节拍时间管理培训

1、节拍时间管理培训车身车间2016.021在没有得到通用汽车公司书面许可的情况下，本材料不得以任何形式或方式(影印，微型胶片，数码等)复制。2Table of Contents目录GM-GMS Relationship 全球制造体系的内部联系Definition 定 义Purpose 目 的Core Requirements 核心要求Benefits 益 处Process Overview 流程概要Workplace Management Cycle 工作场地的管理周期How Standardized Work Supports Other Principles/Elements 标准化操作如何

2、支持其他原则/要素The Definition of Standardized Work & 3 Key Components 标准化操作的定义和三个关键要素-Takt Time 单件工时-Work Sequence 工 序-In-Process Stock 在线存货Job Element Sheets 工作要素单Standardized Operation Sheets 标准化操作单Non-Cyclic Standardized Work 非循环的标准化操作Supporting Tools 支持工具Standardized Work in New Model Development 标准化操

3、作的新模式Checking Standardized Work 检查标准化操作Roles and Responsibilities 角色和责任Summary 总 结Appendix 附 录3GM-GMS Relationship全球制造体系的内部联系GM-GMS#11.0操作指引“标准化操作”，支持GM-GMS“ 标准化”原则，有助于制造系统五个目标的实现。4Definition定义The documentation of work functions performed in a repeatable sequence, which are agreed to, developed, fol

4、lowed, and maintained by the functional organization.对以反复的顺序执行工作职能这一过程进行记录并形成文件，由执行机构同意、建立、执行并维护。5Purpose目的To establish a repeatable, predictable baseline for Continuous Improvement and to involve the operator in both the initial and ongoing improvements to achieve the highest levels of Safety, Qual

5、ity, and Productivity为了建立一可重复的，可预见性的不断改进的基线，并使操作员工参与到改进的发起和进行中以达到安全、质量和生产力的高标准。6Core Requirements核心要求1All repeatable work must be documented and standardized (e.g standardized work charts, standard operation sheets, job element sheets, work combination charts, time fluctuation sheets, line balance a

6、nalysis, etc)所有反复性的工作都必须记录成文并标准化(标准化工作表，标准化操作单，工作要素单，工作组合表，时间波动表，线平衡分析等)The following criteria are documented: 把以下标准整理成文2aall work elements with time (stopwatch or standard time data) 所有工作要素的时间(秒表或标准时间数据) safety/ergonomic points 安全/人机工程要素work sequence 工序quality standards and checks 质量标准和检验value adde

7、d/non-value added time(work, walk and wait)增值/非增值时间(工作，走动，等待)scroll for all moving vehicle assembly line operations and a work flow diagram for all static operations showing standard in-process stock, material, and tools.对于所有动态车辆装配线生产整理成卷，对于显示标准在线存货、物料和工具的所有静态操作制定工作流动图表。takt time, actual takt time,

8、and cycle time单件工时，实际单件工时，周期时间workloads are calculated with representative model and option content用代表车型及其选装内容来计算工作负荷。b c d efgh73All elements and detail of standardized work must be agreed to across all shifts.关于标准化操作的所有要素和细节都必须经过所有班次的同意。Standard Operation Sheets and Job Element Sheets contain orig

9、inal signatures (e.g team leaders, group leaders, shift leaders, and authorized individuals, etc)and the SOS is visually displayed at each work station.标准化操作单和工作要素单都有初始签名(班组长，工段长，值班长以及授权人员等)，标准化操作单在每个工位都要目视化Layered audits are in place to assess operator compliance to standardized work with follow-up

10、 process to address non-compliance.使用跟踪流程的分级评审来评估操作员工对标准化操作的执行情况，以关注不遵守规定的行为。A process is in place to continuously improve standardized work有一适当的不断改进标准化操作的流程Natural owners of the work function(e.g production, material, maintenance, etc) are responsible for involving their employees in the writing of

11、 Standardized Work.Support groups(e.g Health & Safety, Industrial Engineering, etc) are responsible for assisting the manufacturing organization in the creation of Standardized Work工作职能的负责人(生产，物料，维修等)使他们的员工参与书写标准化操作。支持团队(健康与安全，工业工程，等)协助制造部门建立标准化操作。45678Benefits益处To the Team Member 对于班组成员Identifies t

12、he safest, highest quality, most efficient&most ergonomically friendly approach to completing the task.识别最安全、高质量、最有效以及在人机工程方面最友好的方法来完成任务。Provides a method for the Team Member to have input into the improvement of their jobs为组员提出关于改进他们工作方面的建议提供了一种方法Provides the tool for proper training & problem solv

13、ing提供合适的培训和解决问题的工具To External Customers (People buying our vehicles) 对于外部客户(买车的人) Provides great quality and lowest possible cost through the continued execution of the best known method of production.通过坚决执行公认的生产方式，提供高质量和尽可能低的成本9To Internal Customers(Downstream Operation)对于内部客户(下道工序的操作)Provides an e

14、rror-free vehicle or component to the customer down the line.为后道工序的客户提供没有缺陷的车辆或零件Provides a baseline for problem identification and resolution提供一问题确认和解决的基准Internal Suppliers (Upstream Operation) 内部供应者(上道工序操作)Allow for level schedules to Internal Suppliers为内部供应者提供标准的程序Allows for quick identification&

15、feedback of problems to Internal Suppliers.迅速确认并反馈问题给内部供应者To other GMS Principles or Operating Guidelines对于其他GMS原则或指导As a foundational element, Standardized Work is essential to most other elements and principles within GMS.作为一基本要素，标准化操作对于GMS其他绝大多数要素和原则是必须的。The baseline for Continuous Improvement Pr

16、ocess不断改进流程的基准10Process Overview-Workplace Management Cycle过程纵览-工作场地的管理循环The following cycle is part of the foundation of the Global Manufacturing System. It provides an understanding of how Standardized Work fits into the entire system. 以下的循环是全球制造体系的一部分。它解释了标准化操作是如何融入到整个系统中的。5S 工作场地安排流程Standardized

17、 Work For Operation Visual Management 目视化管理标准化操作11Re-balance (if necessary)再平衡(如有必要)Eliminate Waste消除浪费Grasp The Current Situation把握现状Repeat Cycle反复循环Without Standardization没有标准化Working in different causes variations that impact safety, quality, productivity, and difficulty for traceability (problem

18、 solving)对于影响安全、质量、生产力的不同原因的差异，很难有追踪性(解决问题)。With Standardization有标准化By applying standards to work practices, we can identify the best practices and follow them consistently.在工作中应用标准，能识别最佳操作模式并坚持执行。The implementation of Standardized Work requires a strong emphasis on human factors标准化操作的实施强调人员因素Establ

19、ished to create a smooth and effective workflow for the operator (reduced motion and effective balancing of jobs)标准化为操作员工设立了稳定有效的工作流程(减少多余动作，有效平衡工作)Provides an interruption-free operation 提供无间断操作Incorporates good ergonomic and environmental practices 结合了良好的人机工程和环境方面的应素Allows for continuous improveme

20、nt based on operator experience基于操作者的经验不断改进Facilitates commitment by the whole team促进整个团队遵守执行12Standardized Work Supports: People Involvement标准化操作支持：人员参与Documents the safest, most ergonomic work sequence that creates good job flow. 记录最安全、最人性化的工作顺序，建立合理的工作流程Supports Team Member training and flexibili

21、ty.支持员工的培训和柔性化Involves Team Members and Team Leaders in developing and maintaining Standardized Work.使组员和组长建立并维护标准化操作13Supporting People Involvement By:支持人员参与Documenting the safest work sequence记载最安全的工序The work sequence takes into account the ergonomic impact of a job工序中考虑了对工作有影响的人机工程For example, el

22、ements that require frequent bending, lifting, and so on are distributed across the team so that no one team member is overburdened.例如，要求不断弯腰、举起的工作要素会分配到整个班组使得员工不会超负荷工作。- It may not seem like a lot to bend down once during a job but remember that particular element may be performed 420 times per shi

23、ft.一次工作的弯腰看似无关紧要，但要记住整个班次的特定要素要执行420次。Supporting Team Member training and flexibility 支持组员的培训和柔性化Learning new jobs makes team members become more skilled and flexible.学习新的工作使组员更有技能，并有更大的灵活性The SOS and JES are ideal training documents and also help team members, as a memory refresher, when rotated in

24、 to a job.Mutual support is enhanced when everyone on the team performs each job in the same fashion.标准化操作单和工作要素单是理想的培训文件，在论岗时有助组员记忆。班组的每位成员以相同的方式执行每一项工作会增强互相支持A defined sequence makes it easier to learn a new job定义过的顺序使得学习新工作更加容易14Providing a way for Team Members and Team Leaders to create and main

25、tain Standardized Work为组员和组长建立并维护标准化操作提供了一种方法Responsibility and accountability lie within the team在班组中会产生责任感和义务感Team Members know the process the best and are in the best position to suggest improvements.班组成员最了解工艺流程，对于建议改进有最好的发言权15Standardized Work Supports:Built-In-Quality标准化操作对制造质量的支持Documents Bes

26、t Operation Sequence. 记载最佳操作顺序Documents Quality Checks and Key Quality Operations 记录了质量检验和关键质量操作Provides reference to Product Quality Standards for clarification to the operator.为向组员说明产品质量标准提供了参考Supports team member Quality through elimination of variation.消除差异，支持员工质量Supports Problem Solving.支持问题解决流

27、程16Supporting Built-In-Quality by:支持制造质量Documenting the current best operation sequence for a process, which is often quality related, and may also be efficiency, waste, or safety related.记录了目前最佳的操作顺序，不仅和质量相关，同时也和效率、浪费、安全有关。Standardized Work documents necessary quality checks that must be made to en

28、sure final customer quality standards are understood and met.标准化操作记录了必要的质量检验，确保理解并满足最终客户质量标准。Example:the push, click, pull sequence to ensure that connections are secure.例如：推、压、拉的顺序确保了连接的可靠Documenting necessary job elements that ensure the quality of the job.记载了必需的工作要素，确保质量The hand starting of a nut

29、 before using the electric gun ensures that the nut is correctly aligned to prevent cross threading在使用电动枪前，手动预紧螺母使螺纹吻合，防止螺纹破坏17Repetition of the correct job sequence makes it easy for the Team Member to focus on quality.正确的工序的反复使组员能关注质量When there is variation by the team member, the risk of misassem

30、bly or quality problems is heightened.如果员工间的操作有差异，就有错装的危险或会产生质量问题Supporting Problem Solving.支持问题解决方案When a consistent process is used problem solving can be more effective.对一持续的流程采用问题解决方案会更加有效Since the operations, sequence, and tools are standardized, if a quality problem occurs, it is easier to ide

31、ntify the root cause.Standardized Work makes the separation between abnormal and normal conditions easily identifiable.既然操作、顺序和工具都标准化，如果发生质量问题，很容易确认根本原因。标准化操作使得正常和异常状况的分别容易区分。18Standardized Work Supports:Short Lead Time标准化操作对缩短制造周期的支持Documentation of Best Work Sequence and Processes 记录最佳工作顺序和工艺流程Doc

32、umentation of the required Standard In-Process Stock.记录所需的标准在线存货Continuous Improvement Process to reduce time of operations through the elimination of waste.通过消除浪费来减少操作时间的不断改进流程19Supporting Short Lead Time by支持缩短制造周期Documenting the most efficient sequence and work process.记录最有效的工序和流程When you get dre

33、ssed in the morning, is it more efficient to put on your shoes and then your pants?Why?This same concept applies to standardized work.We document the most efficient sequence of work, which reduces the lead-time of the process.You will also learn over time that there is always a better way.You can sa

34、ve seconds or even minutes from an operation through an improved work sequence or part presentation.在早上穿衣服时，先穿鞋再穿裤子会更有效吗？同样的道理可应用到标准化操作。我们记录了最有效的工作顺序，可以减少流程的制造周期。将来肯定会有更好的方法。通过改进工序或零件的传递，我们会节省几秒钟甚至几分钟的时间。20Documenting the required Standard In-Process Stock记录需要的标准在线存货Standard In-Process Stock is the

35、material that is required within a process to complete the job without an interruption within the cycle.If we did not have this material available, we would not be able to complete the standardized work without an interruption.On the other hand, having too much material is also a waste(Inventory). 标

36、准在线存货就是在循环操作中无间断完成流程中的工作所需的物料。如果我们没有可用的物料，就不能无间断的完成标准化操作。此外，过多的物料是一种浪费。(过度库存浪费)Reducing operation time through elimination of waste消除浪费，减少操作时间Eliminating unnecessary movements. 消除不必要的移动Visually displays current situation, thereby making waste easily visible.状况目视化，使浪费容易发现Consistently communicating wo

37、rk practices and processes.不断交流操作实践和流程21Standardized Work Supports:Continuous Improvement标准化操作对不断改进的支持A standard must be in place and followed before you attempt continuous improvement.在进行不断改进之前必须有一合适的标准并且执行The standard should be used to identify the waste in the process.标准用来识别流程中的浪费Proper analysis

38、of the standardized work tools will make waste highly visible.合理的分析标准化操作工具会使得浪费清晰可见22Supporting Continuous Improvement by: 支持不断改进Documenting the current best practice 记录当前最佳操作This allows each improvement to start from a higher standard practice point than before.这使得每次改进都是从比以前更高的起点标准出发Supporting stab

39、ility. 稳定性A consistent stable work environment is the foundation for controlled changes稳定的工作环境是控制变化的基础当前的最佳操作以前的最佳操作下一个最佳操作Making waste highly visible. 使浪费清晰可见The SOS documents the walk pattern, number of zones a Team Member works in, number of trips to the material rack, material pick face vs Team

40、Member envelope and other ways to see the waste on paper.This helps to focus and prioritize the CIP actions.SOS记录了走动方式、工作的区间、走向料架的次数、取物料的面和手势以及其他确认浪费的途径。有助于关注并区分不断改进活动。This documentation makes waste highly visible and easier to target during CIP activities.文件使得浪费清晰可见，在不断改进活动中更容易设定目标23Continuous Impr

41、ovement不断改进What is absolutely necessary before continuous improvement can occur?在不断改进前，什么是绝对必要的？24Stability through Standardization通过标准化达到稳定What must be in place before we attempt improvement?在改进前，什么是必须到位的？A stable and standardized situation needs to exist in order to evaluate the effectiveness of a

42、n improvement.Without standardization first, improvements will be sporadic and may even duplicate actions.必须有一个稳定和标准的状态来评估改进的有效性。如果没有先标准化，改进将会是零星的甚至是重复的行动A standard only works if it is followed.That is what it means to have a stable situation.标准只有执行了才有效。也就意味着要有一个稳定的状况To emphasize the importance of s

43、tandards and their implementation across shifts, note the following example.Several cars went to the yard without a certain part.In this case, the first shift installed the part on process 9.But the second shift installed the part on process 5.So, when the last car from the first shift was installed

44、 with the part at process 9, three cars between 5 and 9 were not fitted with the part:为了在所有班次强调标准及其实施的重要性，关注以下案例。有几辆车到调试的地方少了一个零件。第一个班是在第九个流程中安装的零件。而第二个班是在第五个流程中安装的零件。所以，对于第一个班最后一辆车在第九个流程安装的零件，有三辆车在第五到第九流程之间没有安装此零件。25Introduction to Standardized WorkStandardized Work is the documented, current best

45、method to safely and efficiently organize work elements in a sequence that can be repeated to required quality standards.标准化操作是成文的、当前最佳的方法，安全有效的对工作要素进行有序安排，使其能按照需要的质量标准反复执行SOS&JES are examples of the documentation of work processes.标准化操作单和工作要素单工作流程文件的样例标准化操作的介绍26“Documented”-Standardized Work成文的标准化操

46、作Standardized Work is documented and posted at the work site.If it is not documented and communicated, then there is nothing to follow, and it is not a standard.标准化操作是成文的，并贴在工作现场。如果不成文不交流，也就无法执行，就不能成为标准。The SOS, is the best work sequence with time measurement and location of materials for the safest

47、 and most efficient way to build quality products with minimum waste.标准化操作单是最佳工序，它有时间测量和物料位置，是以最小的浪费来制造高质量产品的一种最安全有效的方法。The JES, shows the major steps, key points&reasons for completing each element of work within a job.It also captures all team members experiences and the history of the element.工作要

48、素单显示了主要步骤、关键点和理由以完成一项工作的每一个要素。它是所有员工经验的积累也是要素的汇总。27“Current Best Method”-Standardized Work当前最佳方法-标准化操作Continuous Improvement is one of the five principles of GM-GMS.This Principle means that once we have set a standard, through the continuous improvement process, that standard might change. Standard

49、s are not meant to imprison us but are meant to help us grow. Therefore, the documentation of Standardized Work is subject to change through the controlled process of Continuous Improvement不断改进是GMS五项原则之一。这项原则意味着我们设定一项标准后，通过不断改进流程，标准有可能发生变化。标准不是用来禁锢我们，而是在帮助我们进步。因此，标准化操作的文件通过不断改进的控制流程可以进行变更。Because th

50、e SOS&JES contain the most current “best methods” and details of completing the jobs successfully, they serve an important role in the training of new Team Members.They are the most up-to-date documents on that job process available in the plant.SOS和JES包含了当前最佳的方式以及顺利完成工作的具体细节，所以它们在培训新员工时扮演了重要的角色。它们是

51、生产基地每个工艺流程最新的文件。28Standardized Work Is标准化操作是The documented, current best method to safely and efficiently perform work that meets the necessary level of Quality with the minimum amount of waste 成文的、当前最好的安全有效的工作方式，以最小的浪费来达到必要的质量标准。Used when there is a definable, repeatable process.用于可定义的、重复性的工艺中Used

52、as a baseline for Continuous Improvement作为不断改进的基准Used as documentation of the three elements important for Continuous Improvement:记录不断改进的三个重要要素Takt Time 单件工时Work Sequence 工序Standard In-Process Stock 标准在线存货29Takt Time单件工时Takt Time单件工时Is the ideal time required to produce a component or vehicle in ord

53、er to meet customer demand.是为满足客户要求而生产一个零件或车辆所需的理想时间Is a factor in determining the speed of the line. 是决定线速度的一个要素Is calculated using the following formula. 用以下公式计算 Available Production Time (Seconds) 可行的生产时间(秒) Customer Demand (Units) 客户需求(车辆数) Available Production Time is simply the planned amount

54、of time to produce vehicles or components.可行的生产时间就是指生产车辆或零件的计划的时间。Takt time is fixed until the next scheduled change in production rate as a result of changes in customer demand, plant allocation of demand, or available production time.单件工时是固定的，除非客户需求、生产基地分配要求或是可行的生产时间的变化会导致生产速度的变化。A Takt time of 76

55、 seconds means that every 76seconds a vehicle is required by a customer.单件工时76秒，意味着客户需要的每一辆车用时76秒30Takt Time单件工时Actual Takt TimeActual Takt Time实际单件工时Is the time allowed to build a component or vehicle based on factors that affect the throughput.考虑影响产量的因素，制造单位零件或车辆所需要的时间Is the speed the line actuall

56、y runs. 是生产线实际流动的速度Is calculated using the following formula: 用以下公式计算Actual Takt Time=Operational Availability(%)Takt Time (Seconds)实际单件工时=操作可行率(%) 单件工时(秒)Operational Availability is defined as normal system losses that can be expected on a regular basis such as allowance for equipment downtime, pro

57、duction stops, material shortages, quality problems (including Andon stops and non-conforming material), and planned tool die changes.操作可行率是由定期可预测的正常系统损失时间而定义的，它包括设备的停机，生产线停线，物料短缺，质量问题(包括暗灯和不符合规格的物料)以及计划性的工具模具的变化。Actual Takt time is fixed until the next scheduled change in production rate as a result of changes in takt time or operational availability.实际单件工时是固定的，除非单件工时