标准化工作定义课件

StandardWorkWorkshop标准化工作训练营StandardWorkWorkshopStandardizedWork

标准化作业Termstoknow: 你需知道的术语Takttime 客户需求节拍Targetcycletime 目标加工周期Actualcycletime 实际加工周期Manualtime 手工时间Walktime 行走时间Waittime 等待时间Unassignedtime 未分配时间Machinecycletime 机器加工周期StandardizedWork

标准化作业TermstStandardizedWork

标准化作业TaktTimeCalculation:客户需求节拍的计算

AvailableDailyOperatingTime(Seconds)每天可用工作时间(秒)_____TotalAverageDailyProductionRequirements(Pieces)总的平均日生产需求(件)

StandardizedWork

标准化作业TaktTiStandardizedWork

标准化作业TaktTimeCalculationExample:客户需求节拍的计算举例Cell3000(Twoshiftoperation) 单元3000(两班)Customerdemand=1504/perday 客户需求-1504/天Availableworktime=16hours 可用工作时间16h =960min/dayLess4breaksperday@10min.each 减

4次休息 =40minTotalAvailableTime 总可用时间

=920min920minutesX60seconds=55,200secondsTaktTime=55,200sec/1504units=36.7secondsWeneedtonet1unitevery36.7seconds我们每36.7秒需要加工一件零件StandardizedWork

标准化作业TaktTiTargetCycleTime

目标加工周期

TargetCycleTime=TaktTime-SpecialAllowances目标加工周期=客户需求节拍-允许的特殊耗时TargetCycleTime

目标加工周期Targe

TargetCycleTimemayincludeplanned,repetitiveoperations目标加工周期包括计划的、重复的操作-ExamplesofSpecialAllowances允许的特殊耗时例子

TeamMeetings小组会议

PM预防性保养

Changeover换装TargetCycleTime

目标加工周期

Planned,repetitiveallowanceswillbedeterminedbyeachBusinessUnit计划的，重复的所允许的耗时由每个业务单元决定。TargetCycleTimemayincludeTargetCycleTimeExample

目标加工周期举例ProductionRequirement: 1504partsperday生产需求每天1504件部件P.M.保养 15minutesX2shifts=30min.EIMeetingEI会议 12minutesX2shifts=24min. 54min.54minutesX60seconds=3240seconds3240/1504=2.15secondslostforSpecialAllowancesTargetCycleTime=36.7(Takt)–2.15(SPA)=34.55sec.目标加工周期TargetCycleTimeExample

目标加工StandardizedWork

标准化作业ActualCycleTime实际加工周期=Manualtime+WalkTime+WaitTime手工时间+行走时间+等待时间StandardizedWork

标准化作业ActualStandardizedWork

标准化作业ActualCycleTime=Manualtime+Walktime+Waittime实际加工周期=手工时间+行走时间+等待时间

Longestoperator’sactualcycletimetellsushowmanypartsthecelliscapableofrunning最长的加工周期告诉我们单元有能力加工多少件零件

ActualCycleTimeisthetimeittakesanoperatortocompleteonecycleofhis/herstandardwork实际加工周期是指一位操作员完成其标准作业的周期StandardizedWork

标准化作业ActualStandardizedWork

标准化作业ManualTime:手工时间Thetimerequiredforanoperatortoperformthephysicaltasksforonecycleofoperation(Inspecting,loading/unloading,andgauging)操作工在一个周期的操作中为完成手工任务所需的时间(如检验，装载，卸载，测量)StandardizedWork

标准化作业ManualStandardizedWork

标准化作业WalkTime:行走时间Thetimerequiredforthephysicalmovementfromonepointtoanother,withorwithoutapart从一点移动到另一点所需的时间，持有或无零件StandardizedWork

标准化作业WalkTiStandardizedWork

标准化作业WaitTime:等待时间Thetimetheoperatorwaitswhilethemachinecompletesitsfunction

操作工等待机器完成其操作的时间StandardizedWork

标准化作业WaitTiUnassignedTime未分配时间Thedifferencebetweenyouractualcycletimeandyourtargetcycletime实际加工周期和目标加工周期之间的差StandardizedWork

标准化作业UnassignedTime未分配时间ThediffStandardizedWork

标准化作业MachineCycleTime:机器周期Thetimerequiredbyamachinetocompleteonecycleofoperation机器完成一个操作循环所需的时间

*MachinecycletimemayalsobereferredtoasAutoTime机器周期也被称为自动时间StandardizedWork

标准化作业MachineTargetCellManning目标单元人员配备#OfMembers=TotalManualTime+TotalWalkTimeTargetCycleTime目标周期员工数

总的手工时间

总行走时间TargetCellManning#OfMemberAvailableDailyOperatingTime(Seconds)TotalAverageDailyProductionRequirements(Pieces)GOAL:actualcycletimetargetcycletimetakttimeTargetCycleTime目标周期=Takttime-specialallowances特殊耗时ActualCycleTime=Thetimeittakesanoperatortocompleteonecycleofstandardwork.Thelongestoperator’sactualcycletimetellsushowmanypartsthecelliscapableofrunning实际周期=一位操作员完成标准作业的整个周期的时间。操作员实际最长耗时告诉我们这个单元可以生产的部件数。TaktTimeCalculation:计算每日可得操作时间(秒)总平均每日生产要求(件数)目标：实际周期目标周期TAKT时间AvailableDailyOperaLaborEfficiency

劳动效率

LaborEfficiency=StandardDirectLaborHoursActualSpentHoursStandardLaborxStandardCycleTime(InHours)xOutputActualLaborxActualHours=LaborEfficiency

劳动效率StandardProductivityBenchmark

生产力参照值CellF1

单元F1AverageManualTime(MT)-36.0seconds平均手工时间-36.0秒Manualtimeisthetimerequiredforanoperatortoperformthephysicaltasksforonecycleofoperation.(Inspecting,loading/unloading,andgauging)手工时间是一操作工完成一个操作周期所花在手工操作上的时间(检验，装卸，检测等)Takt-48.7seconds理论周期-48.7秒Manual(MT)%ofTakt-73.9%手工时间占理论周期的比例-73.9%MTTAKT=3648.7=73.9%ProductivityBenchmark

生产力参照值C

PRODUCTMIX

混流生产

PRODUCTMIX

混流生产ProductMixExample产品混合例子{ProductA+B+C=876产品A=219=25%B=307=35%C=350=40%876=100%TotalAvailableTime总共可用时:8hoursX60’=480’-20’(2-10’breaks)=460’X60”=27,600”27600”/876dailyunitsrequired=31.5”TaktTimeTotalDailyAvailableTime总每日可用时Avg.DailyUnitsRequired(A,B,C)平均每天所需求的件数TAKT=ProductMixExample{ProductATargetCycleTimeCalculation

目标周期的计算TargetCycleTime=TaktTime-SpecialAllowances目标周期=TAKE时间-特殊耗时TaktTime=31.5”SpecialAllowances特殊耗时=10’ATPM +12’TeamMeeting小组会议SpecialAllowances特殊耗时=22’X60”=1320”SpecialAllowancepercycle=1320”/876units=1.5”每个循环的特殊耗时31.5”(TaktTime)-1.5”(SpecialAllowance)=30.0”TCT

TargetCycleTimeCalculation

ProductMixExample产品混合例子Product产品

ABCManual人力306”260”200”Walk走动50”40”40”Total总计356”300”240”%Mix混合比重25%35%40%PartA356”x.25=89”PartB300”x.35=105”PartC240”x.40=96” 290”WeightedAverage加权平均的全部工作内容

CalculationofAvg.TargetManning平均目标人力的计算ProductMixExampleProduct产品MaTargetManningExample

目标人力配备举例290”30.0”TargetCycleTime

目标周期TotalManualTime+TotalWalkTime总手动时间+总走动时间TargetManning目标人力===9.6Weroundtothenextfullpersonanduse10people

我们取整数，用10人。TargetManningExample

目标人力配备举FixedManning/FlexTCT固定人力/可变的目标周期Product产品

ABCManual人力306”260”200”Walk走动50”40”40”Total总共356”300”240”%Mix混合25%35%40%PartA 356”/9.6=37.08”TargetCycleTimePartB 300”/9.6=31.26”TargetCycleTimePartC 240”/9.6=25.00”TargetCycleTimeFixedManning/FlexTCTProduct产FixedTCT/FlexManning固定的目标周期/可变的人力Product产品

ABCManual人力

306”260”200”Walk走动

50”40”40”Total总计

356”300”240”%Mix混合

25%35%40%356”/30.0”=11.8TargetManning目标人力300”/30.0”=10.0TargetManning目标人力240”/30.0”=8.0TargetManning目标人力FixedTCT/FlexManningProduct产ProductMixExample产品混合例子FixedManning固定人力FixedTCT固定目标周期TargetManning目标人力TargetCycle目标周期TargetManning目标人力TargetCycle目标周期A30.0” 11.8 37.0” 9.6B30.0” 10.0 31.2” 9.6C30.0” 8.0 25.0” 9.6Gross30.0” 9.6 30.0” 9.6 ProductMixExampleFixedManni9ContinuousImprovementProcessSteps

持续改进的9个步骤1.Observecurrentmethod 观察目前的方法2. Documentcurrentmethod 记录目前的方法3. Identifyimprovements(stepstoeliminate)识别改进(需消除的步骤)4. Implementimprovements 实施改进5. Validatequalityandproductivityofnewmethod验证新方法的质量及生产力6. Standardizenewmethod 将新方法标准化7. Document“Before”and“After”conditions记录改进前后的情况8. Recognizeachievements认可取得的成绩9. Lookfornextimprovement寻求下一次改进9ContinuousImprovementProceImplementingStandardWork

实施标准作业TrainthecellmembersinStandardWork&TaktTimeProduction.给每个单元的成员就标准作业和理论时间生产进行培训CalculateTaktandTargetCycleTime计算需求节拍和目标周期Developstandardworkchartswithflexmanning,plusandminusoneoperator做出的标准作业图表要体现灵活的人力配置，加1减1模式CreateStandardWorkCombinationTables建立标准作业组合表(SWCT)

CreateaBalanceBoardasatoolforimprovement建立平衡板作为改进的工具ImplementingStandardWork

实施标ImplementingStandardWork

实施标准作业CreateaManningGraphtoidentifytheopportunitiesforimprovementtotargetcycletime

做人力图表来识别需要提高目标周期的改进机会IdentifytheTargetCellManning

识别单元的目标人力CalculateLaborEfficiency

计算日劳动效率CreateaplantomaintainanactiveStandardWork&TaktTimeProductionprogram.

做一个计划来维持积极的标准作业和按客户需求节拍生产的计划ImplementingStandardWork

实施标ITEM要点BEFOREAFTERWIP在制品%UPTIME机器正常运行时间THRU-PUTTIME生产时间MACHINECYCLETIME机器周期PROCESSSTEPS工艺步骤PIECESPERMAN-HOUR每人生产件数%REWORK返工%SCRAP废品CUSTOMERPPM客户PPM%FTTMT/TAKT%PARTFLOWDISTANCE部件流动距离WAIT/TAKT%等待/节拍LABOREFFICIENCY劳动效率BeforeandAfterContinuousImprovementRecord持续改进前后记录ITEM要点BEFOREAFTERWStandardWorkWorkshop标准化工作训练营StandardWorkWorkshopStandardizedWork

标准化作业Termstoknow: 你需知道的术语Takttime 客户需求节拍Targetcycletime 目标加工周期Actualcycletime 实际加工周期Manualtime 手工时间Walktime 行走时间Waittime 等待时间Unassignedtime 未分配时间Machinecycletime 机器加工周期StandardizedWork

标准化作业TermstStandardizedWork

标准化作业TaktTimeCalculation:客户需求节拍的计算

AvailableDailyOperatingTime(Seconds)每天可用工作时间(秒)_____TotalAverageDailyProductionRequirements(Pieces)总的平均日生产需求(件)

StandardizedWork

标准化作业TaktTiStandardizedWork

标准化作业TaktTimeCalculationExample:客户需求节拍的计算举例Cell3000(Twoshiftoperation) 单元3000(两班)Customerdemand=1504/perday 客户需求-1504/天Availableworktime=16hours 可用工作时间16h =960min/dayLess4breaksperday@10min.each 减

4次休息 =40minTotalAvailableTime 总可用时间

=920min920minutesX60seconds=55,200secondsTaktTime=55,200sec/1504units=36.7secondsWeneedtonet1unitevery36.7seconds我们每36.7秒需要加工一件零件StandardizedWork

标准化作业TaktTiTargetCycleTime

目标加工周期

TargetCycleTime=TaktTime-SpecialAllowances目标加工周期=客户需求节拍-允许的特殊耗时TargetCycleTime

目标加工周期Targe

TargetCycleTimemayincludeplanned,repetitiveoperations目标加工周期包括计划的、重复的操作-ExamplesofSpecialAllowances允许的特殊耗时例子

TeamMeetings小组会议

PM预防性保养

Changeover换装TargetCycleTime

目标加工周期

Planned,repetitiveallowanceswillbedeterminedbyeachBusinessUnit计划的，重复的所允许的耗时由每个业务单元决定。TargetCycleTimemayincludeTargetCycleTimeExample

目标加工周期举例ProductionRequirement: 1504partsperday生产需求每天1504件部件P.M.保养 15minutesX2shifts=30min.EIMeetingEI会议 12minutesX2shifts=24min. 54min.54minutesX60seconds=3240seconds3240/1504=2.15secondslostforSpecialAllowancesTargetCycleTime=36.7(Takt)–2.15(SPA)=34.55sec.目标加工周期TargetCycleTimeExample

目标加工StandardizedWork

标准化作业ActualCycleTime实际加工周期=Manualtime+WalkTime+WaitTime手工时间+行走时间+等待时间StandardizedWork

标准化作业ActualStandardizedWork

标准化作业ActualCycleTime=Manualtime+Walktime+Waittime实际加工周期=手工时间+行走时间+等待时间

Longestoperator’sactualcycletimetellsushowmanypartsthecelliscapableofrunning最长的加工周期告诉我们单元有能力加工多少件零件

ActualCycleTimeisthetimeittakesanoperatortocompleteonecycleofhis/herstandardwork实际加工周期是指一位操作员完成其标准作业的周期StandardizedWork

标准化作业ActualStandardizedWork

标准化作业ManualTime:手工时间Thetimerequiredforanoperatortoperformthephysicaltasksforonecycleofoperation(Inspecting,loading/unloading,andgauging)操作工在一个周期的操作中为完成手工任务所需的时间(如检验，装载，卸载，测量)StandardizedWork

标准化作业ManualStandardizedWork

标准化作业WalkTime:行走时间Thetimerequiredforthephysicalmovementfromonepointtoanother,withorwithoutapart从一点移动到另一点所需的时间，持有或无零件StandardizedWork

标准化作业WalkTiStandardizedWork

标准化作业WaitTime:等待时间Thetimetheoperatorwaitswhilethemachinecompletesitsfunction

操作工等待机器完成其操作的时间StandardizedWork

标准化作业WaitTiUnassignedTime未分配时间Thedifferencebetweenyouractualcycletimeandyourtargetcycletime实际加工周期和目标加工周期之间的差StandardizedWork

标准化作业UnassignedTime未分配时间ThediffStandardizedWork

标准化作业MachineCycleTime:机器周期Thetimerequiredbyamachinetocompleteonecycleofoperation机器完成一个操作循环所需的时间

*MachinecycletimemayalsobereferredtoasAutoTime机器周期也被称为自动时间StandardizedWork

标准化作业MachineTargetCellManning目标单元人员配备#OfMembers=TotalManualTime+TotalWalkTimeTargetCycleTime目标周期员工数

总的手工时间

总行走时间TargetCellManning#OfMemberAvailableDailyOperatingTime(Seconds)TotalAverageDailyProductionRequirements(Pieces)GOAL:actualcycletimetargetcycletimetakttimeTargetCycleTime目标周期=Takttime-specialallowances特殊耗时ActualCycleTime=Thetimeittakesanoperatortocompleteonecycleofstandardwork.Thelongestoperator’sactualcycletimetellsushowmanypartsthecelliscapableofrunning实际周期=一位操作员完成标准作业的整个周期的时间。操作员实际最长耗时告诉我们这个单元可以生产的部件数。TaktTimeCalculation:计算每日可得操作时间(秒)总平均每日生产要求(件数)目标：实际周期目标周期TAKT时间AvailableDailyOperaLaborEfficiency

劳动效率

LaborEfficiency=StandardDirectLaborHoursActualSpentHoursStandardLaborxStandardCycleTime(InHours)xOutputActualLaborxActualHours=LaborEfficiency

劳动效率StandardProductivityBenchmark

生产力参照值CellF1

单元F1AverageManualTime(MT)-36.0seconds平均手工时间-36.0秒Manualtimeisthetimerequiredforanoperatortoperformthephysicaltasksforonecycleofoperation.(Inspecting,loading/unloading,andgauging)手工时间是一操作工完成一个操作周期所花在手工操作上的时间(检验，装卸，检测等)Takt-48.7seconds理论周期-48.7秒Manual(MT)%ofTakt-73.9%手工时间占理论周期的比例-73.9%MTTAKT=3648.7=73.9%ProductivityBenchmark

生产力参照值C

PRODUCTMIX

混流生产

PRODUCTMIX

混流生产ProductMixExample产品混合例子{ProductA+B+C=876产品A=219=25%B=307=35%C=350=40%876=100%TotalAvailableTime总共可用时:8hoursX60’=480’-20’(2-10’breaks)=460’X60”=27,600”27600”/876dailyunitsrequired=31.5”TaktTimeTotalDailyAvailableTime总每日可用时Avg.DailyUnitsRequired(A,B,C)平均每天所需求的件数TAKT=ProductMixExample{ProductATargetCycleTimeCalculation

目标周期的计算TargetCycleTime=TaktTime-SpecialAllowances目标周期=TAKE时间-特殊耗时TaktTime=31.5”SpecialAllowances特殊耗时=10’ATPM +12’TeamMeeting小组会议SpecialAllowances特殊耗时=22’X60”=1320”SpecialAllowancepercycle=1320”/876units=1.5”每个循环的特殊耗时31.5”(TaktTime)-1.5”(SpecialAllowance)=30.0”TCT

TargetCycleTimeCalculation

ProductMixExample产品混合例子Product产品

ABCManual人力306”260”200”Walk走动50”40”40”Total总计356”300”240”%Mix混合比重25%35%40%PartA356”x.25=89”PartB300”x.35=105”PartC240”x.40=96” 290”WeightedAverage加权平均的全部工作内容

CalculationofAvg.TargetManning平均目标人力的计算ProductMixExampleProduct产品MaTargetManningExample

目标人力配备举例290”30.0”TargetCycleTime

目标周期TotalManualTime+TotalWalkTime总手动时间+总走动时间TargetManning目标人力===9.6Weroundtothenextfullpersonanduse10people

我们取整数，用10人。TargetManningExample

目标人力配备举FixedManning/FlexTCT固定人力/可变的目标周期Product产品

ABCManual人力306”260”200”Walk走动50”40”40”Total总共356”300”240”%Mix混合25%35%40%PartA 356”/9.6=37.08”TargetCycleTimePartB 300”/9.6=31.26”TargetCycleTimePartC 240”/9.6=25.00”TargetCycleTimeFixedManning/FlexTCTProduct产FixedTCT/FlexManning固定的目标周期/可变的人力Product产品

ABCManual人力

306”260”200”Walk走动

50”40”40”Total总计

356”300”240”%Mix混合

25%35%40%356”/30.0”=11.8TargetManning目标人力300”/30.0”=10.0TargetManning目标人力240”/30.0”=8.0TargetManning目标人力FixedTCT/FlexManningProduct产ProductMixExample产品混合例子FixedManning固定人力FixedTCT固定目标周期TargetManning目标人力TargetCycle目标周期TargetManning目标人力TargetCycle目标周期A30.0” 11.8 37.0” 9.6B30.0” 10.0 31.2” 9.6C30.