Lean-精益生产基础知识

2006-10-13
Defect 不良品
Overproduction 过量生产
Excess Motion 多余动作
8 Wastes 浪费
Waiting 等待
Processing 加工 Inventories 库存
Transportation 运输
Shenzhen Functional Excellence
METHOD
MATERIAL
Find root cause (找出原因)
(提出改善, 进行试 验)
Develop and test improvement
Gauge 4
Train affected associates in new standard operations
(标准化后, 训练员工)
2006-10-13
Ensures Safety 保证安全
Quality…Cost…Delivery…Safety…
2006-10-13
Shenzhen Functional Excellence
Level Loading Is (均衡生产是)...
Variation in volume 产品数量变化
Level Loading 均衡生产
Same to NVA, but it’s necessary activities.意同非增 值，但该活动是必须存在的.
2006-10-13
Shenzhen Functional Excellence
8 Wastes八大浪费
Management 管理不善
浪费 就是 所做 的工 作只 增加 成本 却不 增加 价值
Ensures on-time delivery (保证准时交货)
Quality…Cost…Delivery…Safety…
2006-10-13
Shenzhen Functional Excellence
Jidoka is (自働化是)…
An immediate response to an abnormal condition within the
Monthly Schedule (3200 units) (每月计划: 3,200个)
Model “A” (型号A) 1600 units (1,600个)
Model “B” (型号B) 800 units (800个)
Model “C” (型号C) 800 units (800个)
5
10
15
20
3
20
Shenzhen Functional Excellence
Level Loading Benefits
(均衡生产的好处)
Maintains a consistent high product quality (保持一致优良品质)
Reduces the requirements for capital investment (减少资金投入需求) Ensures on-time delivery (保证准时交货)
Pull system (拉动生产)
One piece follow (单件流生产)
2006-10-13
Shenzhen Functional Excellence
Takt Time (节拍时间)
Takt, 德语，意为节拍，与英文 Pace 意同。
2006-10-13
Shenzhen Functional Excellence
2006-10-13
Shenzhen Functional Excellence
Abnormality Response Process
(异常反应过程)
Q C D S
Measure impact (衡量影响)
React to problem (发现问题)
MAN MACHINE
EFFECT
Alert team (提醒 同事)
“Now You See It!” (“你看吧!”)
2006-10-13
Solectron Shenzhen Functional Excellence
Pull System (拉动系统)
2006-10-13
Shenzhen Functional Excellence
JIT Elements (及时生产的要素)
标准化作业 灵活的人力系统 稳定性(工艺,人员) 员工与管理者之间的相互信任
改善 5S
2006-10-13
Shenzhen Functional Excellence
Just-In-Time Is (及时生产是)...
A manufacturing system which produces (这个系统生产):
Reduces staffing costs (降低员工成本)
Quality…Cost…Delivery…Safety…
2006-10-13
Shenzhen Functional Excellence
VA & NVA (增值与非增值)
难剔 的除 是浪 如费 何并 发不 现难 浪， 费 。
duct mix 产品品种变化
Adapting production rates to variations in customer demand
调整生产速度, 满足客户变化
2006-10-13
Shenzhen Functional Excellence
Variation in Volume (数量变化)
process (异常情况, 立即响应) Goal: Prevent a defective product from being passed to the next operation. (目的: 防止不良品流向下一工序) Equipment autonomation – capable machine processes that enable separation of machine and operator (设备自働化, 人机分开化) Goal: Multi-process handling, increased labor productivity. (目的: 实现多工序操作, 提升劳动生产力)
Check 2B
Update standard operations with tested improvement
(试验成功, 更改运作)
Shenzhen Functional Excellence
Jidoka Elements (自働化的要素)
目视控制
异常反应
原因分析
防错工程
新标培训
自働化
2006-10-13
(每日计划: 160 个)
Production pattern: AABCAABC
Daily Schedule (160 units)
80
A
80
A
Day (日期)
80
A
80
A
40 40
B C
40 40
B C
40 40
B C
40 40
B C
(生产模式: AABCAABC)
2006-10-13
1
2
Day (日期)
实现多工序操作提升劳动生产力20061013shenzhenfunctionalexcellenceabnormalityresponseprocess异常反应过程reactproblem发现问题measureimpact衡量影响alertteam提醒同事trainaffectedassociatesnewstandardoperations标准化后训练员工maneffectmachinematerialmethodfindrootcause找出原因developtestimprovement提出改善进行试check2bgaugeupdatestandardoperationstestedimprovement试验成功更改运作20061013shenzhenfunctionalexcellencejidokaelements自働化的要素自働化的要素目视控制异常反应原因分析防错工程新标培训20061013shenzhenfunctionalexcellencejidokabenefits自働化的好处自働化的好处increasesproductionquality改善产品质量increasesproductivity提升生产力ensuresontimedelivery保证准时交货ensuressafety保证安全qualitycostdeliverysafety
Shenzhen Functional Excellence
精益生产基础知识
（期刊版）
第一期（总第一期）
2006-10-13
Shenzhen Functional Excellence
Hot Topic目录
Lean House 精益生产屋 Just-In-Time 及时生产 Jidoka 自働化 Level Loading 均衡生产 8 Waste 八大浪费
Shenzhen Functional Excellence
Jidoka Benefits (自働化的好处)
Increases production quality 改善产品质量 Increases productivity 提升生产力 Ensures on-time delivery 保证准时交货
NVA 非增值
Value-Adding Activities (增值活动)…
transform materials and information into products & services which the customer wants. 将物料与信息转变成客户需要的产品与服务
Non-Value-Adding Activities (非增值活动)...
Causes Of Waste (浪费原因)
Layout (distance) (布置距离太远) Long setup times (换模时间太长) Incapable processes (制程能力不足) Poor maintenance practices (保养操作不良)
Lack of training (员 工训练不够) Lack of adherence (制度坚持不久) Supervisory roles (监督作用不大) Irrelevant performance measures (考核无关业绩) Poor work methods (工作方法不对)
1 3
2
3 4 5 3
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Shenzhen Functional Excellence
Toyota Production System House 丰田生产方式（精益生产屋）
安全 品质 成本 交付
及时生产 • 流线生产 • 节拍生产 • 拉动系统
自働化 • 安灯 • 防错系统
均衡生产 设备综合效率
Customer Demand (客户需求)
(每日平均需求 = 生产目标)
Avg. Daily Demand = Target Production
Quantity
(数量)
2006-10-13
Time
(时间)
Shenzhen Functional Excellence
Variation in Mix (种类变化)
• What the customer wants (客户所需产品) • In the quantity the customer wants (客户要求数量) • When the customer wants it (客户指定时间)
While using the minimum (使用最少的):
consume resources, but don‘t directly contribute to the product or service. 消耗资源, 而又不直接贡献于产品和服务
丰 田 生 产 方 式 创 始 人 --大 野 耐 一
NNVA 必要存在的 非增值
Necessary Non-Value-Adding Activities (必要存在的非增值活动)...
One Piece Follow (单件流)
(批量生产)
Batch
Fake Flow (假流线生产)
1-Piece Flow
(单件流生产)
2006-10-13
Shenzhen Functional Excellence
One Piece Follow (单件流)
“A Sea of WIP” (一大堆半成品)
Creates a system which is intolerant of production abnormalities (不能容忍生产异常)
Eliminates waste in production processes (消除生产过程浪费)
Reduces lead times (缩短前置生产时间)
Small, inexpensive machines in process order (小巧便宜机器) One-piece flow production, 单件流生产
JIT Elements (及时生产的要素)
Ergonomically-correct operations (人机正确结合)
Standing operations, moving while working
(站立操作, 边走边做)
Pull system discipline (拉动系统训练)
“Std operations” defined and implemented
(定义和实施“标准化运作”)
2006-10-13
Shenzhen Functional Excellence
JIT Benefits(及时生产的好处)
Raw materials (原料) Equipment (设备)
Labor (人力)
2006-10-13
Space (场地)
Shenzhen Functional Excellence
JIT Principles （及时生产三原理）
及时生产 JIT
Takt time (节拍生产)