标准化作业培训教材

Solve Problems解决问题（异
常情况处理）
React to fires救火 Search for things
寻找物品
Prevent Problems预防错误 Find Things Easily
更容易找到物品
Engineers design processes
– 干的更多，并不总意味着更好。生产必要的产品来满足当前的需求。
• Documenting Current Process that are Out of Control
文件化当前超出控制范围的工艺。工业化两个特征：效率、品质的一致性。
– Excessive Variation and Instability of the Process must be Eliminated FIRST in Order to Develop Standard Work
– 为了发展标准化作业，必需首先消除工艺上过多的变异及不稳定性。（系统性误 差和偶然性误差）
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Philosophy
Goals of Standard Work:标准化作业的目标
• Capture and Use the BEST Method.追寻并使用最优的方法（动作、顺序
、制造工艺、行走及物流路线）
• 更改的简易性-持续改进 （节拍变、方便进一步改进，持续改进）
• Identify areas of WASTE which are Opportunities for Improvement. 通过标准化作业过程，识别有机会改进的浪费 • Each step in a Lean Process should be Defined and must be Performed Repeatedly in the Same Manner.
IMI Cornelius Learning & Innovation
Standard Work / 标准化作业
Introductions / 介绍
• Your name?/ 你的名字？
• How long have you been with the company?/ 你来公司多久了？
• What you do and where?/ 你都做些什么工作？在哪做？ • What is something that we wouldn‟t know about you unless you told us?/ 有没有你不告诉我们，我们就不知道的事情？ • What experience have you had with Kaizen, Visual Management, Problem Solving at the workplace?
• Build Quality, Safety, Work In Process (WIP) limits and Productivity Considerations into Process Steps.
• 将质量、安全、在制品控制、以及生产力因素考虑到程序当中去
• Change Easily – Continuous Improvement.
程序方法由工程师自行设计
Process Design by Associate Consensus
程序方法由相关人员协商设定
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Philosophy
Who Generates Standard Work? 谁来制定标准化作业程序？
• The Supervisor / Leader and Manufacturing Engineer / Technician MUST work with the Associates of the area.
• Reduction in Process Variability (if followed).减少程序（工艺）可变性 • Improve Process Stability.改善工艺稳定性（标准化） • Easier to Train New / Existing Operators容易培训新/老员工。 • Increase in Safety and Quality.提高安全性和质量。 • Baseline for Further Improvements.将来改进的基础。 • Reduce Inventory and Reduce Lead Time.减少库存（WIP）及提前期。 • Increase Productivity.提高生产力 • Standardize Manufacturing Process.标准化制造程序 • Increase Capacity Without Increase in Resources.
• 标准化文件的建立需要大家共同的努力以达到有效果的目的。否则它们是注定失败的。
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Philosophy
Benefits of Standard Work标准化作业的好处
• Documentation of the Actual Process and Improvements.
• 记录（文件化标准化）实际工艺及改进
– Improve the “STATUS QUO”. – 改善现状
• Helps ESTABLISH the best and most reliable methods and sequences for each process. • 帮助建立每一道工序的最优及最可靠的方法和顺序。
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Philosophy
What Does Standard Work Look Like?
标准化作业看起来像什么？
Traditional Work
传统作业
Standard Work
标准化作业
Manage Symptoms
管理特征（侧重于人员管理，而非标准化 制度化管理）
• 主管/领导和制造工程师/技师必须与本领域的负责人合作。
• The Creation of the Documents needs to be a Joint Effort in order to be Effective otherwise they are Doomed for Failure.
It is very important that the concepts are well understood at the end of the week / 概念易懂很重要
Focus on session – no blackberries, e-mail, computers outside of breaks /
Open honest and direct communication / 开诚布公的直接的对话 Always ask questions / 总是问问题 We will take the time to explain and gain understanding 我要要花时间去解释和理解
标准化作业看起来像什么？
• Operation Methods are Documented and Posted at the Work Station.操作方法被记录并张贴在工作站旁。 • Operators follow the Same Steps each time they do Work.每次工作，操作员都遵守同样的步骤。 • Operators use the Same, Proper Tools and Machines.
• 精益程序的每一步都需要定义，并且必须以同样的方式重复执行。（标准化，可执行的系统）
Minimize and Control Variations in Output to Improve Quality
通过最小化产出（JIT）并控制过程变异来提高质量
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Philosophy
What Does Standard Work Look Like?
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What is Standard Work ? / 标准化作业是什么？
• The BEST and AGREED UPON combination of people, machines, and materials to do a job with MINIMAL WASTE. • 是将人、机器、材料最好的整合在一起工作，只产生最小的浪费 • • • • • • CLEAR, accessible documentation of that best combination. 使整合文件清晰、易懂 Work done CONSISTENTLY, guided by the documentation. 工作要始终如一的遵循标准文件的规定 An ongoing search for BETTER standard processes. 持续的寻找一个更优的标准化程序
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What is Standard Work ? / 什么是标准化工作？ Standard Work Definition: 标准化定义： – A Precise Description of Each Work Activity, Specifying Cycle Time, TAKT Time, the Work Sequence of Specific Tasks, and the Minimum Inventory or Parts Needed to Conduct the Activity. – 每一项工作的精确定义，具体到工作周期（CT） ，工作节拍（TT），工作顺序，最小库存量或在 制品数量（WIP）等进行定义和指导.
• 有没有Kaizen，可视化管理及解决问题的现场经验？
• What are your expectations of this workshop – what do you hope to learn?对工厂你有什么期望-你希望学习些什么？