一线主管学员手册管理工具：5S、目视化、问题解决

1、continued1 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 5s管理 continued2 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao what is workplace organization? 什么是工作场地有序安排？ trash to wels glov s workplace organization video-

2、wpo 1.工具一：5s-工作场地有序安排(workplace organization) continued3 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 5s 背景 background 跨国企业全球制造(精益生产)系统的策略之一是精益办公/工作环境，它的基 础是全面杜绝浪费。你们将学习如何认清浪费，并用一种称为”5s”的工具来 消除浪费。术语”5s”(或称为用于工作场地有序安排的5个步骤)源于日本toyota, 为获取干净、有序且安全的工作环境所采用的5个

3、词。 a strategy of the multinational global manufacturing system is a lean workplace organization and office environment. the foundation of this strategy is the total elimination of waste. the class you are enrolled in will teach you how to identify waste and how to use a tool called “5s” to eliminate

4、 waste and get your workplace well organized. the term “5s” (or the 5 steps to workplace organization) originally came from 5 words used by toyota to achieve a clean, well organized, and safe workplace. 5s-工作场地有序安排工作场地有序安排 continued4 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou

5、 nantong jinan qingdao 创建并保持安排有序、清洁干净、高效性能的工作场地一种流程和方法 a process and method for creating and maintaining an organized, clean, high-performance workplace 改善所需条件 - 记律a conditioning discipline for kaizen 1 s整理 分离及丢弃(筛选)segregate ; 为那些目前尚无标准的场为那些目前尚无标准的场 所所 制制 定标准定标准; ; 应保证应保证2 2个班次都应知道什么物品贴上了红色标签且都同意将它

6、们清除掉个班次都应知道什么物品贴上了红色标签且都同意将它们清除掉; ; 在将贴上红色标签的箱子或柜子清除之前，应确保它们全部都是空的在将贴上红色标签的箱子或柜子清除之前，应确保它们全部都是空的; ; 在该运动结束时，模拟操作。在该运动结束时，模拟操作。 整理整理 sift 5s-工作场地有序安排工作场地有序安排 continued9 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 设施 - 工具/工作台/桌子/椅子等facilities tools, work ta

7、bles, desks, chairs, etc. 地点 - 地板/书架/房间等location floors, shelves, rooms, etc. 文档 - 通知/通报/备忘录/公告牌等documents notices, circulars, memos, bulletins etc. 机器 - 复印机/计算机/传真机等machines copiers, computers, fax machines, etc. 用具 - 折叠机/装订机/夹纸板等fittings folders, binders, files, etc. 文具 - 铅笔/钢笔/橡皮/夹子/备忘活页簿等station

8、ery-pencils, pens, erasers, clips, memo pads, etc. 其它 -书/杂志/宣传册等others books, magazines, pamphlets, etc. 红色标签活动 red label campaign 什么东西可以贴红色标签? what will be red labeled ? 人人/消防用品不可以贴消防用品不可以贴红色标签红色标签! no red labeled on people/fire pipes! 整理整理 sift 5s-工作场地有序安排工作场地有序安排 continued10 shanghai tianjin shen

9、zhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 到达指定区域go to assigned area. 对指定区域全面拍照photograph assigned area completely. 标明“以前”的照片及日期mark photos “before”and date. 在各区域对各件物品进行讨论，确定是否应贴“红色标签” in each area， discuss each item and decide whether the item should be “red labeled” 采用红色标签

10、张贴标准- use red label standards 在有疑问的物品上亦贴上红标签place a red label on questionable items as well. 在搬动红色标签物品前，应由经理批准before an item is disassembled， manager needs to approve 将贴有红色标签的物品送到汇集处take red labeled item to marshaling area 经理对所有行为有最终审批权 manager has final approval of all actions 贴红色标签的过程the red label

11、ing process 整理整理 sift 5s-工作场地有序安排工作场地有序安排 continued11 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 第二步:整顿 (分类) second s =seiton (sort) 将所有不需要的物品清除出局之后将所有不需要的物品清除出局之后，接下来应使环境有序化。各种物品应归接下来应使环境有序化。各种物品应归 其位其位一亇萝卜一亇坑。物品摆放应按其安全性、质量进行分类一亇萝卜一亇坑。物品摆放应按其安全性、质量进行分类，

12、且在配置且在配置 所需物品时应杜绝搬运浪费。并采用所需物品时应杜绝搬运浪费。并采用”3易易”标准：标准： 易见、易取、易归还易见、易取、易归还 now that all unnecessary material has been removed from the area， it is time to get it organized. a place for everything and everything in its place. everything should be functionally placed for safety， quality， and to eliminate

13、 the waste of motion in locating needed items. the “3 es” should be used: easy to see， easy to get， easy to return. 5s-工作场地有序安排工作场地有序安排 continued12 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 整顿整顿 sort .每件物品都有自己的位置每件物品都有自己的位置 .everything in its place. 为每件

14、物品准备一个地方为每件物品准备一个地方. a place for everything. 5s-工作场地有序安排工作场地有序安排 continued13 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 整顿整顿 sort - 1) categorize for frequency of use. put the number for each item within the appropriate category. 1) 根据使用频率分类 把每件物品的编号填入适当

15、的分类中。 1.tools used by operator for the operation 1.操作人员用于操作的工具 2.replacement parts for 2.设备或工具的备件 3.safety goggles 3.安全眼镜 4.quality check sheets 4.质量检测表 5.parts for vehicles with low frequency options 5.使用频率低的汽车选购件零件 6.cleaning materials 6.清洁材料 7.special cleaning tools for machine maintenance 7.机器维护

16、用的特殊清洁工具 8.tools required for an operation 8.操作需要的工具 整顿整顿 sort 5s-工作场地有序安排工作场地有序安排 continued14 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 第三步第三步:清扫清扫third s = seiso (sweep) 清扫所有的地板、设备、工具、家具、墙壁、桌面、办公桌、工作台等，从 而清除垃圾及尘埃。员工将对其工作环境更为满意，且任何现存问题在此步 骤后将更为醒目。通过清扫工

17、作场地，可以将因垃圾及尘埃而引起的故障降 低到最小程度，提高安全性；而且清扫是一种检查，能够及时地辨别设备问 题，予以纠正。 get rid of trash and grime. clean all floors, machines, equipment, furniture, walls, desktop, workplace etc. cleaning is a form of checking. people will feel better about their work area and problems will be more visible after this step

18、is performed. 5s-工作场地有序安排工作场地有序安排 continued15 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 必须做到必须做到: : 清扫自己的工作环境：清扫自己的工作环境： 桌子、柜子及书架桌子、柜子及书架 清扫公用办公设备：清扫公用办公设备： 传真机、复印机、打印机等传真机、复印机、打印机等 清扫办公室：清扫办公室： 地面、墙壁等地面、墙壁等 清扫地板、墙壁、房梁、天花板，以及清扫地板、墙壁、房梁、天花板，以及 灯灯 罩罩 清扫机器

19、、设备、箱子、清扫机器、设备、箱子、 料料 架和锁架和锁 柜柜 修理泄漏设备修理泄漏设备 重新涂刷路线重新涂刷路线 重新涂刷地板和设备重新涂刷地板和设备 用废料箱装载切削、磨削、钻孔，或者开孔设备用废料箱装载切削、磨削、钻孔，或者开孔设备 废废 碎碎 料料 清扫清扫 sweep 5s-工作场地有序安排工作场地有序安排 continued16 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 清扫清扫 sweep 5s-工作场地有序安排工作场地有序安排 continue

20、d17 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 第四步第四步:清洁清洁 (保持保持)fourth s = seiketsu (sustain) 在放置物品处使用标签、地址标志、彩色编码，及其它视觉工具，使物品一 目了然。应遵从视觉控制管理标准，以确保工作环境清楚明了。将本区域布 局图(layout)及所有应采用的步骤张贴出来，以使工作场地保持清洁有序。使 系统能随时确定异常环境。 use labels, floor markings, color codin

21、g, and other visuals to indicate where items should be located. abide by visual control standard to make sure a visual at glance workplace/office environment. post a layout of the area and all required steps needed to be performed to ensure the workplace remains clean and organized. put systems in p

22、lace to readily identify abnormal conditions. 5s-工作场地有序安排工作场地有序安排 continued18 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 清洁清洁 sustain 确定任务 identify tasks 分派责任 assign responsibility 建立目标 set targets 推广5s promote 5s responsibility chart 责任表 jon lary peter

23、dave greg 1 2 3 4 5 target: major 5s 1/qtr. 目标：主要针对 5s 1/季度 who人员 task任务 5s-工作场地有序安排工作场地有序安排 continued19 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 第五步第五步:素养素养 (自律自律)fifth s = shitsuke (self discipline ) 指派维持各区域精益环境的负责人员。领导者应确认工作有序进行且保持区指派维持各区域精益环境的负责人员。

24、领导者应确认工作有序进行且保持区 域清洁。他们亦可通过此次机会进行指导域清洁。他们亦可通过此次机会进行指导 。 5s措施要求组织中的每一个人均参与。它能正确反映公司的组织状况及员工措施要求组织中的每一个人均参与。它能正确反映公司的组织状况及员工 的参与程度。为获得成功的参与程度。为获得成功，5s措施应得到公司最高领导者的支持措施应得到公司最高领导者的支持 assign individuals who will be responsible for maintaining each area. leaders will verify that the work is being performe

25、d and the area is kept clean. they will also use this opportunity to teach. 5s requires that everyone in the organization is involved. it is a barometer telling how well a company is managed and how much employee participation is present. to be successful， 5s must be embraced by top management/leade

26、rship at your company. 5s-工作场地有序安排工作场地有序安排 continued20 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 素养举例素养举例: 安时上班，有事请假be on time, ask for leave if necessary 休息和午餐后及时返回工位return to workstation on time after lunch/break 遵守各项操作标准follow standardized operations

27、 遵循公司的规章制度和方针政策follow companys riles & regulations 待人客气，可能时给人以帮助be polite, be ready to help 使用、穿戴规定的劳防用品ware necessary ppe 只在指定的区域抽烟smoke only in allowed place 检查所有的工具和材料check tools & materials at work 素养素养 self-discipline 5s-工作场地有序安排工作场地有序安排 continued21 shanghai tianjin shenzhen guangzhou hangzhou

28、suzhou wuxi changzhou nantong jinan qingdao 工作场地的有序安排有利达成我们公司的各项目标工作场地的有序安排有利达成我们公司的各项目标!workplace organization contributes to all our company goals! 安全舒适地操作。安全舒适地操作。operations are performed safely and comfortably. 准确无误地操作，减少浪费。准确无误地操作，减少浪费。(制造质量制造质量) operations are performed without error， resultin

29、g in fewer defects. (built-in-quality) 机械设备得到精心地维修，故障相应减少。机械设备得到精心地维修，故障相应减少。machinery and equipment are carefully maintained， reducing the number of breakdowns. 操作有效地进行，消除了浪费操作有效地进行，消除了浪费。operations proceed efficiently， eliminating waste. 每个人觉得工作环境非常舒适每个人觉得工作环境非常舒适! the environment is pleasant for

30、everyone. 总结总结 wrap-up 5s-工作场地有序安排工作场地有序安排 continued22 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 总结总结 wrap-up 从今以后，你的精益工作环境的标准要么改善，要么恶化， 不太可能一成不变。那么，什么能帮助你改善工作环境？又 有什么会阻碍工作环境的改善呢？ your lean work environment will either improve from todays standard or de

31、teriorate. it probably wont stay just the same . what will help you improve your work environment ? what will keep it from improving? 贵在实践，心动不如行动！坚持不懈!！practice，just do it ! always do it！ 5s的威力只有通过坚持不懈的实施才能体现出来the power of 5s is in the implementation and the follow - through 5s-工作场地有序安排工作场地有序安排 cont

32、inued23 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 目视化管理 continued24 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao a b visualcontrols目视控制 目视控制是指与工作相关的视觉与听觉信号,明白易懂。这类信息可以用于识别、 指示、或指出正常或异常状况的存在以及可能需要采取的措施。 visual

33、controls are job related visual and audio signals that are readily apparent and can be easily understood. this information can be used to identify, instruct, or indicate that normal or abnormal conditions exist and that action may be required. 2.工具二：目视化管理(visualmanagement) continued25 shanghai tianj

34、in shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 目视管理用于目视管理用于visual management is used to: 使标准目视化使标准目视化 make standards visual 显示异常情况显示异常情况 show abnormalities 显示实际与目标之间的差距显示实际与目标之间的差距show actual to target 指导与解释指导与解释instruct and explain 信息交流信息交流communicate information 目视管理目视管

35、理visual management continued26 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 在执行目视管理时必须采取以下步骤：在执行目视管理时必须采取以下步骤：the following steps are necessary for implementing visual management: 1) 定义需求定义需求 define the need 2)决定目视的类型决定目视的类型decide type of visualization 制定标

36、准制定标准set standards 便于理解便于理解easy to understand 显而易见显而易见easy to see 提供重要的信息提供重要的信息provides important information 3) 执行与跟踪执行与跟踪implement and follow-up 目视管理目视管理visual management continued27 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao continued28 shanghai tian

37、jin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 分析问题 continued29 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 3. 工具三：问题解决工具三：问题解决(practical problem solving) 如果你不解决问题，你就是问题。如果你不解决问题，你就是问题。 if you dont solve the problem, you becom

38、e a problem. continued30 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 问题是改进的种子!problems are the seeds for improvement! 问题就是积极的机会!problems are positive opportunities! 没有问题，就是大问题!if there are no problems, than something is wrong! 问题解决问题解决(practical problem s

39、olving) continued31 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 问题并不意味着指责问题并不意味着指责!problems are not about blaming people! 出现问题是由于系统中存在缺陷。出现问题是由于系统中存在缺陷。problems occur because of failures in the system 对于问题，员工负责对于问题，员工负责15% ，系统和管理者负责系统和管理者负责85%。people are

40、responsible for 15%, system & managers 85% 问题解决问题解决(practical problem solving) continued32 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 什么是问题？what is a problem? o 实际情况与现有标准或期望之间的差距。实际情况与现有标准或期望之间的差距。a problem is defined as a discrepancy between an existing

41、 standard or expectation and the actual situation 标准标准 standard 实际实际 actual 差距差距 discrepancy 时间时间 time 水平水平 level 问题解决问题解决(practical problem solving) continued33 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 1 2 34 5 6 描述问题描述问题 problem description 定义问题定义问题

42、problem definition 确定原因确定原因 所在所在 locate point of cause 调查原因调查原因 cause investigation 补救及长期补救及长期 对策对策 band/aid & long-term countermeasure 跟踪和检查跟踪和检查 follow-up & check 问题解决问题解决(practical problem solving) continued34 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingda

43、o 描述问题描述问题problem description -陈述出现的问题陈述出现的问题state the problem that is occurring 1 掌握情况掌握情况 grasp the situation 问题解决问题解决(practical problem solving) continued35 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 定义问题定义问题- -针对具体情况对问题进行定义针对具体情况对问题进行定义 problem defin

44、ition - specifically define the situation o标准the standard o偏差the deviation o持续时间the time period 2 掌握情况掌握情况 grasp the situation 问题解决问题解决(practical problem solving) continued36 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 确定原因所在确定原因所在locate the point of caus

45、e o找出(车辆/部件上)出现问题的位置locate position of occurrence (on the vehicle/ part) o确定原因所在locate point of cause 3 掌握情况掌握情况 grasp the situation 问题解决问题解决(practical problem solving) continued37 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 4 运用5个为什么的调查方法来找出根本原因 5 why in

46、vestigation to find the root cause 调查原因调查原因 cause investigation 问题解决问题解决(practical problem solving) continued38 shanghai tianjin shenzhen guangzhou hangzhou suzhou wuxi changzhou nantong jinan qingdao 5个为什么个为什么5 whys 1.为什么为什么机器人停了why did the robot stop? 保险丝烧断了a fuse in the robot has blown. 2.为什么为什么保险丝烧断了why is the fuse blown? 线路过载circuits overloaded. 3.为什么为什么线路过载why did the circuit overload? 轴承损坏且卡住了the bearings have damaged one another and locked up. 4.为什么为什么轴承会损坏why have the bearings damaged on another? ？ 轴承润滑不够there