精益生产基本概念介绍

25% 缺陷
基础: 现场改善可消除 75% 的缺陷
为什么要六西格码精益生产？/ Why 6-Sigma Lean ?
对于公司
For the Company • 满足客户需求
• To meet customer demands.
• 客户只会为有价值的行为买单
• Customer is willing to pay for only valueadded activities.
• 保持公司的收益
• Sustained profitability of the company.
对于个人
For You • 为了在旭电的安全工作
• Job security for Solectron
• 集中你的时间成就有价值的分派任务
• Focus your time and effort on valuable tasks.
• 停止步行/检查/查找/重做和其他一些无价 值的行为
• Stop walking, checking, searching, reworking and other non-value activities.
• 加入到工厂的成功当中
• Involved in the success of the Plant.
例如 / Examples： - 贴装元件
- Mounting components on the board;
- 集成电路程序烧制
- Programme IC
- 印刷电路板放入盒子
- Secure PCB to the chassis;
- 手工插装元件
- Handload the components;
• 你的技能和领导能力的提高从而得到认 可
• Your skills and leadership development and the opportunity to be recognized.
什么是有附加值的活动？/ What are Value-Added (VA) activities ?
- 波峰焊操作等
- Wave solder the PCB etc
什么是可增加附加值的行为？/ What are Value–Enabled (VE) activities ?
• 不增加附加值但是必须要做的源自文库情
• Activities which are non-value added but necessary … today
集中在质量上
Quality Focus
基础 Foundation
客户之声 Voice Of Customer; 质量体系 Quality System; 5S ; 平整化生产
Heijunka 不断地改善和提高 Gemba Kaizen (Shop Floor Continuous Improvement)
• 防呆 • 扩展好的改善方法
Printer
SMT
6 Sigma 消除缺陷
• 6 Sigma 项目 • Gage R&R • DOE
立刻有效!
用眼镜看, 采取行 动
75% 缺陷
Test
Solder
PT/HHP test
Test
Test
FQA
Customer Test
用测量系统和数据分析, 再采取行动
• 没有价值的行为会增加生产的成本
• Non-value added activities add cost to manufacturing.
• 要想在竞争激烈的商业环境下生存，就 必须最充分地利用资源
• To survive in this competitive business environment, there is a need to maximise utilisation of resources.
Efficiency Focus
一个流 Single Piece Flow
平衡化生产 Takt Time Production
利用数据分析来解决系统的问题
Systematic Problem Solving Via Data Analysis
自动化 Stop @ Abnormality
检查缺陷 Error Proof
例如/ Examples: - 视觉检查与测试
- Visual inspection and testing
- 为了组装操作在小范围拿取工具和原料
- Small movements to reach for tools or materials for assembly etc;
什么是浪费？/ What is waste ?
精益给客户带来什么?
质量
LEAN Solectron Production System TM
(SPS)
竞争力
灵活性
LEAN Implementation (2004)…1 Of 3 Elements For Customer Value Proposition
消除缺陷的二个途径
现场改善 消除缺陷
精益生产基本概念介绍
SPS 的四个主要组成部分 4 Key Elements Of The Solectron Production System
精益之屋
JIT
拉动生产 Pull Production
House of SPS
Six Sigma
零缺陷 Zero Defects
Jidoka
集中在效率上
• 做不增加产品附加值的工作
• Work which does not increase the value of the products
例如 / Examples - 错料返修
- Rework due to the use of wrong parts;
- 补焊
- Touch-up;
- 当机器运转时，操作工等待的时间
- Operator waiting-time while machine is running;
- 找料，计算
- ARF, looking for parts, counting;
• 客户愿意付钱, 并使产品发生转变或给产品增加价值的行为才是有价 值的生产活动
• Activities that transform the products, or add value to the products which the customer is willing to pay for.