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1、1,要素 2：工作场地布置 Element2: Workplace Organization,要素 1：标准化作业 Element1: Standardized Work,要素 3：目视化管理 Element 3: Visual Management,要素 4：单件工时管理 Element 4：Management by Takt Time,标准化Standardization,2,要素1：标准化作业 Element 1: Standardized Work 定义: 由生产车间同意,制定和保持的可用于重复工序的功能性文件 DEFINITION: The documentation of wor
2、k functions performed in a repeatable sequence, which are agreed to, developed and maintained by the production floor. 目的: 为持续改进建立可重复,可预测的基础并使操作工参与最初和不断的改进过程以便获得最高水 平的安全,质量和生产率 PURPOSE: To establish a repeatable, predictable baseline for continuous improvement and to involve the operator in both the
3、 initial and ongoing improvements to achieve the highest levels of safety, quality and productivity.,标准化Standardization,Standardized Work is: 标 准 化 工 作 是： 成 文 的、目 前 最 好 的、安 全 及 有 效 完 成 工 作 的方法， 以 达 到 必 要 的 质 量 水 准。 the documented, current best method to safely and efficiently perform work, that meet
4、s the necessary level of quality. 用 于 可 定 义 的、 可 重 复 的 工 艺 used when there is a definable, repeatable process 是不 断 改 进 的 起 点 a baseline for continuous improvement,3,标准化Standardization,标准化作业 Standardized Work,1 文件的标准化 Standardized documentation 1） 所有重复性工作必须有文件记录并标准化； All repeatable work must be docum
5、ented and standardized; 2） 在每个工位显示标准作业单 SOS displayed at each work station,4,标准化Standardization,操作工严格按标准化文件操作及自检 T/M operates and checks strictly according to standardized document.,2 操作的标准化 Standardized operation,员工操作后自检 Self-checking after operation,5,Andon,当操作工碰到问题时,他该怎么办? Problem occurred, what
6、should T/M do?,操作工拉动暗灯T/M pull Andon 暗灯(Andon)=求助(HELP) 在什么时候拉动暗灯 WHEN PULL? FPS 70% FPS,标准化Standardization,3 响应的标准化(1) Standardized for responsiveness(1),6,暗灯响应的标准化 Standardization for ANDON Responsiveness 1. 相关工位的班组长在暗灯亮起后6秒钟内到达现场。 T/L arrives on spot within 6 seconds since ANDON pulled. 2. 工段长在暗灯
7、亮起停线的1分钟内到达现场。 T/L arrives within 1 minute since line stops. 3. 值班长在停线5分钟内到达现场。 S/L arrives within 5 minutes since line stops. 4. 区域经理在停线15分钟内到达现场. Area manager arrives within 15 minutes since line stops 5 厂长在停线30分钟内到达现场. Director arrives within 30 minutes since line stops,3 响应的标准化(2) Standardized f
8、or responsiveness(2),标准化Standardization,7,班组长在暗灯亮起后何时到现场 How long should T/L arrive on spot since ANDON pulled? 在流水线未停下来之前 即刻到场 Immediately, before line stops.,班组长到现场后应该干什么? What shall T/L do upon arrival? 信息交流(询问情况) communicate problem 评估问题 Evaluate it 解决问题 solve it ANDON 亮起造成停线怎么办? What shall he d
9、o when QCOS ANDON lights?,QCOS暗灯发生停线,需用定值扳手拧紧并确认后按BYPASS按钮进行复位,使流水线正常运行 When line stops at QCOS ANDON, first confirm tightening with click spanner, then press BYPASS button to restore line running. 任何BYPASS复位工作只能由班组长或工段长授权的人执行 Restoration can only be done by T/L or authorized person(by G/L),标准化Stand
10、ardization,3 响应的标准化(3) Standardized for responsiveness(3),8,可在线上修复的缺陷 For defects that can be repaired on line 缺陷能否在 Can defects be repaired 下一个FPS前修复? before next FPS? 返修并反馈给操作工 Repair and feedback to T/M,不可在线上修复的缺陷 For defects that can not be repaired online 填写缺陷单并做好记录 Filled in defect record and
11、keep it 反馈给操作工 feedback to T/M,ANDON响应的流程 ANDON Responsiveness Process,通知返修工段 Advise repair group,标准化Standardization,4 问题解决过程的标准化 Standardized for problem solving,9,标准化Standardization,要素2：工作场地布置 Element 2: Workplace Organization,Motto: A Place for Everything and Everything in its Place 格言：每件事有其位置，每件
12、事在其位置中。,定义：工作场地的安全、清洁和有序的安排，它为每件物品提供一个特定的位置，并去除任何不必 要的东西。 DEFINITION: The safe, clean and orderly arrangement of the workplace that provides a specific location for everything and eliminates anything that is not required. 目的：工作场地的有序安排使工作场地有序化，使“偏离标准”的情况显而易见。它能消除浪费，使 日常工作更舒适、精确、方便并降低成本。 PURPOSE: Work
13、place organization puts order to the workplace, allowing out-of- standard?conditions to be visible. It eliminates waste and makes our daily tasks more comfortable, accurate, easier and less costly.,10,标准化Standardization,如何使工作场地的安排井然有序 ？ How to make workplace in order?,工作场地的有序安排 Workplace Organizatio
14、n=5S,5 Self Discipline自律,4 Sustain保持,3 Sweep清扫,2 Sort整理,1 Sift筛选,工作场地布置 Workplace organization,5S,11,5S-筛选 5S-Sift 1，制定必需和非必需品的评判标准，消除不必要的工具,设备,材料和次品； Make judgement criteria for necessary and unnecessary, Eliminate non-essential tools, equipment , material and salvage. 2，把工作场地内需要的物品与不需要的物品分开，迅速清除不需
15、要的物品 Divide the needed and unneeded items at the job site, and quickly remove the unneeded.,线旁已不再使用的工具应去除 Tools (not used any more) attached with red label,可疑、报废零件分区域放置 Scrap/dubious part put in different colored area,红色red：报废零件scrap 蓝色blue：可疑零件dubious 绿色green：返修确认零件repaired,标准化Standardization,12,5S
16、-整理 5S-Sort,经分类整理后的工具摆放 Tools put in order after sorted,确定位置 “Home location” fixed,制作位置标识 Location marked,为需用的物品指定存放位置，并以简单的方式将其管理起来 如用贴标识的方法清楚地说明，显示工/夹/量具，设备及物料摆放位置 一物一位，物归其位 Specify store location for necessary articles, and control them in simple way, e.g.: identify clearly with labels, display locations of tools/fixtures/gages, equipment and materials, “one thing one pos
