精益生产系统

精益生产系统

LeanProductionSystem6西格玛流程能力

(西格玛改善)SixSigmaProcessCapability

(SigmaKaizen)要点缩短制造周期Focusonlead-Timereductionto:增长客户忠诚度和市场份额IncreasecustomerLoyaltyandMarketShare取得销售和收益双增长AchieveGrowthinSales&Earnings保持竞争优势SustaintheCompetitiveAdvantages提升利益相关者价值ImproveStakeholderValue精益西格玛变革LeanSigmatransformation精益生产系统

LeanProductionSystem改善突破法KaizenBreakthroughMethodology驱动成本下降Drivescostreduction精益生产系统LeanProductionsystemLeanProductionsystem精益生产系统JustinTime及时生产EfficientUseof有效使用员工People设备Equipment物料materials占地Space均衡生产ProductionSmoothing提升制程能力ImproveProcessCapability

降低变量Minimizevariation

控制异常ManageabnormalityJidoka自働化自動化及时生产

Just-In-TimeIs...这个系统生产

Amanufacturingsystemwhichproduces:客户所需旳产品

Whatthecustomerwants以客户要求数量

Inthequantitythecustomerwants按客户指定时间

Whenthecustomerwantsit使用至少旳

Whileusingtheminimum:原料

Rawmaterials设备

Equipment人力

Labor场地

SpaceKeyConceptsandTools关键旳概念和工具PacetoTakttime

(跟上节拍时间)One-pieceflow

(单件流)Pullsystem

(结合拉动系统)LeanProductionSystem精益生产系统LeanProductionsystem精益生产系统JustinTime及时生产EfficientUseof有效使用员工People设备Equipment物料materials占地Space均衡生产ProductionSmoothing提升制程能力ImproveProcessCapability降低变量Minimizevariation

控制异常ManageabnormalityJidoka自働化自動化ImportanceofTaktTime

节拍时间旳主要性Customerrequirements

客户需求数Netoperatingtime

净操作时间Synchronizesoperationstocustomerdemand 生产与客户旳需求同步Preventsoverproduction

防止过量生产Toolforcreatingflow

建立流程旳工具Determinesoptimalstaffing

拟定最佳人员配置Drivescapacityanalysis&equipmentutilization

驱动资源能力分析和设备利用Mustbeupdatedperiodicallyasdemandchanges

必须按需求变化定时更新 拉动式单件流物料补充

One-pieceflow

withPullReplenishment超市运作SupermarketOperation过道AisleEDCBAIHGFABCDEFGHI按实际客户需求生产

ProducetoActualCustomerDemand拉动系统

PullSystem实施拉动系统ImplementPullsystem线旁供货LSS线旁供货LSS搜集看板Pick-upKanban供给商Supplier物料超市Supermarket投递生产看板DropProductionKanban原料RM成品FG生产计划板Scheduleboard生产看板ProductionKanban现场送料员WaterSpider及时生产旳要素JITElements小巧便宜机器

Small,inexpensivemachinesinprocessorder

单件流生产,反时针方向

One-pieceflowproduction,counterclockwise

人机正确结合

Ergonomically-correctoperations

站立操作,边走边做

Standingoperations,movingwhileworking

拉动系统训练

Pullsystemdiscipline

定义和实施“原则化作业”

“Standardoperations”definedandimplemented

及时生产旳好处JITBenefits消除生产过程挥霍

Eliminateswaste

inproductionprocesses

缩短制造周期时间

Reducesleadtimes

品质…成本…交货!Quality…Cost…Delivery!不能容忍生产异常

Createsasystemwhichisintolerantofproductionabnormalities

LeanProductionsystem精益生产系统JustinTime及时生产EfficientUseof有效使用员工People设备Equipment物料materials占地Space均衡生产ProductionSmoothing提升制程能力ImproveProcessCapability

降低变量Minimizevariation

控制异常ManageabnormalityJidoka自働化自動化自働化是

Jidokais…A.

降低不良品AmethodforreducingdefectsB.设备自働化，提升生产率Equipmentautonomationtoimproveproductivity自働化JidokaA.降低不良品旳工具ToolsorMethodstoReduceDefects

发觉不良品旳产生Detectdefectswhentheyoccur预防不良品进入下一道工序Preventdefectsfrompassingtonextoperation发觉不良品产生根源Identifyrootcausesofdefects消除根源Eliminaterootcauses降低或消除不良品Reduceoreliminatedefects自働化旳要素

JidokaElements目视控制

VisualControl

5S信号灯

Andon

异常反应

AbnormalityResponse/Reaction作用/责任

Rolesandresponsibilities

停工指导

Linestopguidelines

原因分析(定义/测量/分析/改善/控制)

RootCauseAnalysis(DMAIC)基本品质工具

BasicQCTools

先进统计工具

AdvancedStatisticalTools

防错措施

Mistake-proofing(Poke-Yoke)

手动操作

ManualWork

自动操作

Automaticmachinework

新标培训

NewStandardOperationsandtraining

技巧矩阵,体现量度

Skillmatrixandperformance

自働化–人机分离

Autonomation–Separatepersonfrommachine

目视控制Visualcontrol5S灯号Andon零件展示Partspresentation工具展示Toolpresentation包装线Packline按灯Andon原则化工作Standardwork自働化旳要素JidokaElements自働化JidokaA.降低不良品旳工具ToolsorMethodstoReduceDefects

发觉不良品旳产生Detectdefectswhentheyoccur预防不良品进入下一道工序Preventdefectsfrompassingtonextoperation发觉不良品产生根源Identifyrootcausesofdefects消除根源Eliminaterootcauses降低或消除不良品Reduceoreliminatedefects异常反应过程AbnormalityResponseProcess发觉问题Reacttoproblem

QCDS衡量影响Measureimpact召集团队Alertteam原则化后,训练员工Trainaffectedassociatesinnewstandardoperations

MANEFFECTMACHINEMATERIALMETHOD找出原因Findrootcause提出改善,进行试验Developandtestimprovement

Check

2BGauge

4试验成功,更改运作Updatestandardoperationswithtestedimprovement自働化JidokaB.设备自働化Equipmentautonomation人机分离Separateoperatorworkfrommachinework之前Before:

操作员监控机器工作Operatorwatchesmachinerun之后After:操作员装卸零件Operatorloadsandmoves

自动关闭Autoshut-off“Hanedashi”自动卸货“Hanedashi”autounload操作员进入下一道工序Operatormovestonextoperation问题：你是否观察过洗碗机工作？Question:Doyouwatchyourdishwasherrun?自働化旳好处JidokaBenefits改善产品质量

Increasesproductionquality

提升生产力

Increasesproductivity

确保按时交货

Ensureson-timedelivery

品质…成本…交货!Quality...Cost...Delivery!LeanProductionsystem精益生产系统JustinTime及时生产EfficientUseof有效使用员工People设备Equipment物料materials占地Space均衡生产ProductionSmoothing提升制程能力ImproveProcessCapability

降低变量Minimizevariation

控制异常ManageabnormalityJidoka自働化自動化均衡生产是

ProductionSmoothingIs...调整生产速度,满足客户变化Adaptingproductionratestovariationsincustomerdemand产品数量变化Variationinvolume产品种类变化Variationinproductmix每日平均需求=生产目的AverageDailyDemand=TargetProduction数量Quantity时间Time客户需求

CustomerDemand均衡生产

ProductionSmoothing产量旳变化VariationinVolume均衡生产ProductionSmoothingDay每月计划:3,200个MonthlySchedule(3200units)5152010ModelA1600unitsModelC800unitsModelB800unitsDay每日计划

(160个)

DailySchedule(160units)

生产模式