Lean-古德里奇培训资料ppt课件

1、1GoodrichContinuous Improvement继续改良5S & Point of Use 5S 和运用现场25S & Point of Use 5S 和运用现场5S & Point of Use5S和运用现场THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE35S & Point of Use 5S 和运用现场5S & POU Learning Objectives 5S和POU的学习目的On completion of this course the students should

2、be able to: 在完成这一课程的培训员应该可以:Define the 5Ss 明确管理5S的定义State the importance and benefits of 5S 阐明5S管理的重要性和益处Define Point of Use 明确运用现场Learn how Point of Use & 5S work together 了解如何结合运用现场和5SKnow how to Implement 5S 知道如何实施5STHIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE45S & Poi

3、nt of Use 5S 和运用现场Definition of 5Ss 5S管理的定义A Method of creating a self-sustaining culture that perpetuates a neat, clean, safe, and efficient work place一种能创建自我维持文化的方法，永远坚持一个整洁，干净，平安，有效率的任务场所Self-sustaining culture means people have internalized the need for performing the 5Ss and do so automatically

4、 自我维持文化是指人们将5S管理的需求内在化因此自发地完成5S的任务THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE55S & Point of Use 5S 和运用现场Why the 5Ss? 为什么要用5S管理?Intuitive goodness 不言而喻的精华A Toyota Production System foundation and tester 丰田消费系统的根底和试金石Helps establish, reinforce and discipline the Standard W

5、ork 协助建立，加强和训导规范作业Least Waste Way will not be achieved without the 5Ss 短少了5S管理，最少浪费方式将不会实现THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE65S & Point of Use 5S 和运用现场Resistance to 5S 5S管理的阻力Any company introducing 5S is likely to encounter resistance - People resist change 任何公

6、司引进5S管理能够会遇到阻力-人们抗拒改革 Some excuses are: 有些借口是:Why clean when it just gets dirty again? 明明知道还是会脏，为什么还要清扫?We tried 5S years ago 在几年前我们试用了5S管理Were too busy for 5S activities 我们太忙了，没有时间顾及5S管理活动Were doing okay, why do we need to implement 5S? 我们都做的不错，为什么我们需求实施5S管理? THIS DOCUMENT SUBJECT TO THE CONTROLS A

7、ND RESTRICTIONS ON THE FIRST PAGE75S & Point of Use 5S 和运用现场Resistance to 5S 5S管理的阻力Ignoring resistance without addressing concerns directly can lead to only superficial improvements 不直接处理本质问题而忽略阻力能够导致只是外表上的改良In order for 5S implementation to be successful, everyone needs to truly understand how nec

8、essary it is为了使5S管理实施胜利，每个人都要真正了解它的必要性Leaders (both formal and informal) are key people in encouraging and implementing the 5S 指点人包括正式和非正式是鼓励和实施5S管理的关键人物THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE85S & Point of Use 5S 和运用现场 Our English “S Equivalents of the Japanese 5S T

9、erms 我们的英文“ S 和日本5S管理的条款的对照 Sort (Seiri) 整理 Straighten (Seiton) 整顿 Shine (Seiso) 清扫 Standardize (Seiketsu) 清洁 Sustain (Shitsuke) 素养THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE95S & Point of Use 5S 和运用现场The First S Sort 第一个S字 整理Sort - Clearly distinguish between what is ne

10、eded and kept, and what is unneeded and thrown out. 整理 -明确区分哪些是必要并且需求保管的，什么是不用要的，可以扔掉的.Critically evaluate all items in the workplace and determine which items are really needed. 严厉评价任务场所一切物品，并诀定哪些物品是真正需求的Keep only items needed to Support the LWW 只保管必要的物品来支持LWWUnneeded items get in the way of produc

11、t flow and are a safety hazard. 不用要的物品妨碍产品流通，也是平安隐患THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE105S & Point of Use 5S 和运用现场The First S Sort 第一个S字 整理CAUTION! When we dispose of unnecessary Company Proprietary or Private information it must be done properly, for example, sh

12、redded 留意！ 当我们处置不需求的公司专利或私人信息时，必需用正确的处置方式-切碎或烧毁Ensure that those things “disposed of are done with the knowledge of the owner处置过程中请确保物主知情THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE115S & Point of Use 5S 和运用现场Performing Sort 执行整理In preparation for a Sort activity: 预备一项整理的

13、活动时Establish the Scope of the Sorting Activity 建立整理活动的范围Establish the “Throw-out Criteria 建立 “丢弃 的规范Establish the holding area (Red Tag Area) for unneeded items 给不需求的物品建立存放区红色标志区Arrange for trash bins and transportation carts to dispose of and move unneeded items. 安排渣滓桶和车辆处置不用要的物品Obtain Red Tags to

14、identify unneeded items 给不需求的物品预备红色标签THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE125S & Point of Use 5S 和运用现场Performing Sort 执行整理Identify the needed and not needed items by asking:确认一切需求和不需求物品: What is it for? 它是什么呢? Why do we have it? 我们为什么拥有它呢? How often is it used? 我们多

15、久才运用一次?Fill out and attach Red Tags to all items in question.给一切有疑问的物品填写和贴上红色标签 Be sure to consult with the “owner of all items prior to Red Tagging 贴上红色标签之前一定要咨询物品的“主人Move all red tagged items into the temporary red tag area.将一切红色标志 物品纳入暂时红色标志区域Disposition all items in the red tag area within a pre

16、determined time period. 在预定的时间段内处置一切带红色标志的物品THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE135S & Point of Use 5S 和运用现场Implementing Sort 实施整理Sample Red Tag 红色标签样本Red tags should be numbered to help keep track 红色标签应上编号来协助追踪记录Create a log sheet 创建 一个记录表Fill out completely 填写完好

17、Items can be dispositioned from Red tag holding area 红色标志区内的物品可以处置掉THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE145S & Point of Use 5S 和运用现场The First S Sort 第一个S字 -整理Office Storage Area 办公场所存储区域Before Applying 1st S 在第一次运用整理之前After Applying 1st S 在第一次运用整理之后 THIS DOCUMENT S

18、UBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE155S & Point of Use 5S 和运用现场Before Applying 1st S在第一次运用整理之前 After Applying 1st S在第一次运用整理之后 The First S Sort 第一个S字 -整理Office 办公场THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE165S & Point of Use 5S 和运用现场The Second S Str

19、aighten 第二个S -整顿Straighten Organizing the necessary items so that they can be used and returned easily 整顿 - 组织必要物品，以便可以容易运用和归还Sort first so that we dont waste time straightening things we dont need 先把它们整理好，这样我们不会浪费时间来整顿我们不需求的物品Organize and locate all needed items 组织和确定一切需求物品的地点Identify where to retu

20、rn items when not in use 确定不被运用的物品的归还地点Identify items and their storage locations 确定物品和其储存地点 Make the order of things clearly understood at a glance 把物品按次序摆放，做到一目了然Eliminate all wasted motion and time 消除一切不用要的挪动和因此浪费的时间 Like a Fire Engine or Ambulance像消防车或救护车一样THIS DOCUMENT SUBJECT TO THE CONTROLS A

21、ND RESTRICTIONS ON THE FIRST PAGE175S & Point of Use 5S 和运用现场Point of Use (POU) 运用现场 (POU)Implicit in the Second of the 5Ss is the notion that all information and things to do the job should be near the employee. 在第二个5S管理的S的里面一个隐含理念是，一切任务用到的资料和物品都应该是在雇员的附近I Know that mouse trapdetector is here somew

22、here我知道捕鼠器探测仪是 在这里某个地方THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE185S & Point of Use 5S 和运用现场Definition Point of Use (POU)定义 - 运用现场 (POU)All information, items, parts or equipment required to do a job are organized and near the employee: 一切的资料，物品，零件或任务上需求的器具都要放在员工附近: Wit

23、h the most frequently used items being the closest. 最常用的物品放在最近的地方Those used not quite so frequently a little farther away. 那些不常运用的可以放远一点Those used infrequently stored remotely but readily accessible. 还有那些更不常运用的可以存储在较远的，但又容易拿到的地方THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE

24、195S & Point of Use 5S 和运用现场Point of Use 运用现场Likewise, the presentation of items, parts, components or information required for the operation or process need to be organized to support the work in the Safest LWW 同样，提供的物品，零件，部件或所需资料也需求妥善安排好，以保证以最平安的LWW规范支持要完成的任务THIS DOCUMENT SUBJECT TO THE CONTROLS A

25、ND RESTRICTIONS ON THE FIRST PAGE205S & Point of Use 5S 和运用现场Straighten / POU 整顿/POUSome Guidelines 一些指点Keep it cheap find countermeasures that dont require spending money 维持廉价 - 寻觅一个不需求花钱对策Get the employees input / help 得到雇员的投入/协助Put them in “build / use sequence 将它们纳入“建造/运用程序Keep it ergonomic and

26、safe 坚持任务场所的人体工学和平安THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE215S & Point of Use 5S 和运用现场Shop Floor POU 车间 POUSome Examples 一些例子“Things you use most frequently, keep close“将他最常用的工具放在身边THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE225S & Point o

27、f Use 5S 和运用现场Shop Floor POU 车间 POU Some Examples 一些例子Put tools and parts in “build / use sequence 把工具和零件纳入 “建造/运用程序THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE235S & Point of Use 5S 和运用现场Conventional Stretch-bend tool configuration requires parts to be clamped onto the t

28、ool during the forming operation.常见的拉伸弯曲工具，在成型操作中要求将零件夹紧在夹具中Shop Floor POU 车间 POUBefore POU在POU以前THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE245S & Point of Use 5S 和运用现场Shop Floor POU 车间 POUMounting the clamps on the tool eliminates variation and reduces the time required

29、 for set-up and change-over安装了夹具后，消除了变位，并减少了预备和转换所需的时间THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE255S & Point of Use 5S 和运用现场Office (Sitting Workstation) POU 办公室坐位POUFrequent motions should be within the optimum work area for ergonomics and LWW在人体工程学和LWW的角度来说，频繁的动作应该处在最正

30、确任务区之内THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE265S & Point of Use 5S 和运用现场Performing Straighten 执行整顿Identify Locations 确定位置Locate items in the workplace according to how frequently they are used the most frequently used items closest to the worker按照运用的频率来放置物品-最经常运用的物品

31、最接近任务者Store items together that are used together and store them in the sequence they are used 将一同运用的物品放在一同，并将其按照运用顺序摆放THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE275S & Point of Use 5S 和运用现场Performing Straighten (cont.) 执行整顿 (续Identify Locations 确定位置Make it visual What?

32、Where? How Many? 一目了然的摆放 有些什么？ 放在哪里? 有多少?Visually show what specific items belong in each location and how many should be there 详细地显示哪个位置有哪些物品，数量有多少Document workplace lay-out including locations for tools and supplies 把任务场所的设计在文件里，并包括工具和物资的地点THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON

33、THE FIRST PAGE285S & Point of Use 5S 和运用现场Performing Straighten 执行整顿Determine Storage Methods 确定储存方法Right-size storage areas to prevent waste from creeping back into the process 确定恰当的储存区尺寸，以防止废物逐渐堆积Develop point of use carts or shadow boards to accommodate hand tools and supplies 制造手推车或影子板以储存手工工具和物资

34、Develop right-sized storage for production aids, templates and other needed supplies运用消费辅助设备，样版和其他所需用品的正确大小的存贮* When possible devise a “just let go method of storing hand tools, so that they are automatically retracted into their storage position * 如有能够，设置一种任其自然的管理手工工具的方法，以使它们可以自动归位。Ensure that ever

35、ything necessary to support the LWW standard work is included 确保一切支持LWW规范任务所必要的物品已包括在内THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE295S & Point of Use 5S 和运用现场After Applying 2nd S在运用第2个S之后 Shop Floor Straighten 车间整顿Before Applying 2nd S 在运用第2个S之前 THIS DOCUMENT SUBJECT TO T

36、HE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE305S & Point of Use 5S 和运用现场Shop Floor Straighten 车间整顿After Applying 2nd S在运用第2个S之后 Tools are visible and easily retrieved for the task being performed工具看得见，要运用的时候也容易获得到相应的工具Before Applying 2nd S在运用第2个S之前 Tools kept in tool boxes with no visibility工具存放在看

37、不见的工具盒内THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE315S & Point of Use 5S 和运用现场Office Straighten 办公室整顿Color code visual control identifies location of items in cabinet.颜色显示物品在柜阁内的位置.After Applying 2nd S在运用第2个S之后 THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON TH

38、E FIRST PAGE325S & Point of Use 5S 和运用现场The Third S Shine 第三个S 清扫Shine Keeping things clean 清扫-坚持物品干净Conduct routine cleaning floors swept, machines and furniture clean, all areas neat and tidy 进展例行清扫-清扫地板，机器和设备，使一切区域整洁Eliminating trash, filth and foreign matter. 去除渣滓，污物和异物Use cleaning as a form of

39、inspection 利用清扫作为一种检查的方式Clean to Inspect 清扫，检查Inspect to Detect 检查，检测Detect to Correct 检测，矫正THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE335S & Point of Use 5S 和运用现场Performing Shine 执行清扫Determine Shine Targets (Usually grouped into three categories) 确定清扫的目的通常分为三类)Spaces 空间

40、 *Office or shop floor areas including floors, walls, windows, lights, shelves, etc. *办公室或车间包括地面和墙壁,窗户，灯光，货架等.Equipment 设备 *Machines, tooling, general tools, transfer carts, etc. * 机械，模具，普通的工具，转运手推车，等等.Other Items其他物品 *Cabinets, desks, raw materials, detail parts, production hardware, etc. *柜，办公桌，原资

41、料，细小零件, 五金器件，等等THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE345S & Point of Use 5S 和运用现场Performing Shine 执行清扫Choosing Targets and Tools 选择目的和工具Define what will be cleaned in each area and what supplies and equipment will be used 确定每一个区域要清理哪些物品，哪些物资和会运用的清理用品Needed cleaning

42、supplies and equipment should be made readily available 需求用到的清扫用品和设备该当随时预备好Supplies used for daily cleaning activities should be stored in places where they are easy to find, use and return 日用清扫用品和工具应存放在容易找到、运用和归还的地方Use standard procedures and standard work to perform routine shine 运用规范的程序和任务来执行日常清扫

43、THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE355S & Point of Use 5S 和运用现场Performing Shine 执行清扫Some techniques 有些技巧Sweep dirt from floor cracks, corners, etc. 清扫地板的裂痕和角落等Mop and wax floors as needed 假设需求，拖洗或者给地板上蜡Wipe off dust from walls, windows and doors 擦去墙壁，窗户和门上的灰尘Be t

44、horough about cleaning dirt, oil, grease, rust shavings from all surfaces (especially machinery) 彻底清扫一切外表上在污垢，油，脂，锈迹，刨花尤其是机械)Use cleansing agents when sweeping and dusting 运用清洗剂清扫If discrepancies are found, enter on the area To-Do List 假设发现不符，把事项登记在该区域的义务列表THIS DOCUMENT SUBJECT TO THE CONTROLS AND R

45、ESTRICTIONS ON THE FIRST PAGE365S & Point of Use 5S 和运用现场The Fourth S Standardize 第四个S 清洁Standardize Maintaining and improving the standards of the first three Ss 清洁-坚持和提高前3个S的规范While the first 3 Ss are activities, the 4th S is a process that facilitates the maintenance and improvement of the first

46、three Ss 前3个S是活动，而第4个S是一个过程，用于维护 和改善前3个SThe 4th S relies on written agreements, visual controls and standard routines established by the group. 第4个S依赖于由组织设立的书面协议，目视管理和规范例程To improve, we move from detection to prevention 我们的重点从检测转移到预防，以做到继续改良THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON T

47、HE FIRST PAGE375S & Point of Use 5S 和运用现场Performing Standardize 执行清洁Prepare and keep current the 5S schedule and responsibility map noted previously 预备和保管当前的5S管理的时间表和以前提到的责任图For each 5S area, the map and schedule should include: 5S管理的每个区域里，责任图和时间表应包括以下内容:5S tasks to be done 所要做的5S管理义务Frequency of th

48、e tasks (daily, weekly, etc.) 义务的频率每天，每周，等等.)Time of the day to do task 每天的执行义务时间Who is responsible for each task 谁担任哪项义务THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE385S & Point of Use 5S 和运用现场Performing Standardize 执行清洁 Prepare and keep current Standard Work (SWS and SWC

49、S) for the 5S activities 预备和保管当前5S管理活动的规范作业SWS的和SWCS 5S Standard Work will specify the time based procedures to perform the 5S tasks 5S管理的规范作业将指定执行5S管理义务的所需时间和步骤 .The cycle time of the 5S Standard Work will allow for more accurate calculation of time available for Takt time determinations 5S管理的规范作业的

50、周期时间将有助于更准确的计算可用时间以确定消费节拍时间THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE395S & Point of Use 5S 和运用现场Performing Standardize 执行清洁Perform regular 5S evaluations to monitor 5S progress and identify opportunities to improve 执行定期评测以监测5S管理的进展，并识别改良的时机Identify when evaluations wil

51、l be performed (weekly is best to maintain progress) 确定评价时间最好是每周，以坚持进展)Prepare an evaluation schedule, listing evaluators and dates 预备一份评价日程表，列出评价者和日期Ensure To-Do lists are used to identify opportunities. Then apply countermeasures and work these promptly. 确保运用改善义务列表来识别改良时机。然后使施运用对策，迅速处置Prepare a 5S

52、 evaluation trend chart as a visual control to show changes in 5S scores over time. 预备一张5S管理评价趋势图作为目视管理工具，显示5S管理成果随着时间的变化情况THIS DOCUMENT SUBJECT TO THE CONTROLS AND RESTRICTIONS ON THE FIRST PAGE405S & Point of Use 5S 和运用现场The 5Ss Evaluation Sheet (Example) 5S管理的评价表样例Factory5SEvaluation FormSortStra

53、ightenShineStandardizeSustainLevel 5HabitNeeded items can be retrieved in 30seconds or less. Obsolete materials areroutinely removed from the area.Preventative measures are in place tokeep unnecessary items, reports etc. fromentering the area.Anyone can walk into the work area andeasily locate work

54、by priority.Corrective measures are in place toaddress abnormal conditions.Work area housekeeping is a routineway of life. Corrective action measuresare in place to address cleanlinessissues.Team is adhering to standard work methods,visual and work area controls. A system ofimproving work methods an

55、d work areacontrols is clearly being utilized. Possible forvisitors to tell what work is performed andwhere in all cases.Information on the area information boardis meaningful and influences the dailydecisions of the work area. Root causesof problems are eliminated and actionsfocus on preventative m

56、ethods.Level 4CommitmentAll work material has been sortedaccording to what will be worked today,this week. Materials, tooling, files andreports are routinely reviewed fornecessity.Team members can easily determinewhat items are currently in-use and theirpriority. Visual controls are in place toindic

57、ate normal / abnormal workconditions.Work area housekeeping responsibilitiesare established and being followed on adaily basis. Cleaning materials arestored and readily available.Team is utilizing standard workmethods and work area controls on adaily basis. Possible for visitors to tellwhat work is

58、performed and where inmost cases.Team routinely checks area to maintain the 5Ss.Information on the area information board ismeaningful to the work area. Source andfrequency of problems are documented andcorrective actions taken. Planning occurs toreach next 5S levels.Level 3OrganizationUnderstanding

59、Only documents and tools necessary tothe work area are stored at the workstations and are stored in an orderlymanner.A priority system has been established tohighlight the order in which jobs will beperformed. All tooling, gages, handtools have designated locations.Cleanliness problems have beeniden

60、tified and preventative measures aredocumented and in place.Team has documented needed items,work methods, and work area controls and hasmade them available in the work area.Possible for visitors to tell what work isperformed and where in some cases.5S presentation has been made to allTeam members a