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1、 物料储存 Material Storage悬挂式电动输送带 Powered & free conveyor物料储存 Material Storage物料储存 Material Storage物料储存 Material Storage物料储存 Material Storage工人灵活Flexible operators 走动方便Freedom of movement 标准化作业Standard operations 目视工场Visual workplace 最少线上存货Minimal line stock 柔性生产Flexible production 调速器Pacemakers 保证质量Qu
2、ality ensured 六西格玛制程能力 (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 Stakeholder Value精益西格玛
3、精益西格玛 变革变革LeanSigma transformation LeanSigma transformation 精益生产系统精益生产系统 Lean Production SystemLean Production System改善突破法 Kaizen Breakthrough Methodology精益生产系统精益生产系统Lean Production systemLean Production system及时 Just in Time 生产有效使用 Efficient Use of 员工 People 设备 Equipment 物料 Materials 厂房 Space 均衡生产
4、Production Smoothing 提升工艺流程能力 Improve Process Capability 尽量减少变化 Minimize variation 控制异常 Manage abnormality 驱动成本下降 Drives cost reductionJidoka自働化精益生产系统 Lean Production system及时生产就是 Just-In-Time Is. 这样的生产系统 A manufacturing system which produces: 按客户所需进行生产 What the customer wants 按客户要求数量生产 In the quant
5、ity the customer wants 按客户要求时间生产 When the customer wants it 利用最少的 While using the minimum: 原料 Raw materials 设备 Equipment 工人 Labor 厂房 Space核心概念和工具Key Concepts and Tools符合节拍时间Pace to Takt time单件流 One-piece flow拉动系统 Pull system精益生产系统精益生产系统 Lean Production system客户需求 Customer requirements净操作时间 Net opera
6、ting time将运作和客户需求同步Synchronizes operations to customer demand防止过量生产 Prevents overproduction建立流动生产的工具 Tool for creating flow确定最佳生产人数 Determines optimal staffing推动产能分析和设备利用率 Drives capacity analysis & equipment utilization必须定期更新以适应需求的变化Must be updated periodically as demand changes超市运作 Supermarket Ope
7、ration过道 AisleEDCBAIHGFABCDEFGHI按需生产 Produce to Actual Customer Demand线旁供货LSS线旁供货LSS收集看板 Pick-up Kanban供应商 Supplier 物料超市 Supermarket投递生产看板 Drop Production Kanban原料RM成品FG生产计划板 Schedule board生产看板 Production Kanban现场送料员Water Spider看板拉动的例子-Kanban systemSupplier供货商Customer顾客Replenishes Consumed Products
8、补充已消耗的产品Visual 直观TOTEVisual Control 直观控制Frequent Deliveries 供货频繁FIFO 先进先出One Piece at a Time 每次一件What you want你想要什么 When you want it何时需要 In the amounts you want it in要多少13小巧便宜机器Small, inexpensive machines in process order 单件流生产, 反时针方向One-piece flow production, counterclockwise 人机正确结合Ergonomically-co
9、rrect 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 消除生产过程浪费Eliminates waste in production processes 缩短运作周期时间Reduces lead times 品质品质 成本成本 交货交货! !Quality Cost Delivery!Quality Cost Delivery! 不能容忍生产
10、异常Creates a system which is intolerant of production abnormalities 精益生产系统精益生产系统Lean Production systemLean Production system及时 Just in Time 生产有效使用 Efficient Use of 员工 People 设备 Equipment 物料 Materials 厂房 Space 均衡生产 Production Smoothing 提升工艺流程能力 Improve Process Capability 尽量减少变化 Minimize variation 控制异常
11、 Manage abnormality Jidoka自働化A.A. 减少不良品A method for reducing defectsB.B.设备自动化，提高生产率Equipment autonomation to improve productivityA. 减少不良品的工具或方法 Tools or Methods 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识别不良品产生根源 Identify root
12、 causes of defects消除根源 Eliminate root causes减少或消除不良品 Reduce or eliminate defects目视控制 Visual Control 5S信号灯 Andon 异常反应Abnormality Response/Reaction作用 / 责任 Roles and responsibilities 停工指引 Line stop guidelines 西格玛改善 Sigma Kaizen (DMAIC)基本品质工具 Basic QC Tools 先进统计工具 Advanced Statistical Tools 措施 Counterme
13、asures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 training 技巧矩阵, 表现量度 Skill matrix and performance 自働化 Autonomation人机分离 Separate person from machine目控 Visual Control5S信号灯 Andon零件展示Parts presentation工具展示 Tool presentation包装线 Pack line信
14、号灯 Andon标准化作业 Standard work发现问题 React to problem Q C D S 衡量影响 Measure impact提醒同事 Alert team标准化后, 训练员工 Train affected associates in new standard operations MANEFFECTMACHINEMATERIALMETHOD找出原因 Find root cause提出改善, 进行试验Develop and test improvement Check 2BGauge 4试验成功, 更改运作 Update standard operations wit
15、h tested improvementB. 设备自働化 Equipment autonomation 人机分离 Separate operator work from machine work改善前 Before: 操作员监控机器工作 Operator watches machine run改善后 After: 操作员装卸零件 Operator loads and moves 自动关闭 Auto shut-off“自动退件” 自动卸货 “Hanedashi” auto unload操作员进入下一道工序 Operator moves to next operation问题：你看过洗碗机是如何工作的吗？问题：你看过洗碗机是如何工作的吗？ Question: Do you watch your dishwasher run?Question: Do you watch your dishwasher run?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 deliver
