伟创力制造系统介绍FMS DL---Chinese & English Version
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11
7 Types of Waste七种浪费
6. Waiting等待
Waiting for… man, machine, materials, information, etc.等待…人,设备,物 料,信息等 - Unbalanced workload工作量不平衡 - Unplanned downtime无计划的停机时间 - Poor workplace discipline工作场所无纪律
Lean Manufacturing精益制造
CUSTOMER
ORDER客户
订单
Waste浪费
PRODUCT
SHIPMENT
出货
Lead Time (Shorter)生产周期(更短)
Cycle Time and Waste生产周期和浪费
Types of Waste*1 七种浪费
Transportation 运输 Inventory库存 Motion动作 Waiting等待 Over production过量生产 Over-processing不必要的过程 Defects缺陷
❖ Highly Motivated and Creative People ❖ 高主动性和创造性的人员
*Toyota Production System
3
DFT* in Flex Today 伟创力目前实施的需求流程技术
*Demand Flow Technology 需求流程技术
4
The Universal Lean Principles普遍的 精益原则
out the waste in processes. 精益生产是这样一种制造业哲学,它认为生产
周期,员工的操作方法是造成浪费的主要原因,并致力于消除这些浪费
Business as Usual
正常工作
CUSTOMER ORDER客户订单
Waste浪费
PRODUCT SHIPMENT出货
Total Lead Time生产周期
Value Stream价值流
Identify the Value Stream and remove all the
Wastes 识别价值流,消除浪费
Value价值
Correctly Specify Value
of Product/Service with Customer in mind从正确 识别产品/服务的价值,始
- Not using Poka-yoke*1没采取防错法
- Lack of Standardization, inconsistent work methods缺乏标准化,不一致的工作方
法
- Ineffective communication 无效的沟通
- Little investment in training 缺乏培训
Examples:举例: - Looking for tools to repair machines寻找工具维修设备 - First piece waiting for the entire batch to finish第一件等待整批完成 - People idle because of no materials to work on因为缺料造成的人员空闲 - Waiting for instructions to proceed等待继续的指示
10
7 Types of Waste七种浪费
4. Over-processing不必要的过程
Processing beyond the customer’s (internal or external) requirements过程 超过客户(内部或外部)的要求 - Poor knowledge of specs or customer requirements缺乏对客户规格或要求的 知识 - Inconsistent work methods (non-standardization) 不一致的工作方法(非标准化) - Ineffective communication 无效的沟通
Examples: - Anywhere sequential operations are broken任何连续作业中断的地方 - Material stored too far from workstation物料存储离工作站太远 - Too many conveyors, forklifts, pallet trucks, etc.过多的传送带,铲车,叉车
Create Value
Banish Wastes Flex E2E Value Stream
Flex Manufacturing System
A Basic Introduction to FMS 伟创力制造系统FMS介绍
Awareness Session for DL 直接员工认知课程
A Brief Introduction to FMS FMS 简介
Create Value
Banish Wastes
Flex E2E Value Stream
Flex Manufacturing System
伟创力制造系统
6ห้องสมุดไป่ตู้
Flex Manufacturing System (FMS) 伟创力制造系统
Lead Time Improvement + Banish Wastes Drive Value Creation 缩短生产周期+消除浪费以驱动价值创造
7
Why Lead Time is crucial to become Lean? 为什么生产周期在精益生产中如此的至关重要
Lean is a manufacturing philosophy that recognizes WASTE as the
primary driver of cycle time, and employs techniques to continually drive
Waste 浪费
Waste 浪费
*1 Prompter: Who is “TIM WOOD”?
敦促者:谁是”TIM WOOD”
MUDA* = Waste MUDA=浪费 *Japanese
9
7 Types of Waste七种浪费
1. Overproduction过量生产
Making more-earlier-faster than the next process or customer needs it相对 于下一工序或客户过早过快生产
• Proper handling of PCB and materials恰当的处理物料
• Follow the takt time, work to cycle time of the process跟随 节拍时间工作以形成过程的周期时间
❖ Built-In Quality (Jidoka)过程品质控制(自动化)
Error Proofing – Poka Yoke防错法 Visual Controls目视控制
❖ Operational Stability 操作稳定性
Standardized Work 标准化作业 Robust Products & Processes 强大的产品&工艺 Total Productive Maintenance 全员生产性维护保养 Supplier Involvement 供应商参与 Kaizen改善 5S/Visual Management 5S/可视化管理
Shorten Production Flow by Eliminating Waste通过消除浪费缩短生产流程
❖ Just In Time 准时生产
Right Part at the Right Time in the Right Amount只在正确的时间生产正确的产品和数量 Continuous Flow 连续流 Pull Systems拉动系统 Level Production分级生产
Produce only to the Pull of Customer Demand以
客户需求拉动生产
5
The Origin of FMS : Flex Manufacturing System伟创力 制造系统的起源
Toyota Production System丰田生产系统
LEAN精益生产
DFT需求流程 技术
Examples:举例: - Manually cleaning product because of dirt用手清除产品上的尘土 - 100% visual inspection at end-of-line线末100%目视检验
5.Transportation运输
Inefficient movement of people, materials and information in the organization人员,物料和信息的低效率的移动 - Poor layout差的工厂布局 - Inefficient “flow” 低效的流动 - Carrying large inventories大量库存 - Exposes product to potential damage/loss during transportation产品在运输过 程中遭受潜在的损害/损失
• TPS, DFT, & Lean •丰田生产系统,需求流程技术,&精益生产 • Integrating Lean & DFT FMS •FMS是精益生产&需求流程技术的集成
2
TPS*: Present Day Structure丰田生产系统的结构
❖ Quality, Cost, Delivery 品质,成本,交期
7. Motion动作
Unnecessary movement of people, parts or machines within the process生产过程中,不必要的人员,工件或机器的移动 •Poor layout不好的工厂布局 •Inefficient Workplace Organization工作场所缺乏组织 •Lack of Standardization, inconsistent work methods缺乏标准化,不一致的工作方法 •Increase operator fatigue leading to other wastes e.g. defects 增加作业员疲劳造成浪费, 如缺陷 •Ergonomic issues causing health e.g. repetitive motion injuries, etc.工效问题对健康的影 响,如重复的动作性伤害
3. Inventory库存
Any supply in excess of one-piece flow一个流之外的任何供给品 - Often the result of “Overproduction” 常常是”过量生产”的结果 - Unbalanced workload工作量不平衡 - Improper scheduling不适当的计划 - Unreliable suppliers不可靠的供应商
- Just in case logic以防万一的逻辑
- Unbalanced workload工作量不平衡
- Improper scheduling不适当的计划
*1 - also called
2. Defects缺陷
mistake or errorproofing
Not doing work Right the First Time没有做到第一次就把工作做对
终考虑客户的需求
Flow流程
Make the Product and Value Flow Smoothly理
顺产品关系和价值流
Perfection完成
Wastes Elimination as
an Ongoing Process towards Perfection浪费
消除,流程趋于完善
Pull拉动
12
How can I contribute to eliminate waste?怎样才能 消除浪费
• Understand the different types of waste理解不同的浪费种类
• Identify them识别浪费
• Carry out your process according to procedure按照程序实施你的方法
7 Types of Waste七种浪费
6. Waiting等待
Waiting for… man, machine, materials, information, etc.等待…人,设备,物 料,信息等 - Unbalanced workload工作量不平衡 - Unplanned downtime无计划的停机时间 - Poor workplace discipline工作场所无纪律
Lean Manufacturing精益制造
CUSTOMER
ORDER客户
订单
Waste浪费
PRODUCT
SHIPMENT
出货
Lead Time (Shorter)生产周期(更短)
Cycle Time and Waste生产周期和浪费
Types of Waste*1 七种浪费
Transportation 运输 Inventory库存 Motion动作 Waiting等待 Over production过量生产 Over-processing不必要的过程 Defects缺陷
❖ Highly Motivated and Creative People ❖ 高主动性和创造性的人员
*Toyota Production System
3
DFT* in Flex Today 伟创力目前实施的需求流程技术
*Demand Flow Technology 需求流程技术
4
The Universal Lean Principles普遍的 精益原则
out the waste in processes. 精益生产是这样一种制造业哲学,它认为生产
周期,员工的操作方法是造成浪费的主要原因,并致力于消除这些浪费
Business as Usual
正常工作
CUSTOMER ORDER客户订单
Waste浪费
PRODUCT SHIPMENT出货
Total Lead Time生产周期
Value Stream价值流
Identify the Value Stream and remove all the
Wastes 识别价值流,消除浪费
Value价值
Correctly Specify Value
of Product/Service with Customer in mind从正确 识别产品/服务的价值,始
- Not using Poka-yoke*1没采取防错法
- Lack of Standardization, inconsistent work methods缺乏标准化,不一致的工作方
法
- Ineffective communication 无效的沟通
- Little investment in training 缺乏培训
Examples:举例: - Looking for tools to repair machines寻找工具维修设备 - First piece waiting for the entire batch to finish第一件等待整批完成 - People idle because of no materials to work on因为缺料造成的人员空闲 - Waiting for instructions to proceed等待继续的指示
10
7 Types of Waste七种浪费
4. Over-processing不必要的过程
Processing beyond the customer’s (internal or external) requirements过程 超过客户(内部或外部)的要求 - Poor knowledge of specs or customer requirements缺乏对客户规格或要求的 知识 - Inconsistent work methods (non-standardization) 不一致的工作方法(非标准化) - Ineffective communication 无效的沟通
Examples: - Anywhere sequential operations are broken任何连续作业中断的地方 - Material stored too far from workstation物料存储离工作站太远 - Too many conveyors, forklifts, pallet trucks, etc.过多的传送带,铲车,叉车
Create Value
Banish Wastes Flex E2E Value Stream
Flex Manufacturing System
A Basic Introduction to FMS 伟创力制造系统FMS介绍
Awareness Session for DL 直接员工认知课程
A Brief Introduction to FMS FMS 简介
Create Value
Banish Wastes
Flex E2E Value Stream
Flex Manufacturing System
伟创力制造系统
6ห้องสมุดไป่ตู้
Flex Manufacturing System (FMS) 伟创力制造系统
Lead Time Improvement + Banish Wastes Drive Value Creation 缩短生产周期+消除浪费以驱动价值创造
7
Why Lead Time is crucial to become Lean? 为什么生产周期在精益生产中如此的至关重要
Lean is a manufacturing philosophy that recognizes WASTE as the
primary driver of cycle time, and employs techniques to continually drive
Waste 浪费
Waste 浪费
*1 Prompter: Who is “TIM WOOD”?
敦促者:谁是”TIM WOOD”
MUDA* = Waste MUDA=浪费 *Japanese
9
7 Types of Waste七种浪费
1. Overproduction过量生产
Making more-earlier-faster than the next process or customer needs it相对 于下一工序或客户过早过快生产
• Proper handling of PCB and materials恰当的处理物料
• Follow the takt time, work to cycle time of the process跟随 节拍时间工作以形成过程的周期时间
❖ Built-In Quality (Jidoka)过程品质控制(自动化)
Error Proofing – Poka Yoke防错法 Visual Controls目视控制
❖ Operational Stability 操作稳定性
Standardized Work 标准化作业 Robust Products & Processes 强大的产品&工艺 Total Productive Maintenance 全员生产性维护保养 Supplier Involvement 供应商参与 Kaizen改善 5S/Visual Management 5S/可视化管理
Shorten Production Flow by Eliminating Waste通过消除浪费缩短生产流程
❖ Just In Time 准时生产
Right Part at the Right Time in the Right Amount只在正确的时间生产正确的产品和数量 Continuous Flow 连续流 Pull Systems拉动系统 Level Production分级生产
Produce only to the Pull of Customer Demand以
客户需求拉动生产
5
The Origin of FMS : Flex Manufacturing System伟创力 制造系统的起源
Toyota Production System丰田生产系统
LEAN精益生产
DFT需求流程 技术
Examples:举例: - Manually cleaning product because of dirt用手清除产品上的尘土 - 100% visual inspection at end-of-line线末100%目视检验
5.Transportation运输
Inefficient movement of people, materials and information in the organization人员,物料和信息的低效率的移动 - Poor layout差的工厂布局 - Inefficient “flow” 低效的流动 - Carrying large inventories大量库存 - Exposes product to potential damage/loss during transportation产品在运输过 程中遭受潜在的损害/损失
• TPS, DFT, & Lean •丰田生产系统,需求流程技术,&精益生产 • Integrating Lean & DFT FMS •FMS是精益生产&需求流程技术的集成
2
TPS*: Present Day Structure丰田生产系统的结构
❖ Quality, Cost, Delivery 品质,成本,交期
7. Motion动作
Unnecessary movement of people, parts or machines within the process生产过程中,不必要的人员,工件或机器的移动 •Poor layout不好的工厂布局 •Inefficient Workplace Organization工作场所缺乏组织 •Lack of Standardization, inconsistent work methods缺乏标准化,不一致的工作方法 •Increase operator fatigue leading to other wastes e.g. defects 增加作业员疲劳造成浪费, 如缺陷 •Ergonomic issues causing health e.g. repetitive motion injuries, etc.工效问题对健康的影 响,如重复的动作性伤害
3. Inventory库存
Any supply in excess of one-piece flow一个流之外的任何供给品 - Often the result of “Overproduction” 常常是”过量生产”的结果 - Unbalanced workload工作量不平衡 - Improper scheduling不适当的计划 - Unreliable suppliers不可靠的供应商
- Just in case logic以防万一的逻辑
- Unbalanced workload工作量不平衡
- Improper scheduling不适当的计划
*1 - also called
2. Defects缺陷
mistake or errorproofing
Not doing work Right the First Time没有做到第一次就把工作做对
终考虑客户的需求
Flow流程
Make the Product and Value Flow Smoothly理
顺产品关系和价值流
Perfection完成
Wastes Elimination as
an Ongoing Process towards Perfection浪费
消除,流程趋于完善
Pull拉动
12
How can I contribute to eliminate waste?怎样才能 消除浪费
• Understand the different types of waste理解不同的浪费种类
• Identify them识别浪费
• Carry out your process according to procedure按照程序实施你的方法