精益生产系统
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发现不良品的产生Detect defects when they occur 防止不良品进入下一道工序Prevent defects from
Time ▪ 员工 People
及时生产 ▪ 设备 Equipment
▪ 物料 materials
自▪ 占動地化Space
▪ 提升制程能力 Improve
Process Capability
▪ 减少变量 Minimize
variation
▪ 控制异常
Manage abnormality
均衡生产 Production Smoothing
Tool for creating flow 建立流程的工具
Determines optimal staffing 确定最佳人员配置
Drives capacity analysis & equipment utilization 驱动资源能力分析和设备利用
Must be updated periodically as demand changes 必须按需求变化定期更新
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -4
Lean Production System 精益生产系统
Key Concepts and Tools 关键的概念和工具 Pace to Takt time
(跟上节拍时间) One-piece flow
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -6
拉动式单件流物料补充
One-piece flow with Pull Replenishment
超市运作
Supermarket Operation
I
H
A
B
C
G
F E D
I HG F E D CB A
▪ 减少变量 Minimize variation
▪ 控制异常 Manage abnormality
自 動化 均衡生产 Production Smoothing
Jidoka 自働化
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -5
保持竞争优势 Sustain the Competitive Advantages
提升利益相关者价值Improve Stakeholder Value
精益生产系统 Lean Production System
6西格玛流程能力 (西格玛改善) Six Sigma Process Capability (Sigma Kaizen) 改善突破法 Kaizen Breakthrough Methodology
拉动系统训练 Pull system discipline
定义和实施“标准化作业” “Standard operations” defined and implemented
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 10
工具展示
Tool presentation
按灯Andon
包装线
Pack line
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 16
自働化 Jidoka
A. 减少不良品的工具Tools or Methods to Reduce Defects
Importance of Takt Time 节拍时间的重要性
Net operating time 净操作时间 Customer requirements 客户需求数
Synchronizes operations to customer demand 生产与客户的需求同步
Prevents overproduction 避免过量生产
品质 … 成本… 交货!
Quality… Cost… Delivery!
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 11
Lean Production system
精益生产系统
Efficient Use of
Just in 有效使用
Time Based Management
精益生产系统 Lean Production System
SKB
© 2005 TBM Consulting Group, Inc. All Rights Reserved.
TBM Consulting Group, Inc. is the sole licensee of LeanSigma, a service mark of Maytag Corporation.
原因分析 (定义 / 测量 / 分析 / 改善 / 控制)
Root Cause Analysis (DMAIC)
基本品质工具 Basic QC Tools
先进统计工具 Advanced Statistical Tools
防错措施 Mistake-proofing (Poke-Yoke)
手动操作 Manual Work
▪ 客户所需的产品 What the customer wants ▪ 以客户要求数量 In the quantity the customer wants ▪ 按客户指定时间 When the customer wants it
▪ 使用最少的 While using the minimum:
▪ 原料 Raw materials ▪ 设备 Equipment ▪ 人力 Labor ▪ 场地 Space
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -2
精益生产系统 Lean Production system
Lean Production system
精益生产系统
Efficient Use of
Just in 有效使用
Time ▪ 员工 People
单件流生产, 反时针方向 One-piece flow production, counterclockwise
人机正确结合 Ergonomically-correct operations
站立操作, 边走边做 Standing operations, moving while working
Jidoka
自働化
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 12
自働化是 Jidoka is…
A. 减少不良品
A method for reducing defects
B. 设备自働化，提高生产率
Equipment autonomation
及时生产的好处 JIT Benefits
不能容忍生产异常 Creates a system which is intolerant of production abnormalities
消除生产过程浪费 Eliminates waste in production processes
缩短制造周期时间 Reduces lead times
(单件流) Pull system
(结合拉动系统)
Lean Production system 精益生产系统
Just in
Time 及时生产
Efficient Use of
有效使用 ▪ 员工 People ▪ 设备
Equipment ▪ 物料
materials ▪ 占地 Space
▪ 提升制程能力 Improve Process Capability
to improve productivity
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 13
自働化Jidoka
A. 减少不良品的工具Tools or Methods to Reduce Defects
发现不良品的产生Detect defects when they occur 防止不良品进入下一道工序Prevent defects from
自动操作 Automatic machine work
新标培训 New Standard Operations and training
技巧矩阵, 表现量度 Skill matrix and performance
自働化 – 人机分离 Autonomation – Separate person from machine
过道Aisle
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -7
按实际客户需求生产 Produce to Actual Customer Demand
拉动系统 Pull System
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
及时生产 ▪ 设备 Equipment
▪ 物料 materials
自▪ 占動地化Space
▪ 提升制程能力 Improve
Process Capability
▪ 减少变量 Minimize
variation
▪ 控制异常
Manage abnormality
均衡生产 Production Smoothing
3 -8
实施拉动系统 Implement Pull system
供应商 Supplier
物料超市 Supermarket
线旁供货LSS
现场送料员Water Spider
成品FG
原料RM
生产计划板 Schedule board
生产百度文库板
Production Kanban
SKB
线旁供货LSS
收集看板 Pick-up Kanban
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 15
自働化的要素Jidoka Elements
目视控制Visual control
5S
灯号Andon
零件展示
Parts presentation
标准化工作
Standard work
Jidoka
自働化
驱动成本下降Drives cost reduction
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -3
及时生产 Just-In-Time Is...
▪ 这个系统生产 A manufacturing system which produces:
投递生产看板 Drop Production Kanban
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -9
及时生产的要素 JIT Elements
小巧便宜机器 Small, inexpensive machines in process order
passing to next operation 发现不良品产生根源Identify root causes of defects 消除根源Eliminate root causes 减少或消除不良品Reduce or eliminate defects
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 14
自働化的要素 Jidoka Elements
目视控制
Visual Control
5S 信号灯
Andon
异常反应
Abnormality Response/Reaction
作用 / 责任 Roles and responsibilities
停工指引 Line stop guidelines
精益西格玛变革 LeanSigma transformation
重点缩短制造周期Focus on lead-Time reduction to :
增加客户忠诚度和市场份额 Increase customer Loyalty and Market Share
取得销售和收益双增长 Achieve Growth in Sales & Earnings
Time ▪ 员工 People
及时生产 ▪ 设备 Equipment
▪ 物料 materials
自▪ 占動地化Space
▪ 提升制程能力 Improve
Process Capability
▪ 减少变量 Minimize
variation
▪ 控制异常
Manage abnormality
均衡生产 Production Smoothing
Tool for creating flow 建立流程的工具
Determines optimal staffing 确定最佳人员配置
Drives capacity analysis & equipment utilization 驱动资源能力分析和设备利用
Must be updated periodically as demand changes 必须按需求变化定期更新
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -4
Lean Production System 精益生产系统
Key Concepts and Tools 关键的概念和工具 Pace to Takt time
(跟上节拍时间) One-piece flow
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -6
拉动式单件流物料补充
One-piece flow with Pull Replenishment
超市运作
Supermarket Operation
I
H
A
B
C
G
F E D
I HG F E D CB A
▪ 减少变量 Minimize variation
▪ 控制异常 Manage abnormality
自 動化 均衡生产 Production Smoothing
Jidoka 自働化
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -5
保持竞争优势 Sustain the Competitive Advantages
提升利益相关者价值Improve Stakeholder Value
精益生产系统 Lean Production System
6西格玛流程能力 (西格玛改善) Six Sigma Process Capability (Sigma Kaizen) 改善突破法 Kaizen Breakthrough Methodology
拉动系统训练 Pull system discipline
定义和实施“标准化作业” “Standard operations” defined and implemented
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 10
工具展示
Tool presentation
按灯Andon
包装线
Pack line
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 16
自働化 Jidoka
A. 减少不良品的工具Tools or Methods to Reduce Defects
Importance of Takt Time 节拍时间的重要性
Net operating time 净操作时间 Customer requirements 客户需求数
Synchronizes operations to customer demand 生产与客户的需求同步
Prevents overproduction 避免过量生产
品质 … 成本… 交货!
Quality… Cost… Delivery!
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 11
Lean Production system
精益生产系统
Efficient Use of
Just in 有效使用
Time Based Management
精益生产系统 Lean Production System
SKB
© 2005 TBM Consulting Group, Inc. All Rights Reserved.
TBM Consulting Group, Inc. is the sole licensee of LeanSigma, a service mark of Maytag Corporation.
原因分析 (定义 / 测量 / 分析 / 改善 / 控制)
Root Cause Analysis (DMAIC)
基本品质工具 Basic QC Tools
先进统计工具 Advanced Statistical Tools
防错措施 Mistake-proofing (Poke-Yoke)
手动操作 Manual Work
▪ 客户所需的产品 What the customer wants ▪ 以客户要求数量 In the quantity the customer wants ▪ 按客户指定时间 When the customer wants it
▪ 使用最少的 While using the minimum:
▪ 原料 Raw materials ▪ 设备 Equipment ▪ 人力 Labor ▪ 场地 Space
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -2
精益生产系统 Lean Production system
Lean Production system
精益生产系统
Efficient Use of
Just in 有效使用
Time ▪ 员工 People
单件流生产, 反时针方向 One-piece flow production, counterclockwise
人机正确结合 Ergonomically-correct operations
站立操作, 边走边做 Standing operations, moving while working
Jidoka
自働化
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 12
自働化是 Jidoka is…
A. 减少不良品
A method for reducing defects
B. 设备自働化，提高生产率
Equipment autonomation
及时生产的好处 JIT Benefits
不能容忍生产异常 Creates a system which is intolerant of production abnormalities
消除生产过程浪费 Eliminates waste in production processes
缩短制造周期时间 Reduces lead times
(单件流) Pull system
(结合拉动系统)
Lean Production system 精益生产系统
Just in
Time 及时生产
Efficient Use of
有效使用 ▪ 员工 People ▪ 设备
Equipment ▪ 物料
materials ▪ 占地 Space
▪ 提升制程能力 Improve Process Capability
to improve productivity
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 13
自働化Jidoka
A. 减少不良品的工具Tools or Methods to Reduce Defects
发现不良品的产生Detect defects when they occur 防止不良品进入下一道工序Prevent defects from
自动操作 Automatic machine work
新标培训 New Standard Operations and training
技巧矩阵, 表现量度 Skill matrix and performance
自働化 – 人机分离 Autonomation – Separate person from machine
过道Aisle
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -7
按实际客户需求生产 Produce to Actual Customer Demand
拉动系统 Pull System
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
及时生产 ▪ 设备 Equipment
▪ 物料 materials
自▪ 占動地化Space
▪ 提升制程能力 Improve
Process Capability
▪ 减少变量 Minimize
variation
▪ 控制异常
Manage abnormality
均衡生产 Production Smoothing
3 -8
实施拉动系统 Implement Pull system
供应商 Supplier
物料超市 Supermarket
线旁供货LSS
现场送料员Water Spider
成品FG
原料RM
生产计划板 Schedule board
生产百度文库板
Production Kanban
SKB
线旁供货LSS
收集看板 Pick-up Kanban
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 15
自働化的要素Jidoka Elements
目视控制Visual control
5S
灯号Andon
零件展示
Parts presentation
标准化工作
Standard work
Jidoka
自働化
驱动成本下降Drives cost reduction
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -3
及时生产 Just-In-Time Is...
▪ 这个系统生产 A manufacturing system which produces:
投递生产看板 Drop Production Kanban
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 -9
及时生产的要素 JIT Elements
小巧便宜机器 Small, inexpensive machines in process order
passing to next operation 发现不良品产生根源Identify root causes of defects 消除根源Eliminate root causes 减少或消除不良品Reduce or eliminate defects
SKB
© 2005TBM Consulting Group, Inc. All Rights Reserved.
3 - 14
自働化的要素 Jidoka Elements
目视控制
Visual Control
5S 信号灯
Andon
异常反应
Abnormality Response/Reaction
作用 / 责任 Roles and responsibilities
停工指引 Line stop guidelines
精益西格玛变革 LeanSigma transformation
重点缩短制造周期Focus on lead-Time reduction to :
增加客户忠诚度和市场份额 Increase customer Loyalty and Market Share
取得销售和收益双增长 Achieve Growth in Sales & Earnings