精益生产基本概念介绍
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• Over production is the worst type of waste as it leads to further waste, such as motion, waiting, transportation, rework.
例如/ Examples:
- 为了周末的野餐,而带了一周的食物
- Boards awaiting press-fit;
- 手工组装的操作员等待板子
- Handload operators waiting for boards etc.
运输 / Transportation
• 工艺过程中不必要的物料和人力移动
• • • Unnecessary movement of parts or people between processes.
• Inventory can be raw materials in warehouse/store or WIP on the line.
• 大量库存会增加成本，并提高损坏，丢失，被盗等的可能性
• High inventory increases the potential for higher operation costs, scrap, loss, theft etc
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
• 防呆 • 扩展好的改善方法 Test Printer SMT Solder PT/HHP test FQA Test Customer Test 用测量系统和数据分析, 再采取行动 Test
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;
• 加入到工厂的成功当中
• Involved in the success of the Plant.
• 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.
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)
精益给客户带来什么?
质量
LEAN Solectron Production System TM (SPS)
- 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事情
• Activities which are non-value added but necessary … today
- Run bottom side faster than top side etc
等待 / Waiting
• 等待材料和机器操作时不做任何事
• Doing nothing while waiting for materials or machine to complete a process.
• 机器和人力利用率低下
• Under utilise machine or manpower
• 实质浪费时间会降低生产运作
• Essential waste time can be filled with productive activities
• 重新平衡生产线会减少等待时间
• Rebalance activities to remove waiting time.
• Over processing • Inventory
过量生产
多余的工作程序 库存
• Motion
• Transportation • Rework
多余动作
运输 返修
• Waiting
• Intellect waste
等待
人才浪费
消除7大浪费
过量生产
多余搬运
多余的工作程序
等待
库存 多余动作
不良品
• To meet customer demands.
对于个人
For You • 为了在旭电的安全工作
• Job security for Solectron
• 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.
什么是有附加值的活动？/ What are Value-Added (VA) activities ?
• 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.
例子 / Examples
- 提早到达, 等待开会
- Arriving an hour early for a meeting;
- 开会迟到, 所以其他与会人员等待
- Coming late for a meeting while the rest are waiting for you;
- 板子等待压配合
生产过剩 / Overproduction
• 客户何时需要，需要什么是我们的生产目的
• Our goal is to produce only what the customers want, when they want it.
• 过量生产是一种最大的浪费，它能够导致更多的浪费，诸如多余动作， 等待，运输，返修;
Six Sigma
利用数据分析来解决系统的问题 Systematic Problem Solving Via Data Analysis
Zero Defects 自动化 Stop @ Abnormality 检查缺陷 Error Proof
Jidoka
集中在质量上
Quality Focus
基础 Foundation
- Bring one weeks worth of food for a weekend picnic; - 存货的返修
- EC rework for inventory;
- 提前36小时备好料
- Kit 36 hours before parts are needed;
- 后道工序运作得比前道工序快
• 差的生产线5S
• Poor 5S on the line
• 例如 / Example:
- Stock up a month’s supply of Maggie Mee when the supermarket is nearby;
- Absenteeism that causes inventory to pile up at certain operations; - Combo boards traffic jam; - Overflow of inventory at parking lots etc
• 集中你的时间成就有价值的分派任务
• Focus your time and effort on valuable tasks.
• 没有价值的行为会增加生产的成本
• Non-value added activities add cost to manufacturing.
• 停止步行/检查/查找/重做和其他一些无价 值的行为
- Operator waiting-time while machine is running;
- 找料，计算
- ARF, looking for parts, counting;
- 走动
- Walking etc.
什么是七大浪费？/ What is “7 + 1 Waste” ?
• Over production
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 ?
多余的工作程序 / Over Processing
• 客户不需求的工艺作业是一种浪费
• Processing beyond what the customer requires is a waste.
• Stop walking, checking, searching, reworking and other non-value activities.
• 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.
• 例如 / Examples: - 传送带太长或工艺间隙太远r gap between process is too far apart;
- 在两站之间不必要的存货, 板子送去清洗和 5DX等
- Unnecessary inventory between stations, boards sent to wash and 5DX etc
立刻有效!
用眼镜看, 采取行 动
75% 缺陷
6 Sigma 消除缺陷
• 6 Sigma 项目 • Gage R&R • DOE
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
库存 / Inventory
• 原料放置不动不能增加附加值
• Materials that are sitting idle do not add value.
• 库存与现金紧密相联
• Inventory ties up cash (million/billion USD)
• 库存可能是仓库里的原料或是生产线上的在制品
• 差劲的物流安排导致不必要的材料运输
Poor logistics layout that cause unnecessary transportation of materials.
• 能造成运输损坏或是产品质量问题等
Can create handling damage and cause production rejects such as knock-off, dropped boards etc
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
House of SPS
拉动生产 零缺陷
JIT
集中在效率上
Efficiency Focus
Pull Production 一个流 Single Piece Flow 平衡化生产 Takt Time Production
• 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
例如/ Examples:
- 为了周末的野餐,而带了一周的食物
- Boards awaiting press-fit;
- 手工组装的操作员等待板子
- Handload operators waiting for boards etc.
运输 / Transportation
• 工艺过程中不必要的物料和人力移动
• • • Unnecessary movement of parts or people between processes.
• Inventory can be raw materials in warehouse/store or WIP on the line.
• 大量库存会增加成本，并提高损坏，丢失，被盗等的可能性
• High inventory increases the potential for higher operation costs, scrap, loss, theft etc
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
• 防呆 • 扩展好的改善方法 Test Printer SMT Solder PT/HHP test FQA Test Customer Test 用测量系统和数据分析, 再采取行动 Test
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;
• 加入到工厂的成功当中
• Involved in the success of the Plant.
• 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.
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)
精益给客户带来什么?
质量
LEAN Solectron Production System TM (SPS)
- 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事情
• Activities which are non-value added but necessary … today
- Run bottom side faster than top side etc
等待 / Waiting
• 等待材料和机器操作时不做任何事
• Doing nothing while waiting for materials or machine to complete a process.
• 机器和人力利用率低下
• Under utilise machine or manpower
• 实质浪费时间会降低生产运作
• Essential waste time can be filled with productive activities
• 重新平衡生产线会减少等待时间
• Rebalance activities to remove waiting time.
• Over processing • Inventory
过量生产
多余的工作程序 库存
• Motion
• Transportation • Rework
多余动作
运输 返修
• Waiting
• Intellect waste
等待
人才浪费
消除7大浪费
过量生产
多余搬运
多余的工作程序
等待
库存 多余动作
不良品
• To meet customer demands.
对于个人
For You • 为了在旭电的安全工作
• Job security for Solectron
• 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.
什么是有附加值的活动？/ What are Value-Added (VA) activities ?
• 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.
例子 / Examples
- 提早到达, 等待开会
- Arriving an hour early for a meeting;
- 开会迟到, 所以其他与会人员等待
- Coming late for a meeting while the rest are waiting for you;
- 板子等待压配合
生产过剩 / Overproduction
• 客户何时需要，需要什么是我们的生产目的
• Our goal is to produce only what the customers want, when they want it.
• 过量生产是一种最大的浪费，它能够导致更多的浪费，诸如多余动作， 等待，运输，返修;
Six Sigma
利用数据分析来解决系统的问题 Systematic Problem Solving Via Data Analysis
Zero Defects 自动化 Stop @ Abnormality 检查缺陷 Error Proof
Jidoka
集中在质量上
Quality Focus
基础 Foundation
- Bring one weeks worth of food for a weekend picnic; - 存货的返修
- EC rework for inventory;
- 提前36小时备好料
- Kit 36 hours before parts are needed;
- 后道工序运作得比前道工序快
• 差的生产线5S
• Poor 5S on the line
• 例如 / Example:
- Stock up a month’s supply of Maggie Mee when the supermarket is nearby;
- Absenteeism that causes inventory to pile up at certain operations; - Combo boards traffic jam; - Overflow of inventory at parking lots etc
• 集中你的时间成就有价值的分派任务
• Focus your time and effort on valuable tasks.
• 没有价值的行为会增加生产的成本
• Non-value added activities add cost to manufacturing.
• 停止步行/检查/查找/重做和其他一些无价 值的行为
- Operator waiting-time while machine is running;
- 找料，计算
- ARF, looking for parts, counting;
- 走动
- Walking etc.
什么是七大浪费？/ What is “7 + 1 Waste” ?
• Over production
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 ?
多余的工作程序 / Over Processing
• 客户不需求的工艺作业是一种浪费
• Processing beyond what the customer requires is a waste.
• Stop walking, checking, searching, reworking and other non-value activities.
• 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.
• 例如 / Examples: - 传送带太长或工艺间隙太远r gap between process is too far apart;
- 在两站之间不必要的存货, 板子送去清洗和 5DX等
- Unnecessary inventory between stations, boards sent to wash and 5DX etc
立刻有效!
用眼镜看, 采取行 动
75% 缺陷
6 Sigma 消除缺陷
• 6 Sigma 项目 • Gage R&R • DOE
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
库存 / Inventory
• 原料放置不动不能增加附加值
• Materials that are sitting idle do not add value.
• 库存与现金紧密相联
• Inventory ties up cash (million/billion USD)
• 库存可能是仓库里的原料或是生产线上的在制品
• 差劲的物流安排导致不必要的材料运输
Poor logistics layout that cause unnecessary transportation of materials.
• 能造成运输损坏或是产品质量问题等
Can create handling damage and cause production rejects such as knock-off, dropped boards etc
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
House of SPS
拉动生产 零缺陷
JIT
集中在效率上
Efficiency Focus
Pull Production 一个流 Single Piece Flow 平衡化生产 Takt Time Production
• 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