《精益生产系统资料》由会员分享，可在线阅读，更多相关《精益生产系统资料（26页珍藏版）》请在金锄头文库上搜索。
1、精益生产系统 Lean Production System,6西格玛流程能力 (西格玛改善) Six Sigma Process Capability (Sigma Kaizen),重点缩短制造周期Focus on lead-Time reduction to : 增加客户忠诚度和市场份额 Increase customer Loyalty and Market Share 取得销售和收益双增长 Achieve Growth in Sales & Earnings 保持竞争优势 Sustain the Competitive Advantages 提升利益相关者价值Improve Stakeh
2、older Value,精益西格玛变革 LeanSigma transformation,精益生产系统 Lean Production System,改善突破法 Kaizen Breakthrough Methodology,驱动成本下降Drives cost reduction,精益生产系统 Lean Production system,及时生产 Just-In-Time Is.,这个系统生产 A manufacturing system which produces: 客户所需的产品 What the customer wants 以客户要求数量 In the quantity the c
3、ustomer wants 按客户指定时间 When the customer wants it,使用最少的 While using the minimum: 原料 Raw materials 设备 Equipment 人力 Labor 场地 Space,Key Concepts and Tools 关键的概念和工具 Pace to Takt time (跟上节拍时间) One-piece flow (单件流) Pull system (结合拉动系统),Lean Production System 精益生产系统,Importance of Takt Time 节拍时间的重要性,Customer
4、 requirements 客户需求数,Net operating time 净操作时间,Synchronizes operations to customer demand 生产与客户的需求同步 Prevents overproduction 避免过量生产 Tool for creating flow 建立流程的工具 Determines optimal staffing 确定最佳人员配置 Drives capacity analysis & equipment utilization 驱动资源能力分析和设备利用 Must be updated periodically as demand
5、changes 必须按需求变化定期更新,拉动式单件流物料补充 One-piece flow with Pull Replenishment,超市运作Supermarket Operation,过道Aisle,E,D,C,B,A,I,H,G,F,A,B,C,D,E,F,G,H,I,按实际客户需求生产 Produce to Actual Customer Demand,拉动系统 Pull System,实施拉动系统 Implement Pull system,及时生产的要素 JIT Elements,小巧便宜机器 Small, inexpensive machines in process ord
6、er 单件流生产, 反时针方向 One-piece flow production, counterclockwise 人机正确结合 Ergonomically-correct operations 站立操作, 边走边做 Standing operations, moving while working 拉动系统训练 Pull system discipline 定义和实施“标准化作业” “Standard operations” defined and implemented,及时生产的好处 JIT Benefits,消除生产过程浪费 Eliminates waste in producti
7、on processes 缩短制造周期时间 Reduces lead times,品质 成本 交货! Quality Cost Delivery!,不能容忍生产异常 Creates a system which is intolerant of production abnormalities,自働化是 Jidoka is,A. 减少不良品 A method for reducing defects B. 设备自働化，提高生产率Equipment autonomation to improve productivity,自働化Jidoka,A. 减少不良品的工具Tools or Methods
8、 to Reduce Defects 发现不良品的产生Detect defects when they occur 防止不良品进入下一道工序Prevent defects from passing to next operation 发现不良品产生根源Identify root causes of defects 消除根源Eliminate root causes 减少或消除不良品Reduce or eliminate defects,自働化的要素 Jidoka Elements,目视控制 Visual Control 5S 信号灯 Andon 异常反应 Abnormality Respons
9、e/Reaction 作用 / 责任 Roles and responsibilities 停工指引 Line stop guidelines 原因分析 (定义 / 测量 / 分析 / 改善 / 控制) Root Cause Analysis (DMAIC) 基本品质工具 Basic QC Tools 先进统计工具 Advanced Statistical Tools,防错措施 Mistake-proofing (Poke-Yoke) 手动操作 Manual Work 自动操作 Automatic machine work 新标培训 New Standard Operations and tr
10、aining 技巧矩阵, 表现量度 Skill matrix and performance 自働化 人机分离 Autonomation Separate person from machine,目视控制Visual control,5S 灯号Andon,零件展示 Parts presentation,工具展示 Tool presentation,包装线Pack line,按灯Andon,标准化工作 Standard work,自働化的要素Jidoka Elements,自働化 Jidoka,A. 减少不良品的工具Tools or Methods to Reduce Defects 发现不良品
11、的产生Detect defects when they occur 防止不良品进入下一道工序Prevent defects from passing to next operation 发现不良品产生根源Identify root causes of defects 消除根源Eliminate root causes 减少或消除不良品Reduce or eliminate defects,异常反应过程 Abnormality Response Process,发现问题 React to problem,自働化 Jidoka,B. 设备自働化Equipment autonomation 人机分离
12、Separate operator work from machine work 之前Before: 操作员监控机器工作Operator watches machine run 之后After:操作员装卸零件Operator loads and moves 自动关闭Auto shut-off “Hanedashi”自动卸货“Hanedashi” auto unload 操作员进入下一道工序Operator moves to next operation,问题：你是否观察过洗碗机工作？ Question: Do you watch your dishwasher run?,自働化的好处 Jido
13、ka Benefits,改善产品质量 Increases production quality 提升生产力 Increases productivity 保证准时交货 Ensures on-time delivery,品质 成本 交货! Quality . Cost . Delivery!,均衡生产是 Production Smoothing Is.,调整生产速度, 满足客户变化 Adapting production rates to variations in customer demand,产品数量变化Variation in volume 产品种类变化Variation in prod
14、uct mix,每日平均需求 = 生产目标Average Daily Demand = Target Production,数量 Quantity,时间 Time,均衡生产 Production Smoothing,产量的变化 Variation in Volume,均衡生产 Production Smoothing,每月计划: 3,200个 Monthly Schedule (3200 units),5,15,20,10,Model C,800 units,Day,每日计划 (160个) Daily Schedule (160 units) 生产模式: Production pattern
15、AABCAABC,80,1,40,40,80,2,40,40,80,3,40,40,80,20,40,40,种类变化 Variation in Mix,均衡生产的好处 Production Smoothing Benefits,保持一致优良品质 Maintains a consistent, high product quality 减少资金投入需求 Reduces the requirements for capital investment 降低员工成本 Reduces staffing costs 保证准时交货 Ensures on-time delivery,品质 成本 交货! Quality . Cost . Delivery!,驱动成本下降Drives cost reduction,
