lean-精益生产基础知识

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2006-10-13ShenzhenFunctionalExcellence精益生产基础知识（期刊版）第一期（总第一期） 2006-10-13ShenzhenFunctionalExcellenceHotTopic目录Just-In-Time及时生产2LevelLoading均衡生产4LeanHouse精益生产屋31Jidoka自働化338Waste八大浪费35 2006-10-13ShenzhenFunctionalExcellenceToyotaProductionSystemHouse丰田生产方式（精益生产屋）安全及时生产自働化交付成本品质标准化作业稳定性(工艺,人员)员工与管理者之间的相互信任安灯防错系统流线生产节拍生产拉动系统均衡生产改善灵活的人力系统设备综合效率5S 2006-10-13ShenzhenFunctionalExcellenceJust-In-TimeIs(及时生产是)...Amanufacturingsystemwhichproduces(这个系统生产):Whatthecustomerwants(客户所需产品)Inthequantitythecustomerwants(客户要求数量)Whenthecustomerwantsit(客户指定时间)Whileusingtheminimum(使用最少的):Rawmaterials(原料)Equipment(设备)Labor(人力)Space(场地) 2006-10-13ShenzhenFunctionalExcellenceJITPrinciples（及时生产三原理）Takttime(节拍生产)及时生产JITPullsystem(拉动生产)Onepiecefollow(单件流生产) 2006-10-13ShenzhenFunctionalExcellenceTaktTime(节拍时间)Takt,德语，意为节拍，与英文Pace意同。 2006-10-13ShenzhenFunctionalExcellenceOnePieceFollow(单件流)1-PieceFlow(单件流生产)Batch(批量生产)FakeFlow(假流线生产) 2006-10-13ShenzhenFunctionalExcellenceOnePieceFollow(单件流)“ASeaofWIP”(一大堆半成品)“NowYouSeeIt!”(“你看吧!”) 2006-10-13SolectronShenzhenFunctionalExcellencePullSystem(拉动系统) 2006-10-13ShenzhenFunctionalExcellenceJITElements(及时生产的要素)Small,inexpensivemachinesinprocessorder(小巧便宜机器)One-pieceflowproduction,单件流生产Ergonomically-correctoperations(人机正确结合)Standingoperations,movingwhileworking(站立操作,边走边做)Pullsystemdiscipline(拉动系统训练)JITElements(及时生产的要素)“Stdoperations”definedandimplemented(定义和实施“标准化运作”) 2006-10-13ShenzhenFunctionalExcellenceJITBenefits(及时生产的好处)Createsasystemwhichisintolerantofproductionabnormalities(不能容忍生产异常)Eliminateswasteinproductionprocesses(消除生产过程浪费)Reducesleadtimes(缩短前置生产时间)Ensureson-timedelivery(保证准时交货)Quality…Cost…Delivery…Safety… 2006-10-13ShenzhenFunctionalExcellenceJidokais(自働化是)…Animmediateresponsetoanabnormalconditionwithintheprocess(异常情况,立即响应)Goal:Preventadefectiveproductfrombeingpassedtothenextoperation.(目的:防止不良品流向下一工序)Equipmentautonomation–capablemachineprocessesthatenableseparationofmachineandoperator(设备自働化,人机分开化)Goal:Multi-processhandling,increasedlaborproductivity.(目的:实现多工序操作,提升劳动生产力) 2006-10-13ShenzhenFunctionalExcellenceAbnormalityResponseProcess(异常反应过程)Reacttoproblem(发现问题)QCDSMeasureimpact(衡量影响)Alertteam(提醒同事)Trainaffectedassociatesinnewstandardoperations(标准化后,训练员工)MANEFFECTMACHINEMATERIALMETHODFindrootcause(找出原因)Developandtestimprovement(提出改善,进行试验)Check2BGauge4Updatestandardoperationswithtestedimprovement(试验成功,更改运作) 2006-10-13ShenzhenFunctionalExcellenceJidokaElements(自働化的要素)Andon信号灯5S作用与责任停工指引DMAIC品质及统计工具目视控制异常反应原因分析自动与手动操作Poke-Yoke技巧矩阵表现量度人机分离及时反馈防错工程新标培训自働化 2006-10-13ShenzhenFunctionalExcellenceJidokaBenefits(自働化的好处)Increasesproductionquality改善产品质量Increasesproductivity提升生产力Ensureson-timedelivery保证准时交货EnsuresSafety保证安全Quality…Cost…Delivery…Safety… 2006-10-13ShenzhenFunctionalExcellenceLevelLoading均衡生产Adaptingproductionratestovariationsincustomerdemand调整生产速度,满足客户变化Variationinvolume产品数量变化Variationinproductmix产品品种变化LevelLoadingIs(均衡生产是)... 2006-10-13ShenzhenFunctionalExcellenceVariationinVolume(数量变化)CustomerDemand(客户需求)Avg.DailyDemand=TargetProduction(每日平均需求=生产目标)Quantity(数量)Time(时间) 2006-10-13ShenzhenFunctionalExcellenceVariationinMix(种类变化)Day(日期)MonthlySchedule(3200units)(每月计划:3,200个)5152010Model“A”(型号A)1600units(1,600个)Model“C”(型号C)800units(800个)Model“B”(型号B)800units(800个)Day(日期)DailySchedule(160units)(每日计划:160个)Productionpattern:AABCAABC(生产模式:AABCAABC)A801B40C40A802B40C40A803B40C40A8020B40C40 2006-10-13ShenzhenFunctionalExcellenceLevelLoadingBenefits(均衡生产的好处)Maintainsaconsistenthighproductquality(保持一致优良品质)Reducestherequirementsforcapitalinvestment(减少资金投入需求)Reducesstaffingcosts(降低员工成本)Ensureson-timedelivery(保证准时交货)Quality…Cost…Delivery…Safety… 2006-10-13ShenzhenFunctionalExcellenceVA&NVA(增值与非增值)VA增值Value-AddingActivities(增值活动)…transformmaterialsandinformationintoproducts&serviceswhichthecustomerwants.将物料与信息转变成客户需要的产品与服务NVA非增值Non-Value-AddingActivities(非增值活动)...consumeresources,butdon‘tdirectlycontributetotheproductorservice.消耗资源,而又不直接贡献于产品和服务NNVA必要存在的非增值NecessaryNon-Value-AddingActivities(必要存在的非增值活动)...SametoNVA,butit’snecessaryactivities.意同非增值，但该活动是必须存在的.剔除浪费并不难，难的是如何发现浪费。丰田生产方式创始人---大野耐一 2006-10-13ShenzhenFunctionalExcellence8Wastes八大浪费8Wastes浪费Overproduction过量生产Defect不良品Waiting等待Transportation运输ExcessMotion多余动作Processing加工Inventories库存Management管理不善浪费就是所做的工作只增加成本却不增加价值 2006-10-13ShenzhenFunctionalExcellenceCausesOfWaste(浪费原因)Lackoftraining(员工训练不够)Lackofadherence(制度坚持不久)Supervisoryroles(监督作用不大)Irrelevantperformancemeasures(考核无关业绩)Poorworkmethods(工作方法不对)Ineffectiveproductionplanning/scheduling(生产计划无效)Lackofworkplaceorganization(工场凌乱不堪)Supplierquality/reliability(供应料品质差)More(还有)…Layout(distance)(布置距离太远)Longsetuptimes(换模时间太长)Incapableprocesses(制程能力不足)Poormaintenancepractices(保养操作不良) 2006-10-13ThankYou! 2006-10-13ShenzhenFunctionalExcellenceThankYou!