精益生产工具

Material Information Empty container Full container 1 Sequence / Timing
4
Mech. Clean
Mech. Clean
Mark
Hydro Test
Cell or Chaku-Chaku line
2
1
Assembly Line
JIT Jidoka
Hydro Test
Outside Cell FPI X-Ray EDM
Weld
End Finish
Scope of Operations
From: Raw material To: Finished Goods
Quality Check
Safety Precaution
Standard Work-in-Process
Zero Defects = 0 Defects Not 3.4ppm
Quality, Quality, Quality…Defects are the Worst Kind of Waste
Batch
Building Quality into the Process Single Piece Flow
Inspect
Transport Process
Inspect
Process
Transportation is integrated into the production process via automation e.g., moving line
Inspect
Process
Inspect
Transport
Production Line Cell 6
Part Number All Parts
Part Name
All Tubes
Operator
Orbital Weld
Flex
Weld
End Finish
Weld
End Finish
Torch Braze
Mech. Clean
Mech. Clean
Mark
Process
Building Quality into the Process 2 ways to perform SPF
Transportation is integrated into the production process via human conveyance e.g., Chaku-Chaku
process of any problem. - an obligation to stop the process until any
problem has been resolved.
Single piece or one piece flow is a means to primarily build Quality into the process. This is achieved by establishing a takt Time, developing std work, and swip. The premise is that an Operator can only work on one piece at a time, and performs a Quick quality check on the CTQs of the process before moving The part to the following process. If a defect is detected, Jidoka Is enacted…the line is stopped, and immediate action is taken To remediate the situation and take countermeasures to prevent reoccurence
e
GPS for GPC
Heijunka
Level Loading
taken from memory Jogger
•Finding a balance between the volume of work
that your organization needs to do and your
capacity
flaw in 100 parts. The next person checks your work and can catch 1/100 so that’s 1/10,000. Then that person Verifies their work and can catch 1/100. That’s 1/1,000,000 errors that can get through.
1. Takt time 2. Std work
Flow: work (process) that is done in conjunction with or simultaneous to transportation
One Piece Flow
• The production is organized into a synchronous chain where each person has a balanced amount of work relative to his/her supplier and customer in the chain.
Single Piece Flow catches Defects immediately • When you find a Defect
• You only have one • You know where it occurred • You Can find/Resolve the Root Cause immediately
The next process is the customer … never send defects !
Check, Do, Verify
Check - The previous operators work. Do - Your work. Verify - That you did your work correctly.
Leveled Production
Leveled production means
Amount of products that can be sold
lowering the peaks among the daily production volumes
HEIJUNKA
as much as possible and making the production flow smooth and unflucuating.
The next process is the customer … never send defects !
Check, Do, Verify
Gets you into Parts Per Million qualityWhen you verify your work, you catch 1
Single Piece Flow
From: The Toyota Produ Inspect catches Defect too Late • When you Finally Find a Defect
• How many more do you have? • Where are they in the process? • What is the root Cause?
Legend
8 Parts
10
Orbital Weld Flex
Torch Braze
9
Weld
End Finish
Weld
End Finish
Mech. Clean
Mech. Clean
Mark
Hydro Test
Weld
6 5
End Finish
7
Weld
End Finish
Supplier
3
Supermarket
Tenants of 1 pcs Flow
• Do Not Make Defects • Do Not Pass Along Defects • Do Not Accept Defect
Quality, Quality, Quality…Defects are the Worst Kind of Waste
Tenants of Single Piece Flow
• Do Not Make Defects • Do Not Pass Along Defects • Do Not Accept Defects
7 Types of Waste
• Defective Parts • Over Production • Inventory • Motion • Transportation • Waiting • Manual Touches
Check, Do, Verify
One Piece Flow
Your customer is the next step in the process. Give to your customer, exactly what they need ( 1 item), exactly when they need it, done perfect every time.
# Lots of
Total Manual & Travel Time
Standard Work-in-Process
Operator
Man/Travel Time
27 - avg lot = 6
Turns