manufactory excellence 1

1、 what is manufacturing excellence ? 什么是卓越制造什么是卓越制造 business and manufacturing strategy 经营与制造战略经营与制造战略 manufacturing process vs supply chain 制造与供应链制造与供应链 manufacturing process vs pdca wk15-16 fty changed plastic parts supplier; wk23 slide switch shortage clip ppm level (ave. defects) company 26 motor

2、ola 10 texas instruments 100 hewlett packard (hp) (source: ge 6) world class benchmark process capability defects per million opportunities s sppm 2308,537 3 66,807 46,210 5 233 6 3.4 process quality jan. - aug., 2000 381 245 49 0 4473 605 176 0 391 237 122 333 341 274 614 223 00 163 000 158 0 200 4

3、00 600 800 1000 ppm hq 200/30027134282206266397154109 hq 20/3038124549044736051760 hp000278006100 moulding391237122333341274614 pcb22300163000158 jan.feb.mar.apr.mayjun.jul.aug. targets: hq 20/30/200/300 & hp/pcb - 400 ppm moulding - 500 ppm process quality dap zhuhai 199419951996199719981999 years

4、0% 5% 10% 15% 20% 25% inventories in % of sales dell philips inventories/sales dell - philips benchmark dap zhuhai inventory total days 0 10 20 30 40 50 60 70 80 90 97.1 97.3 97.5 97.7 97.9 97.1 98.1 98.3 98.5 98.7 98.9 98.1 99.1 99.3 99.5 99.7 99.9 99.1 00-1 00-3 00-5 00-7 00-9 working days dap zhu

5、hai total quality 全面质量全面质量 jit manufacturing 即时制造即时制造 people involvement 全员参与全员参与 source:robert w. hall, attaining manufacturing excellence, the irwin professional publishing for a factory, the utmost manufacturing objective is to make the material flow and information flow through the supply chain

6、as fast as possible. a goal 一个目标一个目标 to be one of the best companies in the world: the best to trade with, work for and invest in. 成为世界最好的公司 a mindset 一种思维一种思维 we can always improve the way we improve 我们总能改进自己的工作方法 we can always increase our speed of learning 我们总能加快学习的速度 an approach for managing imp

7、rovement 一套改进的方法一套改进的方法 plan-do-check-act-plan-do-check-act-plan. pdca不断循环 a set of tools 一系列工具一系列工具 bbs, survey tools, pqa/pbe, mini co., glasswall, tpm, jit, 5s etc.业务平衡卡, 调查工具, pqa/pbe, 小公司, 展 示板, 全员预防性生产维护, 即时生产, 五常法等等 design review设计评估, fmea, field test, call rate md, skill matrix 技能矩阵 伙伴供应商，pi

8、tstop/sprint(jit)，看板管理 建议机制，小公司，qit，qcc pdca，六步工作法，质量七工具，doe，pst iso 9002 pqa - 90 pbeiso 14001 ppm 检验，iqc免检，过程能力，非质量成本 glasswall 白板管理，5s，tpm，flowline 流水线 people involvement 全 员 参 与 jit ?jit ? qcdsm 展示板 建议的数量 出勤、投诉、委屈情况 housekeeping与组织 现场图表、照片的应用 通过可视材料、报纸等共 享信息 现场会议：日会、周会、月 会等 高层领导共同参与改进活动 高层管理在现场的

9、可视程度 教育与培训的效果 管理过程的清晰度 暴露问题的机制 i make the staff 做东西做东西 ii copy competition 模仿对手模仿对手 iii manufacturing tuned to other functions 制造随着其他工作转制造随着其他工作转 iv world class manufacturing plays key role 世界级水平的制造发挥关键作用世界级水平的制造发挥关键作用 v innovative, rigid flexibility 创新、执着灵活创新、执着灵活 degree of integration and pro-acti

10、ve acting 整合与预先行动整合与预先行动 source: philips cft 15th mmp, block 1 lower level 低水平低水平 you belong in stage i or ii if these characteristics apply to your organization 如具备以下特点那么你们单位属于第如具备以下特点那么你们单位属于第i或第或第ii阶段阶段 “command and control mentality 命令、控制的思维方式 organization is considered a collection of specialis

11、ts who operate within fairlynarrow job description 工厂由专业人员在狭隘的工作描述范围内各自做自己的事 senior mgrs makes major resource allocation decisions with help of staff andexternal experts 主 要由高层经理对资源分配决策（职员和外面的专家协助） role of line mgrs is simply to operate the resulting configuration of facilities etc.部门经理的作用只 是按既定方针执行

12、 values specialists,missing capabilities are bought outside有价值的专业人员及知识、能力要从外 面买入 mgts primary task is orderly assimilation, exploitation and coordination ofseparate source of expertise 经理们主要是将现成的资源、知识进行吸收、剥削 organization is hierarchical, primary relationships between people are vertical分层、垂直式机构， 人员之

13、间的关系是纵向关系 higher level 高水平高水平 source: philips cft 15th mmp, block 1 you belong in stage iv if these characteristics apply to your organization 如具备以下特点那么你们单位属于第如具备以下特点那么你们单位属于第iii或更高阶段或更高阶段 employee are so skilled & effective that other cos are continually to attract 员工技能好、效率高，其他公司都想不断地挖走他们，但他们却不愿意离开

14、 equipment suppliers are continually seeking ones advice 设备供应商不断地来向你咨询 more nimble than competitors in responding to market shifts or price change, and in getting new products to the market faster 在市场及价格变化方面比对手更灵活，新 产品投入市场比对手快 interwinning the design of a new product with the design of its manufactu

15、ring process 紧密结合制造过程的设计开展新产品“内部双赢”设计 continually improving facilities, support systems, and skills that are considered to be optimal or state of art when first introduced, to surpass their initial capabilities 不断改进设施、支持系统及技能达到最优，并不断超越从前的能力 horizontal relationships throughout the company 横向合作遍布全公司 - - - - - - - the best