areas of enquiry.Each cause identified should be fully explored for further more specific causes which,in turn,contribute to them.LeanManufacturing4精益生产4英文problem solvingBrainstorminga group creativity technique to generate a large number of ideas for the sol

16、ution of a problembreak out of stale,established patterns of thinking to develop new ways of looking at thingsLeanManufacturing4精益生产4英文problem solving 3.Consider solutions through consensusStep 1.Broadly consider all possibilitiesStep 2.Narrow list by eliminating impractical solutionsStep 3.Evaluate

17、 based on simplicity,cost,quality and ability to implement quicklyStep 4.Develop consensus on the proposed solutionConsensus through cross-functional team supervisor,operator,quality,manufacturing engineering,logistics,design engineering etc LeanManufacturing4精益生产4英文problem solving4.PDCA-also known

18、as Shewhart CycleAn iterative 4 step quality control strategyGet from“problem faced”to“problem solved”LeanManufacturing4精益生产4英文problem solvingP-PlanDevelop action plan to deliver required resultsD-DoImplement solutions rapidlyC-CheckVerify the resultA-ActMake necessary adjustments to solutions and a

19、ction plan and determine future stepsLeanManufacturing4精益生产4英文problem solving5.Reflect&learn from processBecome a learning organization through relentless reflection and continuous improvement(kaizen)LeanManufacturing4精益生产4英文A3 report Telling the story using an A3 reportcommunication process used as

20、 part of problem solving processdocument key information and decisions at each step to share with others for evaluationassist with arriving at consensusWhy A3?Size large enough to display information clearly and concisely and little time needed to share messageWaste elimination extends to all activities of the organisationLeanManufacturing4精益生产4英文A3 reportA3 problem solving story format2023-2-11LeanManufacturing4精益生产4英文