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1、2019-10-13Shenzhen Functional Excellence 精益生产基础知识精益生产基础知识（期刊版）（期刊版）第一期（总第一期）2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Hot Topic目录目录Just-In-Time 及时生产及时生产2Level Loading 均衡生产均衡生产4Lean House 精益生产屋精益生产屋3 1Jidoka 自働化自働化3 38 Waste 八大浪费八大浪费3 52019-10-13Shenzhen Functional 2019-1
2、0-13Shenzhen Functional Excellence Toyota Production System House丰田生产方式（精益生产屋）丰田生产方式（精益生产屋）安全安全及时生产及时生产自働化自働化交付交付成本成本品质品质标准化作业标准化作业稳定性稳定性(工艺工艺,人员人员)员工与管理者之间的相互信任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均衡生产改善改善灵活的人力系统灵活的人力系统设备综合效率设备综合效率5S2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellen
3、ce Just-In-Time Is (及时生产是及时生产是). A manufacturing system which producesA manufacturing system which produces ( (这个系统生产这个系统生产): ):What the customer wants (客户所需产品客户所需产品)In the quantity the customer wants (客户要求数量客户要求数量)When the customer wants it (客户指定时间客户指定时间) While using the minimumWhile using the mini
4、mum ( (使用最少的使用最少的使用最少的使用最少的): ):Raw materials (原料)Equipment (设备)Labor (人力)Space (场地)2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence JIT Principles （及时生产三原理）及时生产三原理）Takt time (节拍生产节拍生产)及时生产及时生产JITPull system(拉动生产拉动生产)One piece follow(单件流生产单件流生产)2019-10-13Shenzhen Functional 201
5、9-10-13Shenzhen Functional Excellence Takt Time (节拍时间节拍时间)Takt, 德语，意为节拍，与英文德语，意为节拍，与英文 Pace 意同。意同。2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence One Piece Follow (单件流单件流)1-Piece Flow(单件流生产单件流生产)Batch (批量生产批量生产)Fake Flow (假流线生产假流线生产)2019-10-13Shenzhen Functional 2019-10-13Shen
6、zhen Functional Excellence One Piece Follow (单件流单件流)“A Sea of WIP”(一大堆半成品一大堆半成品)“Now You See It!”(“你看吧你看吧!”)2019-10-13Shenzhen Functional 2019-10-13Solectron Shenzhen Functional Excellence Pull System (拉动系统拉动系统)2019-10-13Solectron Shenzhen F2019-10-13Shenzhen Functional Excellence JIT Elements (及时生产
7、的要素及时生产的要素)Small, inexpensive machines in process order (小巧便宜机器小巧便宜机器)One-piece flow production, 单件流生产单件流生产Ergonomically-correct operations (人机正确结合人机正确结合)Standing operations, moving while working (站立操作站立操作, 边走边做边走边做)Pull system discipline (拉动系统训练拉动系统训练)JIT ElementsJIT Elements ( (及时生产的要素及时生产的要素及时生产的
8、要素及时生产的要素) )“Std operations” defined and implemented(定义和实施定义和实施“标准化运作标准化运作”)2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence JIT Benefits(及时生产的好处及时生产的好处)Creates a system which is intolerant of production abnormalities (不能容忍生产异常不能容忍生产异常)Eliminates waste in production processes (
9、消除生产过程浪费消除生产过程浪费)Reduces lead times (缩短前置生产时间缩短前置生产时间)Ensures on-time delivery (保证准时交货保证准时交货)QualityCostDeliverySafety2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Jidoka is (自働化是自働化是)An immediate response to an abnormal condition within the process (异常情况, 立即响应)Goal: Prevent
10、 a defective product from being passed to the next operation. (目的: 防止不良品流向下一工序)Equipment autonomation capable machine processes that enable separation of machine and operator (设备自働化, 人机分开化)Goal: Multi-process handling, increased labor productivity. (目的: 实现多工序操作, 提升劳动生产力)2019-10-13Shenzhen Functional
11、 2019-10-13Shenzhen Functional Excellence Abnormality Response Process (异常反应过程异常反应过程)React to problem (发现问题发现问题)Q C D S Measure impact(衡量影响衡量影响)Alert team (提提醒同事醒同事)Train affected associates in new standard operations (标准化后标准化后, 训练员工训练员工)MANEFFECTMACHINEMATERIALMETHODFind root cause(找出原因找出原因)Develop
12、 and test improvement (提出改善提出改善, 进行试进行试验验)Check 2BGauge 4Update standard operations with tested improvement(试验成功试验成功, 更改运作更改运作)2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Jidoka Elements (自働化的要素自働化的要素)Andon信号灯信号灯5S作用与责任作用与责任停工指引停工指引DMAIC品质及统计工具品质及统计工具目视控制目视控制异常反应异常反应原因分析原因
13、分析自动与手动操作自动与手动操作Poke-Yoke技巧矩阵技巧矩阵表现量度表现量度人机分离人机分离及时反馈及时反馈防错工程防错工程新标培训新标培训自働化自働化2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Jidoka Benefits (自働化的好处自働化的好处)Increases production quality 改善产品质量改善产品质量Increases productivity 提升生产力提升生产力Ensures on-time delivery保证准时交货保证准时交货Ensures Sa
14、fety保证安全保证安全QualityCostDeliverySafety2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Level Loading均衡生产均衡生产Adapting production rates to variations in customerAdapting production rates to variations in customer demanddemand调整生产速度调整生产速度调整生产速度调整生产速度, , 满足客户变化满足客户变化满足客户变化满足客户变化Vari
15、ation in volume产品数量变化产品数量变化Variation in product mix产品品种变化产品品种变化Level Loading Is (均衡生产是均衡生产是).2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Variation in Volume (数量变化数量变化)Customer Demand (客户需求客户需求)Avg. Daily Demand = Target Production(每日平均需求每日平均需求 = 生产目标生产目标)Quantity(数量数量)Time
16、 (时间时间)2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Variation in Mix (种类变化种类变化)Day (日期日期)Monthly Schedule(3200 units)(每月计划每月计划: 3,200个个)5152010Model “A” (型号型号A)1600 units (1,600个个)Model “C” (型号型号C)800 units (800个个)Model “B” (型号型号B)800 units (800个个)Day(日期日期)Daily Schedule (1
17、60 units)(每日计划每日计划: 160个个) Production pattern: AABCAABC(生产模式生产模式: AABCAABC)A801B40C40A802B40C40A803B40C40A8020B40C402019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Level Loading Benefits (均衡生产的好处均衡生产的好处均衡生产的好处均衡生产的好处) )Maintains a consistent high product quality (保持一致优良品质保持一致优
18、良品质)Reduces the requirements for capital investment (减少资金投入需求减少资金投入需求)Reduces staffing costs(降低员工成本降低员工成本)Ensures on-time delivery (保证准时交货保证准时交货)QualityCostDeliverySafety2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence VA & NVA (增值与非增值增值与非增值)VAVA增值增值Value-Adding Activities (增值活
19、动增值活动) transform materials and information into products & services which the customer wants.将物料与信息转变成客户需要的产品与服务NVANVA非增值非增值Non-Value-Adding Activities (非增值活动非增值活动). consume resources, but dont directly contribute to the product or service.消耗资源, 而又不直接贡献于产品和服务NNVANNVA必要存在的必要存在的必要存在的必要存在的非增值非增值非增值非增值N
20、ecessary Non-Value-Adding Activities (必要存在的非增值活动必要存在的非增值活动). Same to NVA, but its necessary activities.意同非增值，但该活动是必须存在的.剔除浪费并不难，剔除浪费并不难，难的是如何发现浪费。难的是如何发现浪费。 丰田生产方式创始人-大野耐一2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence 8 Wastes八大浪费八大浪费8 Wastes浪费Overproduction过量生产Defect 不良品Wait
21、ing等待Transportation运输Excess Motion多余动作Processing加工Inventories库存Management管理不善浪费浪费浪费浪费就是就是就是就是所做所做所做所做的工的工的工的工作只作只作只作只增加增加增加增加成本成本成本成本却不却不却不却不增加增加增加增加价值价值价值价值2019-10-13Shenzhen Functional 2019-10-13Shenzhen Functional Excellence Causes Of Waste (浪费原因浪费原因)Lack of training (员员工训练不够工训练不够)Lack of adheren
22、ce (制度坚持不久制度坚持不久)Supervisory roles (监督作用不大监督作用不大)Irrelevant performance measures (考核无关业绩考核无关业绩)Poor work methods (工作方法不对工作方法不对)Ineffective production planning/scheduling (生产计划无效生产计划无效)Lack of workplaceorganization (工场工场凌乱不堪凌乱不堪)Supplier quality/reliability (供供应料品质差应料品质差)More (还有还有)Layout (distance) (布置距离太远布置距离太远)Long setup times (换模时间太长换模时间太长)Incapable processes (制程能力不足制程能力不足)Poor maintenance practices (保养操作不良保养操作不良)2019-10-13Shenzhen Functional 2019-10-132019-10-13Thank You !2019-10-13Shenzhen Functional Excellence 2019-10-13Shenzhen Functional
