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1、TenantsofSinglePieceFlow DoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectsZeroDefects 0DefectsNot3 4ppm Quality Quality Quality DefectsaretheWorstKindofWaste 7TypesofWasteDefectivePartsOverProductionInventoryMotionTransportationWaitingManualTouches Batch SinglePieceFlow From TheToyotaProductio
2、nSystem BuildingQualityintotheProcessSinglePieceFlow Thenextprocessisthecustomer neversenddefects SampleInspectcatchesDefecttooLateWhenyouFinallyFindaDefectHowmanymoredoyouhave Wherearetheyintheprocess WhatistherootCause SinglePieceFlowcatchesDefectsimmediatelyWhenyoufindaDefectYouonlyhaveoneYouknow
3、whereitoccurredYouCanfind ResolvetheRootCauseimmediately Check Do Verify Check Thepreviousoperatorswork Do Yourwork Verify Thatyoudidyourworkcorrectly Process Inspect Transport Transportationisintegratedintotheproductionprocessviaautomatione g movingline Process Inspect Process Inspect Transport Pro
4、cess Inspect Transportationisintegratedintotheproductionprocessviahumanconveyancee g Chaku Chaku BuildingQualityintotheProcess2waystoperformSPF Thenextprocessisthecustomer neversenddefects Check Do Verify GetsyouintoPartsPerMillionquality Whenyouverifyyourwork youcatch1flawin100parts Thenextpersonch
5、ecksyourworkandcancatch1 100sothat s1 10 000 ThenthatpersonVerifiestheirworkandcancatch1 100 That s1 1 000 000errorsthatcangetthrough Check Do Verify EveryCustomerinaProcesshas arighttoexpectperfectmaterial anobligationtoinspectthematerialbeforeuse anobligationtoinformthepreviousstepintheprocessofan
6、yproblem anobligationtostoptheprocessuntilanyproblemhasbeenresolved SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess ThisisachievedbyestablishingataktTime developingstdwork andswip ThepremiseisthatanOperatorcanonlyworkononepieceatatime andperformsaQuickqualitycheckontheCTQsofth
7、eprocessbeforemovingTheparttothefollowingprocess Ifadefectisdetected JidokaIsenacted thelineisstopped andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurence TakttimeStdwork Flow work process thatisdoneinconjunctionwithorsimultaneoustotransportation OnePieceFlow Th
8、eproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis hersupplierandcustomerinthechain Asonepersonfinishestheirelement sodoall Workisthenmoveddownthelinesynchronously Everypersonisempoweredtostoptheproductionprocessifarejectisspotted Organization Area Superv
9、isor New Rev Page of Date ProductionLine PartNumber PartName Operator StandardWorkSheet To Turns DPU s EndFinish Weld EndFinish Weld OrbitalWeld HydroTest Mark Mech Clean TorchBraze Tubing CFMCell FernBissonnette Cell6AllPartsAllTubes 11 Mech Clean Rawmaterial Weld 100 Day FPIX RayEDM 2ndQtr 01 EndF
10、inish OutsideCell 27 avglot 6 Flex FinishedGoods ACTIONWORKOUT g GEMSGlobalProductionSystem Thenextprocessisthecustomer neversenddefects Check Do Verify OnePieceFlow Yourcustomeristhenextstepintheprocess Givetoyourcustomer exactlywhattheyneed 1item exactlywhentheyneedit doneperfecteverytime Tenantso
11、f1pcsFlow DoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefect Quality Quality Quality DefectsaretheWorstKindofWaste Systemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals intheexactstandardizedamountneeded PullProductionMethodology Sequenc
12、e Definition RefMaterialPresentationtrainingforexplanationonSupermarketdefinitionanduse 1 3 4 5 6 7 8 9 10 2 AssemblyLine CellorChaku Chakuline Supplier PullProductionMethodology Sequence JIT Jidoka eGPSforGPC Heijunka LevelLoading Sequencing Findingabalancebetweenthevolumeofworkthatyourorganization
13、needstodoandyourcapacityAdjustingaproductionscheduletomeetunexpectedchangesincustomerdemand OrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitems takenfrommemoryJogger Leveledproductionmeansloweringthepeaksamongthedailyproductionvolumesasmuchaspossibleandmakingtheproductionflowsmooth
14、andunflucuating Ingeneral themorefluctuationsyouintheproductionflow themoremudayouenduphaving Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand Iftheproductionlineproducesonlyasingleproduct youmaybeabletoreducemudasimplybyadjus
15、tingtheproductionscheduleandstaffinglevel Butifyouwanttoproduceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline youhavetodotheaveragingnotjustinvolumebutinkindsaswell ThiswayofaveragingbothvolumeandinkindsiscalledproductionlevelingorheijunkainJapanese Levele
16、dProduction LeveledLoadProduction BuildtoforecastBuildtoFGinv BuildafterorderisreceivedALLcomponentsneedtobestockedinRMAnorderfromtheseproductstakesprecedenceover1 2 3products buildthisfirst F1 F1 F1 F1 F1 F1 F2 F2 F2 F2 F2 F2 TAKTTimeDeterminedbyPSI 2Q 3Q 4Q OktoBuildtoFG RepeatableProducts Non RepeatableProducts NeedtoDetermine HowMuch20bulbsperdayWhatKind15 60Watts5 100WattsWhen5 60W 2 100W 5 60W 2 200W 5 60W 1 100W TAKTLevelLoadMixLevelLoadSequence Ifweweremakinglightbulbs QuarterlyWeeklyWee
