精益生产丰田问题解决办法

1、1BPI 莱西工厂精益培训课程BPI Laixi Plant Lean Training Session模块10 8步问题解决法Module ten Eight Step Problem Solving2内容Agendal冰山理论 Ice-berg theoryl概念介绍 Definition introductionl内容介绍 Content instructionl问题 & 讨论Question & Discussion3冰山理论Ice berg Theory表象Visual presentation根源The rootu可视觉化的只是问题的表象uWhat can be s

2、een is only the visual presentation of the problemu问题的根源却在表象之下uThe root of a problem hides behind its presentationu发掘根源才能彻底解决问题uOnly finding the root can help to completely resolve the problem标准 Standard目前状态 Current situation差距 Gap = 问题 Problem目前状态与标准之间的差异就是问题The current situation gap to the standar

3、d is problem解决问题的根源就是使目前状态彻底达到标准要求Resolve the root of a problem is to make the current situation completely meet the standard4概念介绍Concept Introductionn八步问题解决法是一套系统的有逻辑的问题解决步骤，旨在发现问题的根源并对问题解决办法进行跟踪以形成新的标准。8 step problem solving is a systematic and logical problem solving procedure, which aims to find

4、 the root cause and follow the actions to establish a new standard.1. 澄清问题 Clarify the problem 2. 分解问题 Break down the problem3. 设定目标 Target setting4. 根源分析 Root cause analysis5. 制定对策 Develop countermeasures6. 分析对策 See countermeasures through 7. 监督结果与过程 Monitor both results and processes 8. 将成功的过程标准化

5、Standardize successful processesPDCA5内容介绍Content Introduction1. 澄清问题Clarify the problem(1)澄清你所负职责&工作的“最终目标” Clarify the “ultimate goal ” of your responsibilities & work(2)澄清你所负工作的“标准” Clarify the “standard” of your work(3)澄清你所负工作的“目前状态” Clarify the “current situation” of your work(4)目视观察“目前状

6、态”与“标准”之间的差距 Visualize the gap between the “current situation” and the “standard”标准 Standard目前状态 Current situation差距 = 问题Gap = problem6内容介绍Content Introduction澄清你所负职责&工作的“最终目标”Clarify the “ultimate goal ” of your responsibilities & work我所付的职责 & 工作My responsibilities & work我的工作的目的My j

7、ob purpose最终目标Ultimate goal完成生产计划 To meet production plans满足客户需求 To meet customer demand在规定的时间内将合理价格的高性能和高质量的刹车片提供给客户To provide customers with high functional and high quality pads at reasonable prices in a timely manner7举例Example1.澄清问题 Clarify the problemu最终目标：提供客户需求的高性能的无任何质量问题的合格刹车片产品 Ultimate go

8、al: Provide high quality pads for customers with no any quality risk defectsu标准：包装区检查不合格品率为零 Standard: Zero audit defect from packing areau目前状态：每百个成品中不合格品为20 Current situation: 20 defects from every 100 finished parts20实际 Actual标准 Standard0差距为 20 Gap is 208内容介绍Content Introduction2. 分解问题 Break down

9、the problem(1)分解问题 Break down the problem(2)确定首要问题 Identify the PP(3)现场流程检查以发现问题发生点 Specify the PoO by checking the process将大问题分解成小的更具体的问题 Break the big problem into small and specific problems将问题进行分类并进行轻重标识 Classify and quantify the problems将问题进行描述并指出问题发生点 Describe the PP and find the PoO如果不能正确描述问题

10、，也就无法正确解决问题 If you cant describe the PP correctively, you cant resolve the PP correctively.9举例Example2.分解问题 Break down the problem抽查包装区100个成品中有20个不合格品20 defects from every 100 finished parts移印不良（10）Printing failure组件错误 （3）HW failure标签错误（5）Label failure包装盒错误（2）Box failure首要问题PP调油墨Blend the printing i

11、nc安装印版Install the plate安装移印头Install the head样品测试Sample test移印开始Start printing问题点PoOu油墨调的不合适导致包装区抽查百个成品中有10个移印不良品The printing inc was not blended properly so there were 10 printing defects from 100 finished parts during the check10内容介绍Content Introduction3 . 设定目标 Target setting(1)作出承诺 Make a commitme

12、nt(2)设定可测量的，具体的并具有挑战性的目标 Set measurable, concrete and challenging targets标准Standard目前状态Current situation大问题Big problem主要问题 PP问题 Problem问题 Problem问题 Problem问题点 PoO目标Target11举例Example抽查包装区100个成品中有20个不合格品20 defects from every 100 finished parts移印不良（10）Printing failure组件错误 （3）HW failure标签错误（5）Label fail

13、ure包装盒错误（2）Box failure首要问题PP调油墨Blend the printing inc安装印版Install the plate安装移印头Install the head样品测试Sample test移印开始Start printing问题点PoOu油墨调的不合适导致包装区抽查百个成品中有10个移印不良品The printing inc was not blended properly so there were 10 printing defects from 100 finished parts during the check目标：移印区零不良Target: Zero

14、 defect in printing area12内容介绍Content Introduction4. 根源分析 Root cause analysis(1)头脑风暴，分析所有可能导致原因 Brainstorm to analyze all possible causes(2)征求现场作业者的意见，查看问题发生点 Get input from job performers and check the process(3)选取最具可能性的问题导致原因 Select the most likely causes(4)创建“原因”和“结果”分析链 Create “why chain” apply

15、“therefore” test问题Problem人Man机Machine料Material法Method环Environment13举例Example油墨调的不正确Inc was not properly blended油墨颜色太浅Color of inc was very light稀料添加的太多Too much thinner added操作方法不正确Operation method was not correct现场没有比例说明No ratios instructing work at job site没有比例测试装备No ratio test gage之前未考虑到，未购买Didnt

16、consider this so didnt buy it 为什么？ Why?因此 Therefore14内容介绍Content Introduction5. 制定对策 Develop countermeasures(1)尽可能多的考虑解决措施 Develop as many countermeasures as possible(2)选取增值最高的解决措施 Select the highest value added countermeasures(3)与其他人取得一致意见 Build consensus with others(4)创建一个清晰的详细的行动计划 Develop a clea

17、r and detailed action plan通常在对所有可能的解决对策进行评价时需要综合考虑一下因素，以确定最佳解决对策：Usually, when we do evaluation for all possible countermeasures , we need to comprehensively consider the following elements in order to find the best one:安全 Safety质量 Quality有效性 Effectiveness成本 Cost时间 Time needed劳动量 Efforts needed15举例E

18、xample最有效的办法是购买比例测试仪 The best countermeasure is to buy one ratio test gage可安排品管人员在现场进行收件检验，作为临时措施 We can arrange QC to do in process first sample check as temporary action16内容介绍Content Introduction6. 分析对策 See countermeasures through (1)制定一份明确的实施计划，指明内容，负责者和完成时间 Make one clear action plan, listing wh

19、at, who and when(2)依靠团队力量进行对策的快速执行 With all members united, implement countermeasures with speed (3)积极与相关人员进行信息的分享 Share information with all related people actively说明说明 Note:一旦团队通过对策执行计划，就必须要有专人跟踪，并且按时进行实施情况的公布There must be one person designated to follow the schedule once it was agreed by the team

20、 and report the progress regularly.17举例Example187. 监督结果与过程 Monitor both results and processes (1)评价结果与流程，将信息与所有相关人员分享 Evaluate the results and the processes, and share it with members involved(2)好的结果并不代表好的流程，好的流程能够支撑好的结果 Good result doesnt mean good process, good process can support good result (3)评价时从以下三个方面考虑：客户方，八步问题解决法，自身 Evaluate from three key perspectives: customers, 8