精益生产手册

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,LeanHandBook,精,益生产手册,1,Defect: X1/10,缺陷,降低,90%,Inventory:X ,库存减半,Productivity :X 2,生产效率翻,倍,倍,Lead Time:X ,生产周期减,半,半,Scrap: X1/10,报废降低,90%,Space: X,面积减半,Goal: AddValue & Eliminate Waste, Relentlesslyfor Our Customers,目标,:,减少浪费,&,创造价值,全,全心全意,为,为客户服务,ETE (End to End) ProductivityImprovement,端到端,(,从头到尾,),产能提高,ETE Zero Defect(Quality,TPM,OEE& etc.),端到端,(,从头到尾,),零缺陷（质,量,量，全面生,产,产维护，全,局,局设备利用,率,率等）,InventoryReductions,降低库存,LeadTimeReductions,缩短生产前,置,置期,CrewSizeOptimization,优化,人员数量,SpaceReduction,减少,使用面积,Double,the Good,好的加倍,Halve,the Bad,坏,的减半,Double,the,Speed,改善速度加,倍,倍,Kaizen WorkshopGoal,改善目标,No Money,不投入更多,金,金钱,No Space,不占用更多,面,面积,No Manpower,不使用更多,人,人力,2,Standard Work &StandardCombination Sheet,标准化作业,&,标准作业合,并,并表,1) Standard work defined,标准作业定,义,义,a) Takt time defined,节拍时间的,定,定义,b) Work sequence defined,工序的定义,c) Standard WIPdefined,标准在线库,存,存定义,d) Cycle time defined,周期时间定,义,义,e) Noof operators defined,操作员数量,的,的定义,f) Safety,安全性,g) Multi skill,多技能,2) Standard work combination sheetdefined,标准,作业合并表,定,定义,a) Manualtime,手动时间,b) Auto time,机器,(,自动,),时间,c) Walkingtime,走动时间,d) Waitingtime,等待时间,3) IstheQuality check legenddefined on each processon std work sheet?,标准作业合,并,并表上，有,定,定义每个流,程,程中的品质,管,管控的关键,点,点吗？,3 KeyElements,3项,关键要素,3,3 Types ofStandardWorks3,种标准作业,4,3 Types ofStandardWorks3,种标准作业,Type1 : Standard Work tosupport machine (90%) &man (10%)combination task.,类型,1,：标准作业,适,适用于,90%,的机器作业,和,和,10%,的手动作业,的,的组合作业,方,方式,。,Type2 : Standard Work tosupport man (90%) &machine (10%)combination task.,类型,2,：标准作业,适,适用于,90%,手动作业,和,10%,机器作业的,组,组合作业方,式,式,。,Type3 : Standard Work (also calledas Work Standard) to supporttaskcarried out once signal is triggered.,类型,3,：标准作业,（,（也叫做作,业,业标准）适,用,用于当信号,产,产生时才去,执,执行相应任,务,务的作业方,式,式,。,No Std Work means noKaizen Std Work is theMother ofallKaizen,没有标准作,业,业就没有改,善,善,标准作业是,改,改善之母,5,How to start the Takt Time CalculationBasedOn Customer Demand,怎样根据客,户,户需求计算,节,节拍时间,Step1:CalculateTakttimeBasedonCustomerDemand,第,一,一,步,步,：,：,根,根,据,据,客,客,户,户,需,需,求,求,计,计,算,算,节,节,拍,拍,时,时,间,间,Example,例,如,如,:,CustomerDemandperMonth792K.Workinghourperdayis22hours,20daysamonth.,客,户,户,每,每,月,月,需,需,求,求,量,量,是,是,792K,。,每,每,天,天,工,工,作,作,小,小,时,时,是,是,22,小,时,时,，,，,一,一,个,个,月,月,20,天,。,。,TaktTimecalculationshalldisplayallthevariableandunits,tomakeclaritytoall.,计,算,算,节,节,拍,拍,时,时,间,间,时,时,要,要,显,显,示,示,所,所,有,有,变,变,量,量,及,及,单,单,位,位,，,，,便,便,于,于,大,大,家,家,理,理,解,解,。,。,6,HowtostarttheTaktTimeCalculationBasedOnProductandProcessDesign,怎,样,样,根,根,据,据,产,产,品,品,和,和,制,制,程,程,设,设,计,计,计,计,算,算,节,节,拍,拍,时,时,间,间,Step2:CalculateProcessTakttimeBasedonProductandProcessDesign,第,二,二,步,步,：,：,根,根,据,据,产,产,品,品,和,和,制,制,程,程,设,设,计,计,计,计,算,算,节,节,拍,拍,时,时,间,间,BasedonStep1,TaktTimeis2secondtoproduce1pcs.,根,据,据,步,步,骤,骤,1,，,节,节,拍,拍,时,时,间,间,是,是,每,每,2,秒,生,生,产,产,1,件,产,产,品,品,。,。,7,HowtostarttheTaktTimeCalculationBasedOnProductandProcessDesign,怎,样,样,根,根,据,据,产,产,品,品,和,和,制,制,程,程,设,设,计,计,计,计,算,算,节,节,拍,拍,时,时,间,间,Scenario1:Productdesignis6pcsperonePCBpanel.TheProcessTaktTimewillbeevery12secondapanel.Besides,yourprocessdesignisusingapallettoplace4panels,thenyourProcessTaktTimeis48secondapallet.If2linerunning,processTakttimewillbe96sec.,情,节,节,1,：,产,产,品,品,设,设,计,计,为,为,每,每,块,块,PCB,板,由,由,6,块,小,小,板,板,组,组,成,成,，,，,节,节,拍,拍,时,时,间,间,是,是,每,每,块,块,PCB,板,12,秒,;,制,程,程,设,设,计,计,治,治,具,具,同,同,时,时,放,放,置,置,4,块,PCB,板,，,，,则,则,制,制,程,程,的,的,节,节,拍,拍,时,时,间,间,是,是,48,秒,/,治,具,具,。,。,如,如,果,果,同,同,时,时,有,有,2,条,生,生,产,产,线,线,生,生,产,产,，,，,制,制,程,程,的,的,节,节,拍,拍,时,时,间,间,则,则,为,为,96,秒,。,。,Scenario2:IfTopandBottomproductrunningonsamelineatthesametime,Takttimeshallbehalf=48sec,情,节,节,2,：,如,如,果,果,正,正,反,反,面,面,产,产,品,品,同,同,时,时,在,在,一,一,条,条,生,生,产,产,线,线,生,生,产,产,，,，,节,节,拍,拍,时,时,间,间,则,则,为,为,一,一,半,半,，,，,48,秒,。,。,AssuchtheProcessTaktTimeCalculationasfollowing:,制,程,程,节,节,拍,拍,时,时,间,间,计,计,算,算,如,如,下,下,：,：,=TaktTimeXProductUpxProcessUpXNumberofLine,=2secX6productsperpanelX4PanelperpalletX2Lines,=96sec,8,WhatisStandardWIP,什,么,么,是,是,标,标,准,准,WIP,VarioustypesofWIPinourmanufacturingprocess,生,产,产,过,过,程,程,中,中,存,存,在,在,各,各,种,种,类,类,型,型,的,的,WIP,StandardWIP,标,准,准,WIP,ProcessWIP,制,程,程,WIP,ProcessToProcessWIP,制,程,程,与,与,制,制,程,程,间,间,WIP,StationToStationWIP,工,位,位,与,与,工,工,位,位,间,间,WIP,9,WhatisStandardWIP,什,么,么,是,是,标,标,准,准,WIP,WIPmeansINVENTORY.INVENTORYisBasically,bad,.,WIP,就是,库,库存,。,。库,存,存从,根,根本,上,上说,是,是“,不,不好,”,”的,。,。,StandardWIPistheIdealorShouldbeconditionsforWIP,标准,WIP,是理,想,想,WIP,或者,是,是,WIP,的应,有,有状,态,态。,However,beforeyoufullyachievedStandardWIPQuantity,youmightneedtogothroughvariousstagestounderstandyourprocessMudaandbottleneck,然而,，,，在,完,完全,达,达到,标,标准,WIP,数量,前,前，,你,你需,要,要经,过,过不,同,同的,阶,阶段,了,了解,制,制程,中,中的,浪,浪费,和,和瓶,颈,颈。,KeyNotefromSensei:,老师,的,的重,要,要提,示,示：,TounderstandtheaboveWIPdefinitions,gotoTheGenbaandperformyourownworktowardsEstablishingtherightWIPquantities.ThisistheOnlywayyoucanunderstandthedefinition.,要理,解,解,WIP,定义,，,，你,需,需要,去,去到,现,现场,在,在工,作,作中,实,实践,正,正确,的,的,WIP,数量,。,。这,是,是让,你,你理,解,解这,个,个定,义,义的,唯,唯一,方,方法,。,。,10,WhatisStandardWIP,什么,是,是标,准,准,WIP,ThepurposeofStandardWIPis:,标准,WIP,的目,的,的：,Separationbetweenmachinejobandmanjob,区分,机,机器,作,作业,和,和手,动,动作,业,业,Ensuresqualityrequirements,确保,质,质量,要,要求,EnsuressmoothflowbasedonTakttime,确保,基,基于,节,节拍,时,时间,的,的连,续,续流,Example1:,例子,1,WIPinthereflowovenforcuringwithprocesstime6minandTakttime30sec.,在回,流,流焊,炉,炉中,固,固化,的,的,WIP,，制,程,程时,间,间,6min,，节,拍,拍时,间,间,30sec.,StandardWIPinthecuringoven=ProcessTime/TaktTime,回流,焊,焊炉,的,的标,准,准,WIP=6min/30sec,=12Pcs,11,WhatisStandardWIP,什么,是,是标,准,准,WIP,Example2:,例子,2,WIPinthetesteratbackendassemblywithprocesstime60secandTaktTime30sec.,后段,组,组装,线,线测,试,试机,的,的,WIP,，制,程,程时,间,间,60sec,，节,拍,拍时,间,间,30sec.,StandardWIPintheTeststation=60sec/30sec,测试,工,工位,的,的标,准,准,WIP=2pcs,Inotherwords,StandardWIPinordertofulfilltheabove1),2),3)functions,ItisthecompulsoryWIPinthemachine/processbeforeestablishstandardworkfortheprocess.,换句,话,话说,，,，标,准,准,WIP,能够,确,确保,上,上述,1),2),3),达成,，,，在,建,建立,标,标准,作,作业,前,前，,标,标准,WIP,是机,器,器和,制,制程,强,强制,的,的,WIP,。,12,WhatisStandardWIP,什么是标,准,准,WIP,ProcessWIP,制程,WIP,WIPwithin sameprocesswithlowvariation of cycletime,同一个制,程,程中的,WIP,，,周期时间,CT,变化很小,It is all that WIP in the same process,notcategorizedas StandardWIPor PTP WIP.,所有在同,一,一个制程,中,中的,WIP,，不是标,准,准,WIP,或制程间,WIP.,Example:-,例如,Before Kaizen, Manual Insert(MI) Line Process WIP =9 pcs. AfterKaizenMI Process WIP is 3.Standard WIP for each station is 1pc.,改善前，,插,插件拉的,制,制程,WIP=9 pcs,。改善后,插,插件拉制,程,程,WIP=3pcs,。每个工,位,位的标准,WIP,为,1pcs.,T.T,60 sec,51,45,58,43,Person,Time,A,B,C,D,T.T,60 sec,60,60,60,12,Person,Time,A,B,C,D,variance,After,Before,ProcessWIP= 3,Standard WIP =1,ProcessWIP= 9,NostandardWIP,13,WhatisStandardWIP,什么是标,准,准,WIP,ProcessTo Process WIP (PTPWIP),制程间,WIP,WIPbetween2 differentprocesses with big gap cycletime,两个周期,时,时间相差,很,很大的不,同,同制程间,的,的,WIP.,PTPWIPIs needed due tochangeoverin upstreamline.,上游制程,需,需要转拉,，,，则需设,定,定制程间,WIP.,NotAlllineneed PTP WIP.,不是所有,产,产线都需,要,要制程间,WIP.,If Cycletime ofUpstream Process isLess thenDownstreamprocess,如果上游,制,制程的周,期,期时间小,于,于下游制,程,程的周期,时,时间,Example1:-,SMTCycle time (30 sec)Lessthen ManualInsertion (60 sec),例,1,：,SMT,周期时间,(30sec),小于,MI,插件周期,时,时间,(60sec),CT (Upstreamprocess) NeedPTPWIP,需要制程,间,间,WIP,If Cycletime Upstream process is Equalor greater thenDownstreamprocess,NoPTPWIPrequired.,如果上游,制,制程的周,期,期时间大,于,于或等于,下,下游制程,的,的周期时,间,间，不需,要,要制程间,WIP.,14,WhatisStandardWIP,什么是标,准,准,WIP,ProcessTo Process WIP,制程间,WIP,Example2:-ProcessA cycletime15sec.Itis faster then Process Bcycle time25sec. Process Aisrunning2 product modelsascapacityrequirement. Inorder to Keep Process linerunning,processtoprocessWIPis requiredbetweenProcessA and B.Thecalculationasbelow:-,例,2,：,制程,A,周期时间,是,是,15sec,，,比制程周,期,期时间,25sec,快。制程,A,根据生产,能,能力需求,，,，需要生,产,产,2,种产品。,为,为了保证,产,产线正常,运,运作，需,要,要在制程,A,和制程,B,之间设定,制,制程间,WIP,。计算如,下,下：,TaktTime =30sec,Changeover Time= 5min,30sec,ProcessA,ProcessB,15,TaktTime,节拍时间,Cycle time Takt time (1 Station Process ),C/Tthan takt for single process (2same stationsneeded),C/TTakt(,需要,2,个相同工,位,位,),TAKTTime =20s,10,20,30,40,Machine/Process A : St. #1,Machine/Process A : St. #2,Note,注,注: CT TT: Additional Machine/Man needed,需要额外,的,的机器,/,人员,It can be used to calculate,节拍时间,可,可以计算,Total Operatorsneeded,员工需求,数,数量,Total machines needed,机器需求,数,数量,StandardWIPneeded& Etc,标准,WIP,需求数量,，,，等,16,IstheTakttime visible(withcounterandtriggeringpoint)?,节拍时,间,间可以,直,直观地,看,看出来,吗,吗？有,没,没有借,助,助工具,(,计数器,和,和触发,机,机制,),。,2)IstheTaktboarddefined (ontheboard)?,节拍时,间,间确定,了,了吗？(把节拍,时,时间写,在,在白板,上,上),3)AretheStandardWIP defined?,标准,WIP,有定义,吗,吗?,4)Do youknow howtoseparatemanual(persons)from auto(themachines) work?,你知道,如,如何区,分,分手动,作,作业和,自,自动作,业,业吗?,5)Is theWork loadlevelingdefinedforman,，,machine andC/O?,人工,机器以,及,及换线,使,使用工,作,作负荷,均,均衡表,分,分析了,吗,吗？,6)Is theH/CcalculatedbasedonTakt time?,人力的,多,多少是,根,根据节,拍,拍时间,计,计算出,来,来的吗?,7)Is theStdwork(frontpage)SWCS(backpage)postedinfrontofeachoperator?,每个工,站,站前都,有,有标准,作,作业,(,前页,),和标准,作,作业合,并,并表,SWCS(,背页,),吗?,Operations,操作,17,Operations (continue),操作(,续,续页),8)Isthestd workbeingfollowedbythe operator?,操作员,有,有没有,按,按照标,准,准作业,流,流程作,业,业?,9)Isthestd workdefinedforwaterstrider?,有没有,定,定义物,料,料员的,标,标准作,业,业?,10)Isthe operator idleatthe station?,在作业,过,过程中,操作员,是,是否有,等,等待?,11)Doestheoperatorsearch forcomponents or tools?- Locatealltoolsandpartswithineasyaccessorreach(Doctor&Nurse).,在作业,中,中,操作员,有,有没有,寻,寻找物,料,料或工,具,具的动,作,作?工具或,物,物料应,该,该放置,在,在易于,获,获取的,位,位置,定点定,位,位.(遵,循,循医生,和,和护士,概,概念：,Doctor,医生,指直接,作,作业的,人,人员,nurse,护士,指辅助,作,作业人,员,员,如物料,员,员),12)Doyou havestd workfor inspectionstation?,检查工,站,站有没,有,有标准,作,作业书?,13)Doyou haveshortestcycletimeforinspection?,对于检,查,查工站,有没有,定,定义最,短,短周期,时,时间?,18,Operations (continue),操作(续页),14)At the hand load station,do you apply doctorandnurseconcept?,在手工作业,工,工站,有没,有,有运用医生,和,和护士理念,?,15)Do you meet thetarget of3 sec percomponentduring insertion athandload?,在手插工站,有没有达到,每,每3秒一颗零件,的,的插件速度?,16)SIC less at hand load station(withtemplate).,手插工站不,需,需要,SIC(,用模板来显,示,示需要插件,的,的位置)?,Handloadmanual CT Takt time nurse not required. Arethere system in place tostopworkwhenabnormalconditionsarise?,当手动作业,的,的周期时间,小,小于节拍时,间,间时，不需,要,要,”,护士,”,(护士,nurse:,辅助作业人,员,员),当异常情况,出,出现时，有没有系统,来,来控制停止,作,作业?,18 )Doesthe supervisorrespond ina quick/crudemanner?,当异常发生,时,时，管理人员的,反,反映是快速,还,还是迟钝?,19)Do you have 6Simplemented onyourline?,线上有实行,6,S,吗?(,6,S=5S+Safety,),19,Operations( continue ),操作(续页),20) Is theproduction qtyforthe day defined?,日产量有没,有,有定义?,21) Is theMulti skill chartsvisible and available?,有没有显示,和,和使用多技,能,能培训表？,22) Do youallow banana peeling onthe line?,允许在线拆,卸,卸物料包装,吗,吗?,23) Are you able todetect bottleneck stationat aglance?,瓶颈工站能,一,一眼看出来,吗,吗?,24) The operator must notre-orientthepart,操作员不允,许,许重新调整,零,零件方向,防止零件极,性,性弄错.(这里操作员,指,指辅助作业,人,人员,即,nurse),25)Change over :,快速换型,a) Internal time,内部时间,d) Adjustment time,调整校准时,间,间,b) External time,外部时间,e) Clean,清洁,c) Trial run,试运行,20,Operations( continue ),操作(续页),26) ETE Operation criteria:,端到端运行,标,标准,The line shouldrunbasedon Takt time,生产线必须,按,按照客户需,求,求节拍合理,安,安排生产,The H/C shouldbe loadedbasedon Takt time,生产线应按,客,客户需求节,拍,拍时间合理,安,安排人员,Material shouldbe loadedbased onTakttime,按客户需求,节,节拍时间备,置,置原材料,The line shouldbe configuredto zero defects,配置生产线,时,时需满足零,缺,缺陷,Supermarket should meet all the 15criteria,超市必须符,合,合,15,个设置准则,27) ETE consists of:,端到端包括:,a) Productivity improvement (MLT,H/C, WIP, Space),提高生产效,率,率(生产前,置,置期,科学,的,的人员配置,适当的在,线,线库存,有,效,效的空间利,用,用,),b) Material replenishment (Water strider, Min- Max, Supermarket),灵活精益的,原,原材料供给,方,方式(水蜘,蛛,蛛补货原则,，,，设置最低,最,最高库存，,超,超市),c) Quality improvement (Zerodefects),提高质量(零缺陷),d)C/O(ifthetime more than10 minutes),换型时间,(,如果时间,超,超过,10,分钟,),21,Operations (continue ),操作,(,续页,),28)4 functionsof,Conveyor,Say,NO,to Conveyor, ifbelow criterias not meet,“,传送带”,的,的,4,个功能，,如,如果不,符,符合以下,条,条件则不,能,能使用“,传,传送带”,Functionasa Pace Setter (TaktManufacturing ),节拍调节,器,器（节拍,生,生产）,Functionasa Valueadding workstation( Valuebeing addedas it moves),增,值工位（传送带移,动,动时产品,可,可以增值,，,，如在传,送,送带上作,业,业）,Functionasa Jidoka( Stopevery abnormal ),自働化（异常时停,止,止作业）,Functionasa transportationmode (,5% of the function,),传送作用,（只占,5%,的功能）,22,Layout,布局,1) Insure the shortwalkingdistance.,确保产线,行,行走距离,短,短.,2) Do you have 3TEIimplementedonyourline?,产线有没,有,有对物品,实,实施三定,原,原则?,a) Fix place,定点,b) Fix things,定位,/,定物,c) Fix qty,定量,3) Is the safetyaisle easily accessed by the operator?,安全通道,是,是否易于,员,员工通过?,4) Are theretrash binsinside the cell?,单元生产,线,线内有没,有,有垃圾箱?,5) Do you have cellconceptimplementedon yourline?,有没有在,生,生产线上,应,应用单元,生,生产的概,念,念,.,23,Layout (continue ),布局(续,页,页),6) The operatormovementina cell :isit counter clockwise(1)orclockwise(0).Counterclock wiseis recommended,操作员在单元内的移动,是,是逆时针,还,还是顺时,针,针(逆时针为,佳,佳),7) The gap in acell: is itwider(0) ornarrower(1)(narrower recommended).,单元内工站间,的,的间距合,适,适的吗?宽,(0),还是窄,(1)(,推荐用窄,).,8) Is the station made of crefoam material and is itonthewheel for flexible movement?,工作台是,由,由复合管,做,做成的吗?是否有滑,轮,轮易于移,动,动呢?,9) The flowof alayoutmust belike asinglestroke,no zigzag.,产线布局,的,的流向必,须,须是单行,程,程的，而,不,不是弯曲,交,交错的。,10)Do you use 7ways when designingtools,jigs, fixtures,layout or process?,在设计工,具,具,夹,具,具,治,具,具,工,厂,厂,布,布,局,局,和,和,流,流,程,程,时,时,有,有,没,没,有,有,采,采,用,用7种,方,方,法,法,(7ways)?,11)DoyouusePughmatrixtoevaluate7ways?,有,没,没,有,有,使,使,用,用,Pughmatrix,来,评,评,估,估7种,方,方,法,法?,.,24,Layout(continue),布,局,局(,续,续,页,页),12)Handloadstationshouldmeetthebelowrequirements:,手,动,动,作,作,业,业,工,工,站,站,应,应,该,该,满,满,足,足,以,以,下,下,要,要,求,求:,a)Partpresentation,物,料,料,摆,摆,放,放,方,方,式,式,b)Zerodefect,物,料,料,品,品,质,质,零,零,缺,缺,陷,陷,c)Layout/Ergonomic,插,件,件,的,的,顺,顺,序,序,/,根,据,据,人,人,机,机,工,工,程,程,学,学,来,来,安,安,排,排,d)Bothhandsofoperatorhavetobeusedduringinsertion,插,件,件,时,时,要,要,双,手,手,作,作,业,业,13)Arethecables,wiresandnetworkusingtheoverheaddroppointforflexibility?,电,线,线,网,线,线,信,号,号,线,线,是,是,否,否,架,架,设,设,在,在,线,线,体,体,上,上,端,端,并,并,连,连,接,接,到,到,产,产,线,线,，,，,易,易,于,于,灵,灵,活,活,使,使,用,用?,14)DoyouusetheSpaghettiCharttodothelayout,process,movement?,在设计,layout,，流程,行走路,线,线时有,没,没有使,用,用到,SpaghettiChart(,意大利,面,面条图)工具,清晰的,画,画出人,流,流、物,流,流及产,品,品流路,线,线?,15)Isthe linevisibilityclearforthe supervisor? (boarder postdefinedforclearvisibility),对于管,理,理者来,说,说，产线可,视,视化吗?(定义看,板,板使其,清,清晰可,视,视化),16)Doyou usemock-up layout?,有没有,模,模拟,layout,实施后,的,的情况,吗,吗?,17)TreeandBranch connectingsubassembly&main assembly,主干和,枝,枝条,主装配,线,线和辅,助,助装配,线,线的合,理,理衔接,25,Layout(continue),布局,(,续页,),18)ShortTakttime 1minute,multiplytakttime by (x)factorand duplicatethebackendcell accordingly,客户节,拍,拍时间,太,太短小,于,于,1,分钟时,，,，增大,节,节拍时,间,间,X,倍并建,立,立相应,数,数量的,相,相同的,单,单元产,线,线。,19)Doyourwork stations areinsame height?,工作台,都,都是同,一,一个高,度,度吗？,20)Doyou carry out,“,“ropetest”tovalidatethecontinuousvalueflow ?,有,实施“,绳,绳子测,试,试”验,证,证连续,价,价值流,吗,吗？,26,Zero Defect,零缺陷,Cannormal andabnormalbevisuallydifferentiated?,正常和,异,异常现,象,象易于,区,区分吗?,2)Arethe escalationpathswelldefined if abnormality occurs?,针对异,常,常的发,生,生,有没有,制,制定出,逐,逐级上,报,报的流,程,程?,3)Arethedefectsallowed to escapetodown stream?,有没有,不,不良流,入,入下一,工,工站?,a),Donotpassdefect,( DownstreamInternalorToEnd Customer ),不流出,不,不良品,(,内部下,游,游客户,或,或终端,客,客户,),b),Donotmakedefect,( In OwnProcess ),不制造,不,不良品,（自己,的,的工位,）,）,c),Donotaccept defect,( FromUpstream),不接收,不,不良品,（从上,游,游工序,）,）,d),Donotrework,( NotBuildProduct ViaRework),不允,许,许返,工,工,（不,通,通过,返,返工,生,生产,产,产品,）,）,4)Doyouhaveacommonareatoviewthedefect(fishmarket)?,有没,有,有特,定,定的,地,地点,来,来检,讨,讨不,良,良?(,fishmarket,鱼市,场,场,),27,ZeroDefect(continue),零缺,陷,陷(,续,续页),5)Doyouapply3Gens?,有没,有,有做,到,到三现?,a)Genba-Actualplace,现场,b)Genbutsu-Actualproduct,现物,c)Genjitsu-Actualfact,现实,6)Doyouuse5W(who,what,where,when,why)+1H(how),whereruleandregulationapplied?,规章,制,制度,的,的制,定,定有,没,没有,运,运用5,W+1H,的方,法,法?,7)Doyouhavehandfreeinspectionstation?,视检,工,工站,有没,有,有不,需,需要,用,用手,的,的?,8)Doyouhavetemplatewithnavigationorpointertoguideinspectionoperators?,有没,有,有模,板,板来,辅,辅助,视,视检,作,作业,？,？,28,ZeroDefect(continue),零缺,陷,陷(,续,续页),9)DoyouapplySDCA,PDCA?andfordefectsdoyouapplyPDCA?(Problem,Display,Clear&acknowledge)SDCA(Standardize,Do,Check&Action),工作,中,中有,没,没有,运,运用,SDCA,、,PDCA,方法,？,？针,对,对不,良,良现,象,象，,有,有没,有,有运,用,用,PDCA,的方,法,法？,10)DoyouhaveKaizenNewspaperdisplayed?,改善,活,活动,的,的海,报,报有,没,没有,展,展示,出,出来?,11)Doyouhave1hr,2hr,4hr,8hrtrackingsystemonthefloor?,(leadtozerodefect),产线,有,有没,有,有跟,踪,踪系,统,统，随时,了,了解,每,每1小时,，,，每2小时,，,，每4小时,，,，每8小时,的,的状,况,况？(向零,缺,缺陷,靠,靠近),12)IdentifyPOO& POD to solvetheproblem,当问题发,生,生时,鉴别出问,题,题的起源(,POO),和问题的,发,发现点(,POD),来解决问,题,题.,POO=point oforigin(where is the firstpoint are the causeproblem),POD=point ofdetection (where the pointtheproblembeencaptured),13)Learn how tomake the defecttounderstand rootcause,研究如何,会,会产生不,良,良,从而了解,根,根本原因,。,。,29,ZeroDefect( continue ),零缺陷(,续,续页),14)Do you haveAutoJidokaimplementedin yourline?,产线有没,有,有运用自,働,働化系统,？,？,15)Talktothedefect to understandtheroot cause,深入研究,不,不良或缺,陷,陷，找出,根,根本原因,16)Duplicate the defecttounderstand the rootcause,多次重复,不,不良现象,的,的发生，,找,找到根本,原,原因。,17)Do you havemeantest ?- challengethecurrentstate (PotentialProblemAnalysis),有运用均,值,值检验吗?,对现状,进,进行寻根,究,究底(分,析,析潜在的,问,问题),18)Do you use 5Whyanalysis tounderstandtherootcause?,有没有运,用,用5个为什么,来,来分析根,本,本原因？,19)Landscape concept ,View,fromallangles(themountain) ,Search,forthetruth (the forest),Look/Focus,(thetree),See,andfixit (thebranch),全局概念-,-,全方位,-,远看,(,山,),，寻找真,相,相,-,近观,(,森林,),，细看,(,树,),，深究并,解,解决问题,(,枝干,),30,OnePiece Flow,单件流,1) One pieceflow,单件流,2) Are the linevisibility clearforthesupervisor?Std.WIP?Takt counter? Lineflow?,对于管理,者,者来说，,产,产线状况,可,可视化吗,？,？有标准,WIP?,节拍计数,器,器？产线,是,是流动的,吗,吗？,3) One pieceflow whichlikeastheeggsinsidethechickenshould be one byoneflow ,but notin parallel.,单件流就,像,像母鸡肚,里,里的鸡蛋,一,一样是一,个,个一个下,蛋,蛋的，而,不,不是一起,下,下出来的,。,。,4) To shorten the information ofdefectfeedback, one pieceflowcanreduceourleadtime.,为缩短不,良,良现象的,信,信息反馈,，,，单件流,可,可以帮助,减,减少前置,时,时间。,5) Whenwe set up new layout,wemust consider use the one pieceflow.,当建立新,的,的生产线,布,布局时，,必,必须考虑,使,使用单件,流,流。,6) The Ideally layout isonepiece flowaccording our Takt time.,理,想,想,产,产,线,线,布,布,局,局,是,是,按,按,照,照,节,节,拍,拍,时,时,间,间,的,的,单,单,件,件,流,流,。,。,7)Thelayoutof,“,“Y,”,”isbetterthanthelayout,“,“III,”,”series,“Y,”,”,型,布,布,局,局,比,比,“III,”,”,型,布,布,局,局,好,好,。,。,8)Asthequalityfeedbackisfastandquickactiontaken.,品,质,质,反,反,馈,馈,速,速,度,度,快,快,，,，,能,能,够,够,快,快,速,速,响,响,应,应,采,采,取,取,行,行,动,动,。,。,31,VSM,价,值,值,流,流,图,图,Doyouhavevaluestreamdoneonyourproduct?,1.,产,线,线,有,有,没,没,有,有,做,做,价,价,值,值,流,流,分,分,析,析,？,？,a)haveyouvisualizedimprovementstotheoverallproductionflow,insteadofspotimprovementstosingleprocesses,有,没,没,有,有,把,把,所,所,有,有,产,产,线,线,流,流,程,程,存,存,在,在,改,改,善,善,空,空,间,间,的,的,地,地,方,方,明,明,显,显,地,地,标,标,识,识,出,出,来,来,，,，,而,而,不,不,是,是,仅,仅,标,标,示,示,某,某,个,个,地,地,方,方,。,。,b)haveyoucreatedacompletematerialandinformationflow,有,没,没,有,有,规,规,划,划,出,出,完,完,整,整,的,的,物,物,料,料,流,流,和,和,信,信,息,息,流,流,c)currentstate-howtheprocessworkstoday,现,状,状-产,线,线,现,现,在,在,是,是,如,如,何,何,运,运,作,作,的,的,d)futurestate-mapshowsimprovementstowardsalongtermidealstate,未,来,来,的,的,情,情,况,况-价,值,值,流,流,图,图,表,表,示,示,出,出,改,改,善,善,之,之,后,后,的,的,理,理,想,想,状,状,况,况,e) 3DVSMfor bettervisualization(foroffice kaizen),3D,价值流图使,流,流程更加直,观,观（针对办,公,公室改善）,32,VSM (continue),价值流图(,续,续页),2) 7typesof flow must be clearlydefined :,7,大流程必须,定,定义清楚,a) Material Raw,物料,-,原材料,b) Material WIP,物料,-,在线库存,c) Material - FinishGoods,物料,-,成品,d) Information- what info isrequired to move materials, what isthetiming,信息,-,移动/搬运物料时,需,需要什么信,息,息，什么时,间,间点,e) People- std.work, Takt time,人流,-,标准作业，,节,节拍时间,f) Equipment -carts, conveyor, racks, andons, TPM,设备流,-,手推车，传,送,送带，物料,架,架，,andons,异常停线系,统,统，全面生产维,护,护(,TPM=TotalProductiveMaintenance,),g) Engineering- quality,tooling,programs,工程,-,品质，工具,，,，程序,33,MoonshineShop,月光工作室,1) Do youhavemoonshinecapability inyourplant?,工厂有没有,月,月光工作室,可,可以自己动,手,手制作治具,或,或工具以及,时,时满足产能,需,需求的能力.?,34,GolfScore,动作评估表,Are the operators havingto bent down?,操作员在作,业,业过程中需,要,要弯腰吗?,2)Are operators havingto reachhigh?,操作员的手,需,需要伸到很,高,高的位置(获取物料或,工,工具)来完成作业,吗,吗？,3)Are operators havingto twist/turn?,操作员在作,业,业过程中需,要,要转身吗?,4)Are operators leaving work area?,操作员在作,业,业过程中离,开,开工作区吗?,5)Are operators needing 3 arms?(handbeingusedas fixtures),操作员必须,依,依靠三只手,才,才能完成作,业,业吗?（第三只指,的,的是治具）,6)Is the C/Tsetat 90% orlessof the Takt time?,周期时间是,设,