通用汽车精益生产模式

精益生产的历史

LeanManufacturingHistory1955丰田制造系统TOYOTAPRODUCTIONSYSTEM1979质量体系QUALITYSYSTEM1983NUMMI,SYCHRONONSMANUFACTURING1990LEANMANUFACTURING,ESENACH1995DELPHIMANUFACTURINGSYSTEM1996GM-GMS1998COMPETITIVEMANUFACTURING丰田准时化生产方式的技术构造体系企业教育，开发人力资源全员参加的改善和合理化活动自动化全面质量管理设备快速准备设备合理布置多技能作业员标准化作业质量保证小批量生产同步化生产均衡化生产良好的外部协作看板管理准时化生产消除浪费、降低成本全公司整体性利润增加柔性生产、提高竞争力适应性经济性尊重人才，发挥人的作用不断暴露问题，不断改善意识改革*5S精益生产方式体系架构生产的快速与维护精益品质保证与自动化柔性生产系统均衡化同步化现场IE作业研究生产设计与物流系统产品开发设计系统精益工厂追求7个“零”极限目标精益工厂追求7个“零”极限目标“零”“零”切换浪费“零”库存“零”浪费“零”不良“零”故障“零”停滞“零”灾害GMS简介GMSBriefIntroduction

GMS简介GMSBriefIntroduction

通用汽车全球制造系统的原则和要素构成了一个完整的系统,只有把它作为一个完整的整体实施才能有效。各原则之间相辅相成，没有一个原则或要素能独立存在。因此我们用一个类似太阳系的图标来表示GM－GMS。只有当五个原则共同实施，GM－GMS才是一个完整的系统。TheprinciplesandelementsofGM-GMScompriseacomp-letesystem,andtobeeffectivemustbetakentoget-herasawhole.Eachprinciplesupportsandreinforcestheothers.Nooneprincipleorelementcanstandalone.Forthisreas-on,thesolarsystemiconisusedtosymbolizeGM-GMS.GM-GMSisacompletesystemwhenallfiveprinciplesareimplemented.

GMS简介GMSBriefIntroduction

GMS简介GMSBriefIntroduction

8个要素

8Elements 宗旨、价值观和文化理念

Vision,Values,&CulturalPriorities 使命

Mission 健康和安全第一

Health&SafetyPriority 合格的员工

QualifiedPeople 人员支持系统/小组原则 PeopleSupportSystem/TeamConcept 员工参与 PeopleInvolvement 开放式交流 OpenCommunicationProcess 车间现场管理

ShopFloorManagement目的的：：引导导员员工工的的个个人人行行为为和和公公司司决决策策，，创创造造一一个个关关注注过过程程和和结结果果的的氛氛围围。。Purpose:Toguideindividualbehaviorandorganizationaldecisions,creatingaprocessandresultsfocusedculture.核心心要要求求CoreRequirements:领导导层层维维护护和和纠纠偏偏LeadershipchampionstheCorporateVision,CoreValues,andCulturalPriorities明确确清清晰晰TheVision,Values,andCulturalPrioritiesareclearly公司司的的政政策策（（包包括括一一、、二二、、三三级级文文件件））与与其其一一致致Policies,practices,procedures,andsystemsareconsistentwiththeVision,Values,andCulturalPriorities领导导层层以以身身作作则则Leadershipleadsbyexample评估估和和改改进进，，确确保保公公司司宗宗旨旨、、价价值值观观和和文文化化理理念念的的一一致致性性EvaluateandimprovetoensureconsistencywiththeVision,Values,andCulturalPriorities1.宗旨旨、、价价值值观观和和文文化化理理念念Vision,CoreValuesandCutrualPriorities2.使命命MISSION定义义：：传达达给给具体体车车间间或或职职能能部部门门的一一个个目目标标或或者者期期望望值值的的陈陈述述Definition:Alocalstatementthatconveysamentalimageofthegoalordesiredstateforaspecificplantorfunction.目的的：：激励励员员工工工工作作并并使使全全体体员员工工知知道道、、理解解并并趋趋近近公司司的的奋奋斗斗目目标标Purpose:Tomotivate/inspirepeopletoactandhelptheentireworkforcevisualize,understand,andrelatetotheorganization’’scompetitivegoalsandobjectives.核心心要要求求：：Corerequirements:是公公司司领领导导层层制制定定和和牵牵头头，，全全公公司司共共同同参参与与的的Developedandchampionedbyleadershipandsharedwiththeentireorganization.支持持公公司司的的宗宗旨旨、、价价值值观观和和文文化化理理念念，，并并与与其其保保持持一一致致AlignedwithandsupportstheCorporateVision,Values,andCulturalPriorities.全公公司司上上下下理理解解和和全全力力支支持持Understoodandcommittedtobyalllevelsoftheorganization审查查策策略略、、行行动动和和体体系系以以保保证证提提供供支支持持Strategies,activities,andsystemsarereviewedtoensuretheysupportpeople’’seffortstoreachthemission.需支持持公司司的业业务目目标Supportsthebusinessgoalsandobjectives.有定期期评审审使命命陈述述的流流程AprocessisinplacetoperiodicallyevaluatetheMissionStatement.定义：：实施一一系列列的行行为、、措施施、政政策和和方法法以帮帮助员员工工实现现一个个健康康无伤伤害的的工作作环境境。Definition:Implementationofbehaviors,actions,policies,andpracticesthathelpouremployeesrealizeahealthy,injuryfreeenvironment.目的：：以安全是是最重重要的的、所所有的的事故故都是是可预预防的的理念为指导导，采采取切切实的的措施施保证证员工工良好好的健健康状状况和和健康康无害害的环环境Purpose:Toensureweprotectthewellbeingofourpeoplethroughactionsconsistentwiththebeliefthatsafetyisouroverridingpriorityandallaccidentsarepreventable.3.健康和和安全全优先先HealthandSafetyPriority核心要要求：：CoreRequirements:领导层层对所所有健健康和和安全全核心心要素素的实实施和和监控控负责责LeadershipisresponsibleforimplementationandmonitoringoftheseHealthandSafetycorerequirements工厂安安全回回顾板板PlantSafetyReviewBoard定期安安全巡巡检SafetyObservationTours安全作作业（危险险的工工作，，有健健康和和安全全作业业指导导书））SafeOperatingPractices(HealthandSafetystandardizedworkinstructionsaredocumentedandimplementedforjobswhereriskstoemployeeswarrant)事故调调查（“5个为为什么么”问问题解解决流流程)IncidentInvestigation(““5Why””problemsolvingprocess)严格遵遵守安全规规章Abidebythesafetyrulesstrictly4.合格的的员工工QualifiedPeople目的：：确保员员工的的能力力与竞竞争性性的生生产制制造角角色和和职责责相匹匹配Purpose:Toensurethebestpossiblefitofpeople’sabilitieswiththeexpectationsofthecompetitivemanufacturingrolesandresponsibilities.核心要求CoreRequirements：制定行为规规范，体现现公司核心心价值观，，书面形式式交流Competencies(RequiredBehaviors)aredefinedforeachleveloftheorganization选择Selection培训Training激励Inspirit发展Development5.员工支持系系统/班组组原则PeopleSupportSystem/TeamConcept定义：赋予各班组组主人翁和和基本工作作单位的功功能使小组成员员共同承承担职责相相互支持，通过不断断改进达到到共同的的目标Definition:Smallgroupsofemployeesthatareempoweredtofunctionastheownersandbasicworkunitwhosharecommontasks,supporteachother,andachievecommongoalsthroughcontinuousimprovement.目的：通过团队合合作使员工工参与整个个工作过程程，不断改改进自自身表现现，产品质质量和工作作环境，最最终树立员工自自豪豪感和工作作成就感并促进员工工个人的发发展Purpose:Toinvolveemployeesintheworkprocesstocontinuouslyimproveperformance,productquality,andworkingconditionsthroughteamwork.Todevelopemployeepride,jobsatisfaction,andpersonalgrowth.核心要求CoreRequirements：制定各级和和职能块的的职责Rolesandresponsibilitiesforeachlevelandfunctionoftheorganizationaredefined.履行,交流流T/M,T/L,G/L职责Teammembers,teamleaders,andgroupleadersfulfillresponsibilitiesoftheirposition.班组原则Teamcriteria.业务系统和和实践操作作支持小组组原则的实实施Businesssystemsandpracticessupportimplementationoftheteamconcept.班组长的选选择Teamleaderselection.班组长支持持小组和班班组目标的的标准化任任务TeamLeadersarenotassignedstandardizedworkbutareassignedstandardizedtasksthatsupporttheteamandobjectives.支持部门对对于班组的的支持（HR,财务，工工程部，质质量部等））Supportorganizations(e.g.HR,Finance,Engineering,Quality,etc.)understandandexecutetheirresponsibilitytotheteams.6.人员参与PeopleInvolvement定义：一整套鼓励励员工以积积极的态度度参与公司司不断改进活活动动的系统、程程序、实践践和方案Definition:Systems,procedures,practices,andprogramsthatinvolveallemployeesasactiveparticipantsincontinuousimprovementactivities.目的：营造和保持持一种培育育“自豪感””的氛围。Purpose:Createandmaintainanenvironmentwhichfostersa"spiritofpride””.核心要求：：实施计划帮帮助员工作作出有依据据的决策和和改进Programsandactivitiesareimplementedtohelppeoplemakeinformeddecisionsandimprovements.实施活动（合理化建建议，Gofast(加速），，持续改进进等）Implementactivities(e.g.suggestionprogram,GoFast Activities,CIPPrograms,etc.)建立小团队队参与持续续改进Smallgroupsareestablishedandparticipateinimprovementactivities.给予员工/团队认可可Recognitionisprovidedtoemployees/teams.个人、小组组和公司绩绩效应与福福利待遇系系统挂钩Individual,team,andcompanyperformanceisfactoredintothecompensationsystem.7.开放式交流流流程OpenCommunicationProcess定义：为营造一种种所有层次次都能畅所欲言和和有效交交流的氛围的手段段和方法。。Definition:Behaviorsandpracticesthatcreateanenvironmentthatfostersafreeandopenflowofcommunicationatalllevels.目的：交流信息使使各级员工工作出有依依据的决策策和改改进进部门的表表现。Purpose:Toexchangeinformationthathelpspeopleatalllevelsmakeinformeddecisionsandimproveorganizationalperformance.核心要求CoreRequirements：会议交流Conductregularlyscheduledmeetingstocommunicate交流媒介（（Notes，暗灯板，其它可行行的交流工工具）Usecommunicationmediaeffectively(e.g.Notes,Andonboards,oranycommunic－ationtoolsavailable).营造公开交交流的办公公环境（开开放式办公公室，玻璃璃分隔，支支持部门靠靠近制造生生产部门，，小组会议议区域，关注操作人人员信息的的及时获取取）Ensurethephysicalenvironmentfostersopencommunication(e.g.openoffices,glasspartitions,supportdepartmentsincloseproximitytothemanufacturingorganization,groupmeetingareas,concernabout).领导层以以身作则则（平易易近人，，能主动动听取意意见和深深入车间间）Theleadershipstyledemonstratesbehaviorsexhibitingopencommunication(e.g.accessibility,activelisteningskills,floorpresence).信息快速速传递的的结构程程序Astructuredprocessisinplacetoquicklydisseminateinformation(motionannouncement,cancellationofovertime).8.车间现场场管理ShopFloorManagement定义：管理和支支持小组组的行动动要在工工作现场场进行，，便于理理解解，支持持和管理理操作Definition:Thebehaviorofmanagementandsupportgroupstogotowheretheworkisperformed,tounderstand,support,andmanagetheoperations.目的：确保所有有的决策策均在工工作现场场利用相相关、实实际、正正确的第第一手材材料作出出Purpose:Toensurethatdecisionsaremadeattheworksitebyutilizingrelevant,factual,accurate,andfirst-handinformation.核心要求求：定期的管管理评审审（SPQRC)和流程程评审(5S,标准化化工作））RegularManagementreviewsincludeSPQRC(Safety,People,Quality,Responsiveness,Cost)andprocessevaluations(e.g.WorkplaceOrganization/5S,StandardizedWork).每个员工都了了解SPQRC的状态SPQRCstatusindicatorsarevisiblesoeveryemployeecanseeandunderstandcurrentconditions.管理支持人员员帮助班组成成员通过直接接观察相关工工艺/工作区区域来解决问问题ManagementandSupportPersonnelassistTeamMemberstosolveproblemsbydirectlyobservingtheprocess/workareawhereconcernsexist问题的通报流流程（问题题升级）Problemescalationprocessesaredeveloped车间办公室到到达所有生产产区域，TeamRoom设置在线旁Shopofficesmustbeaccessibletoallproductionareasandteamleaderworkstationsarelocatedlineside.会议/休息区区域能容纳所所有员工且在在一线主管（（工段长/值值班长）的控控制/责任范范围内Meeting/breakareasaretobesizedtoaccommodateallmemberswithinthefirstlinesupervisor’’sspanofcontrol/responsibility(groupleader/arealeader)whereappropriate.定义和消除浪浪费（七种浪费）Wasteisactivelyidentifiedandeliminated.目视化管理VisualManagement：-偏离标准的的情况对每个个人可见makedeviationsfromstandardsvisibletoeveryone-用显而易见见的方式显示示操作状态displaytheoperatingstatusinaneasytoseeformat-提供指示和和/或信息给给员工provideinstructionand/orinformationtoemployees标准化标准化是不断断改进的基石石4个要素4Elements工作场地有序序布置WorkplaceOrganization节拍定额时间间管理ManagementByTaktTime标准化作业StandardizedWork目视化管理VisualManagement9.工作场地地有序布置WorkplaceOrganization核心要求CoreRequirements：5S标准员工的参与Peopleinvolvement去除多余物品品Excessornon-essentialthingsareeliminated.评估和改进AuditandadressSort分类Sift筛选Sweep清扫Sustain保持Self-discipline自律物在其位，位位有其物目的：通过工作场地地的布置和保保 持，使“不符合标标准”的情况况 显而易见见。Purpose:Toputordertoandmaintaintheworkplacebymaking"outofstandard"conditionsreadilyvisible.定义：：用于调调节和和均衡衡满足足销售售需求求的生生产产产量的的测量量体系系。。Definition:AmeasurementsystemthatregulatesandlevelstheproductionoutputtomeetsalesdemandTT=生产时时间（（秒））/客客户需需求（（件））目的：：均衡生生产计计划且且生产产所需需的产产量。。Purpose:Toleveltheproductionscheduleandproducewhatisneededwhenitisneeded.作用：：杜绝七七种浪浪费之之：““过量生生产，，等待待”zl:结合开开动率率，分分析一一下TT,ATT,CT,JPH之间间的关关系。。10.节拍拍定额额时间间管理理ManagementByTAKTTime核心要要求CoreRequirements：ATT近似满满足需需求，，TT与AT在某一一段时时间内内（至至少一一个月月）保保持节节拍定定额时时间和和实际际节拍拍定额额时间间固定定。Takttimeandactualtakttimeremainsfixedforaperiodoftime––onemonthminimum.应对变变化的的流程程（具具体的的流程程）Proceduresmustbeestablishedtomanagetakttimeandactualtaketimechanges(detailedprocess).相关关文文件件的的修修改改Relevantdocumentsmodification辅助助设设施施Assistantfacility11.标标准准化化作作业业SOS定义义：：由功功能能组组织织同同意意，，制制定定，，遵遵守守和和保保持持的的可可用用于于重复复性性工工序序的功功能能性性文文件件。Definition:Thedocumentationofworkfunctionsperformedinarepeatablesequence,whichareagreedto,developed,followed,andmaintainedbythefunctionalorganization.目的的：：为持续续改改进进建立立可重重复复，可预预测测的基础础并使使操操作作者者参参与与最最初初和和不不断断的的改改进进过过程程以以便便获获得得最最高高水水平平的的安安全全，，质质量量和和生生产产率率。。Purpose:Toestablisharepeatable,predictablebaselineforcontinuousimprovementandtoinvolvetheoperatorinboththeinitialandongoingimprovementstoachievethehighestlevelsofsafety,quality,andproductivity.核心心要要求求CoreRequirements:记录录并并且且标标准准化化所有有重重复复性性工工作作Allrepeatableworkmustbedocumentedandstandardized需记记录录的的要要素素Thefollowingcriteriaaredocumented所有有班班次次的的同同意意（（保保证证不不同同班班次次、、不不同同的的人人做做的的一一样样））Allelementsanddetailofstandardizedworkmustbeagreedtoacrossallshifts.清晰晰可可见见Visuallydisplayed评审审和和改改进进Auditandadress生产产和和支支持持人人员员共共同同参参与与Manufacturingandsupportpersonnelinvolvementzl:可以以在在标标准准化化作作业业单单中中体体现现出出改改版版的的历历史史。。12.目目视视化化管管理理VisualManagement目的的：：使工工作作场场地地的的标准准和和实实际际状状况况一一目目了了然然Definition:Aprocessinwhichstandardsandactualconditionsbecomequicklyvisualintheworkplace.特点Specialty：：1.作为为一种管管理手段段Workasanmeasureofmanagement2.管理理差异性性Managethediscrepancy3.是即即时的Instantaneous核心要求求CoreRequirements：目视管理理使用和和范围theextentanduseofvisualmanagement在标注化化作业中中，关键键或规范范的程序序应有特特别的目目视标示示Criticalorregulatedprocessesreceivespecialvisualidentificationsonthestandardizedwork.更新并维维护目视视管理表表格和工工具Visualmanagementformsandtoolsarecurrentandmaintained用于相同同应用的的目视化化方法必必须标准准化Themethodstovisualizecommonapplicationsmustbestandardized当前和标标准的（（指标或或目标））的状态态必须清清晰可辨辨Boththecurrentandstandard(targetorgoal)conditionsmustbeclearlyidentifiable.简单明了了Easilyunderstood难以立即即改正，，应记录录、张示示并交流流其相应应对策Countermeasuresforobservedout-of-standardconditionsthatcannotbeeasilyrectifiedmustbedocumented,displayed,andcommunicated.（与问题题解决的的链接））应用：工工位地址址牌，标标签，线线标识，，暗灯板板Application:stationaddressbrand,label,lineindication,Andonboard5个要素素5Elements产品质量量标准ProductQualityStandards制造工艺艺认证ManufacturingProcessValidation工序内控控制及验验证In-ProcessControl&Verification质量反馈馈/前馈馈QualityFeedback/Feedforward质量系统统管理QualitySystemManagement13.产品品质量量标准准ProductQualityStandards定义：：产品特特性可可测的的要求求，这这些要要求如如能满满足，，将将确确保我我们的的产品品达到到内/外部部客户户的要要求Definition:Measurablerequirementsforproductcharacteristics,whichwhensatisfied,ensureourproductsmeetinternal/externalcustomerrequirements.目的：：提供产产品评评估的的标准准Purpose:Toprovidecriteriaforproductevaluation.核心要要求CoreRequirements:制定,批准准,修修改的的流程程(PTQ-1-00-0021.012004.12.30)Adocumentedprocessisinplacetodevelop,approve,andrevisetheproductqualitystandards.(PTQ-1-00-0021.012004.12.30)质量标标准qualitystandards满足用用户,工程程,法法规的的要求求Productqualitystandardsmustsatisfycustomer用于反反馈给给工程程部的的正式式的流流程Aformalprocessexiststofeedback工具tools：KPC,SOS,VisualAids，边界样样品，，工序序检查查记录录表表，质质量检检验规规范，，冷试试规范范，热热试规规范14.制造造工艺艺认证证ManufacturingProcessValidation定义：：在开始始全面面生产产前进进行工工艺准准备和和认证证的方方法Definition:Themethodbywhichprocessesarepreparedandvalidatedbeforestartingfullvolumeproduction.目的：：确保每每道制制造工工序在在完成成生产产计划划的同同时达达到既既定的的产品品质量量标准准Purpose:Toensurethateachmanufacturingprocessiscapableofmeetingdefinedproductqualitystandards,whileachievingschedule.核心要要求CoreRequirements:符合GPDP工具Tools：ProcessFlowDiagram（（Review)ProcessControlPlan（（Review)PFMEA（RPN）PTRBucketBuildPPAP，，Pilot，，Firstpiece15.在线线控制制及验验证In-ProcessControl&Verification定义：：通过预预防，，检测测和遏遏制非非正常常状况况在工工位上上造入入质量量的系系统Definition:Thesystemofbuildingqualityinstationthroughprevention,detection,andcontainmentofabnormalities.目的：减少工序的的波动以确确保在工位位上的所有有产品都符符合质量要要求，并且且尽可能能快地在制制造后的下下道工序得得到确认以以减少缺陷陷相关的浪浪 费Purpose:TominimizeprocessvariationtoensurethatallproductsareOKinstationandareconfirmedassoonaspossiblefollowingmanufactureandtoreducewasteassociatedwithdefects.核心要求:预防Prevention检测Detection遏制Containment下述情况前馈缺陷外溢备用工具/设备问题解决（（经验借鉴鉴）产品/工艺艺变更下述情况反馈缺陷确定问题解决为问题解决决提供流程程记录跟踪工具：暗灯灯，问题解解决跟踪系系统,CARE前馈：对于于可能发生生的质量问问题进行事事先的控制制反馈：对于于已发生的的质量问题题进行控制制16.质量量反馈/前前馈QualityFeedback/Feedforward目的：确保质量信息达到需要这这些信息的的人员手中中Purpose:Toensurethatinformationonqualityreachesthosewhoneedit.核心要求CoreRequirements:文件形式确确定:每道工序的的客户和供供应商客户和供应应商所需的的时间表,内容等工序内测量量(FTQ等)17.质量量系统管理理QualitySystemManagement目的：定义和规范范质量活动动的既定操操作Purpose:Todefineandregulatetheintendedoperationofthequalityactivities.包括：QS-9000体系，质量量阀流程，，GPDP（（GQS））Including:QS-9000system,Qualityvalveprocess,GPDP(GQS)核心要求CoreRequirements:质保向工厂厂领导汇报报HeadofqualitydepartmentreportstoManager/Directoroftheplant.质保有足够够的资源Assureresourceallocationforqualityactivitiesissufficient与质量体系系相符compliantwiththeappropriatequalitysystemstandard(s)与质量相关关职能的合合适的组织织结构AnappropriateorganizationalstructureisinplaceforqualityrelatedfunctionsBPD来管理和跟跟踪TheBPDprocessisusedtomanagemeasurementsandtrackprogresstogoals.17.质量量系统管理理QualitySystemManagement产品质量标标准清晰易懂clearlycommunicatedtotheuser融于标准化化作业中incorporatedinstandardizedwork统一的common不能比前道道工序应用用的标准更更苛刻nottighterthanthoseappliedinupstreamprocesses在工艺的每每一阶段都都有定义和和应用defined&appliedateachstageoftheprocess对于已经建建立的标准准是可测量量,可比较较measurableand/orcomparablewithestablishedcriteriaGPDP结合合防防错错到到工工艺艺/产品品设设计计中中在工工艺艺开开发发过过程程（（至至少少:关关键键工工艺艺））中中使使用用FEMA方方法法确定定和和实实施施工工序序控控制制来来符符合合工工程程要要求求（（KPC工工艺艺控控制制计计划划））有人人、、机机、、料料、、法法和和环环的的变变更更时时，，对对工工艺艺进进行行认认证证(PTS-0101.012000-4-24工艺艺验验证证程程序序)在生生产产情情况况下下实实施施制制造造认认证证(PPAP)使用用前前认认证证工工具具、、设设备备、、料料箱箱、、检检具具和和方方法法(PTS-0101.012000-4-24工艺艺验验证证程程序序)在系系统统完完成成之之前前实实施施TPM计计划划预防防Prevention标准准化化作作业业(生生产产,维维修修,检检查查)SOS(Manufacture,Maintenance,Inspection)TPM遵循零件质量量控制计划Followpartsqualitycontrolplan符合标准的部部件才能运到到生产线旁(来料检查)Onlyqualifiedpartscanbedeliveredtotheline(materialcheck)关键设备的检检查Keyequipmentchecking验证工序改变变后的有效性性Effectivenessvalidationforprocesschanging在标准化过程程中对相似过过程进行借鉴鉴。Usesimilarprocessforreferenceduringstandardization防错计划，防错清单，，防错验证error-proofingplan,error-proofinglist,error-proofingvalidation检测Defection把所需的质检检纳入标准化化作业中（装装配）Requiredqualitychecksareincludedinstandardizedwork(assembly).质检项目有标标准Qualitycheckitemsarebasedondefinedcriteria根据质量计划划配备足够的的资源Sufficientresourcesareallocatedinaccordancewiththequalityplan更新系统Qualitychecksystemsareupdated制定重要工序序的检测频次次Inspectionfrequenciesofcriticaloperationsareestablished检查站Inspectionstation把检查方法（（触摸，听，，看）纳入标标准化作业（（装配）Point,touch,listen,andcountinspectionmethodsareincorporatedinstandardizedwork.用声光信号Audio/visualsignalsareimplemented遏制CONTAINMENT采用暗灯AnAndonsystemisimplemented本工位控制缺缺陷Aprocessisstoppedwhendiscrepanciesthatimpactdownstreamactivitiesmustbecontrolledinstation.问题解决流程程确定有效的的长期措施Aproblemsolvingprocessisinitiatedtoidentifypermanentcorrectiveactionthatisverifiedasbeingeffective.缩短制造周期期整体制造周期期(从得到订订单到收到货货款）产品发展周期期（从概念到到投产）过程制造周期期（从原材料料到最终装配配）9个要素9Elements简易的工艺流流程SimpleProcessFlow少量包装SmallLotPackaging固定周期定货货系统/定购购零部件FixedPeriodOrderingSystem/OrderParts受控的的外部部运输输ControlledExternalTransportation有计划划的交交运/收货货ScheduledShipping/Receiving临时物物料储储存-CMA（中心心物料料区域域）TemporaryMaterialStorage(CMA––CentralMaterialArea)拉动式式系统统PullSystems均衡已已定购购车辆辆的生生产计计划LevelVehicleOrderSchedules供应链链管理理SupplyChainManagement18.简易易的工工艺流流程SimpleProcessFlow定义:以获得得一个个简易易的物物料与与信息息流为为目的的的流流程Definition:Aprocessthatincorporatesaconstantdrivetoattainasimplesequentialprocessflowofmaterialandinformation.目的:设计和和实行行流程程，来来维护护“先进先先出”，可追溯溯，可可视，缩缩短制制造周周期，，检查查降低低成本本时的的问题题，降降低库库存和和按按流程程工作作。(简易易的物物料和和信息息流））Purpose:TodesignandimplementprocessesthatmaintainFIFO,allowtraceability,arevisual,reduceleadtime,easilydetectsproblemswhileoptimizingcost,andreducesinventoryandworkinprocess.核心要要求CoreRequirements：：所有操操作中中体现现“先进先先出”FIFOpresentinalloperations.工序和和缓冲冲区（（车辆辆，零零件））是受受控，，优化化和目目视的的Work-in-processandbuffers(vehicles,parts)arecontrolled,optimized,andvisualized.需要批批量或或少量量生产产时，，尽量量减少少规模模。Whenbatchorsmalllotproductioniseconomicallynecessary,batchorlotsizemustalwaysbechallengedforreduction.布局和和工艺艺要有有助于于形成成直接接，持持续和和简易易的物物料流流Layoutsandprocessesfacilitateadirect,continuous,andsimplematerialflow.操作工工的工工作区区域设设置必必须考考虑安安全有有效的的零部部件摆摆放Operatorenvelopesaresettoallowsafe,efficientpartspresentation.生产目目视化化辅助助（载载货单单，屏屏幕，，拉动动式系系统，，等等等）以以简洁洁的格格式显显示在在车间间现场场Productionvisualaids(manifest,screens,pullsystems,etc.)arepresentontheshopfloorinasimpleformat.移动设设备和和生产产设备备要有有助于于形成成简易易的流流程Mobileequipmentandproductionequipmentfacilitatesimpleflow.19.少量量包装装SmallLotPackaging定义:确定，分分配或设设计合适适的标准准数量和和料箱Definition:Determining,assigningordesigningtheappropriatestandardquantityandcontainer.目的：以在运输输，储存存和运送送中不易损坏坏，容易易控制制的“用户户喜欢””的包装装方式为为操作工工提供零零件件。Purpose:Toprovidepartstotheoperatorinauser-friendlypackagethatfacilitatesdamage-freeandeconomicalhandlingduringshipment,storageanddelivery.核心要求求CoreRequirements：料箱设计计ContainerDesign标准包装装数量应应能满足足多次重重复运输输的需要要Standardpackquantityprovidesforfrequentdelivery.a.手工处理理的料箱箱，使用用点库存存：2小小时Pointofuseinventorytargetis2hoursformanuallyhandledcontainer.b.大件料箱箱，使用用点库存存：少于于4小时时Pointofuseinventoryforbulkcontainerstargetedfor4hoursorless.将料箱装装满（没没有多余余空间））Containercontentsshouldfillthecontainer(noair).核心要求求CoreRequirements：尽可能使使用通用用的可回回用料箱箱Useofthecommonreturnablecontainersismaximized.人工搬运运的料箱箱和部件件间衬垫垫应满足足人机工工程提升升准则（（把手孔孔，重量量等）Manuallyhandledcontainersanddunnagemeetergonomicliftingguidelines(e.g.handholes,weight,etc.).物料在生产性料箱中运运输Materialshouldbeshippedinproductioncontainers最小化/消除重重新包装装Repackingisminimized/eliminated.核心要求求CoreRequirements：空箱返回回区域Emptycontainerreturnareas指定的收收集，分分类和分分级运输输区Aredesignatedforcollecting,sortingandstaging地址和目目视化识识别（““分类””，“分分级”区区域，供供应商，，箱盖说说明等）Areclearlyidentifiedwithappropriateaddressesandvisualcontrols(e.g.typeofarea"Sort","Stage",supplier,returnschedule,cappinginstructions,etc.)能容纳计计划数量量的料架架、托板板和料箱箱Accommodateplannedquantitiesofracks,palletsandcontainers每个供应应商（和和/或供供应商组组）的料料箱有指指定区域域Aredesignatedforeverysupplierand/orcontainercombination减少运输输距离和和标准化化作业流流程Arelocatedtominimizetraveldistanceandstandardizetheworkflow核心要求求CoreRequirements：空箱处理理准则确保操作作工把空空箱放置置在合适适的返回回装置中中Assureoperatorplacesemptycontaineronappropriatereturndevice遵循书面面形式的的内部衬衬垫处理理流程Conformtoawrittenprocessforhandlinginternaldunnage遵循书面面形式的的分类，，分级，，装载和和卸载工工作流程程Conformtoawrittenprocessforpropersorting,staging,loading,andunloading防止错用用料箱Preventmisuseofcontainers确保在运运送至供供应商之之前，空空箱中无无碎屑物物Assureemptycontainersarefreeofdebrisbeforeshippingthemtosupplier确认损坏坏的料箱箱并制定定处理的的方式Identifyandroutedamagedcontainersforrepair/disposal核心要求求CoreRequirements：验证新包包装或改改进已有有包装的的流程Processexiststovalidatenewpackagingorchangestoexistingpackagingforimprovementopportunities.20.固定周期订订货系统/定购零零部件FixedPeriodOrderingSystem/OrderParts定义：为了能够在在均衡基础础上有效地地提供物料料而预先先确定零零部件定购购的固定周周期。Definition:Pre-determined,fixedperiodforpartsorderingallowingfortheeffectivesupplyofmaterialonaleveledbasis.目的：确保物流供供应可靠，，可预测。。Purpose:Toensurepredictable,reliableflowofmaterialsthroughthepipeline.固定周期订订货系统/定购零零部件FixedPeriodOrderingSystem/OrderParts核心要求CoreRequirements：零件订货和和发运固定定周期Establishfixedperiodforpartsorderinganddelivery.根据双方协协定的时间间期限，与与供应商及及运输部门门商定物料料日程Materialschedulesarecommunicatedtothesupplierandthetransportationcontactperagreedupontimehorizon.物料计划单单应注明标标准包装数数量Materialschedulesarestatedinstandardpackquantities.处理紧急事事件的流程程Anexceptionprocessexiststocoveremergencies.零部件订购购流程的内内部管理Partsorderingprocessismanagedlocally.21.受控控的外部运运输ControlledExternalTransportation定义：相关物流部部门管理的的有计划的的可控的物流流程程。Definition:Scheduledlogisticspipelinewithestablishedcontrolsmanagedbyaleadlogisticsprovider.目的：为经常性物料的运送送提供可预预测的方法法，最大大化资资源利用。Purpose:Toprovideapredictablemethodforfrequentmaterialmovementthatmaximizesuseofresources.核心要求CoreRequirements：主要物流部部门（LLP)或者者对口部门门：LLP和工工厂应建立立重点业务务的审查标标准和定期期审查制度度AprocesstomeasurekeyperformancecriteriaandregularperformancereviewswithLLPandplant工厂里的常常驻人员aresidentintheplant建立并维护护运输路线线计划Astrategicrouteplanandmaintainsrouteboard进一步降低低成本的流流程Aprocessforfurthercostreduction为货运和/或运输商商提供培训训Trainingforcarrierand/ortransportationproviders将工厂的目目标融入LLP的BPD中Thattheplant’sobjectivesareintegratedintotheLLP’sBPD以小时-小小时，天-天和周-周来分层层衡量运送送周期Thewindowdeliverytimestoplantarelevelhour-to-hour,day-to-day,week-to-week.将所有零部部件运输至至工厂和/或分配中中心，有计计划地定期期供货Allpartsaredeliveredtotheplantand/ordistributioncentertoscheduledwindows.建立不断提提高运送方方式空间效效率的流程程Processisinplacetocontinuouslyimprovecubeefficiencyofalltransportationmodes.根据经济性性和可靠性性,为每一一条路线确确定现场卸卸货还是中中转卸货"Live"unloadingvs."dropandswap"isdeterminedforeachroutebasedoneconomicsandtransportationreliability.有相应的流流程保证运运货司机执执行规定的的流程检查查(在供应商商处提货时时根据零件件号检查料料箱数)Processisinplacetoconfirmthattheroutedriverperformstheagreedprocesschecks(suchasverifyingthecontainercountbypartnumberfortheshipmentatthetimeofpick-upatthesupplier).有正确划分分供应商责责任导致的的额外运输输费用的流程Processisfollowedtoproperlyclassifysupplier-responsiblepremiumtransportation.执行以下流流程Aprocessisinplaceto:货运延误或或发货错误误确保货运运公司及时时通知工厂厂有关部门门Assurethatcarriersnotifytheplant