某电气精益生产摘要培训材料

,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,三一电气精益生产摘要培训材料,LEVEL 1:,精益简要,排除浪费,2,培训注意事项,尊重自己、尊重其他学员，保持手机静默或关机,;,优秀的人才从守时开始,(,迟到一分钟罚款,5,元,),培训前请签到，请假需提前,1,天报告,培训结束后做好您方圆,0.5M,的,5S,对自己的成长负责，积极发问；,空杯心态，获得更多；,Agenda,议程,The History of Lean-Toyota Production System,精益的历史与丰田生产系统,Lean Definition&7 Wastes,精益的定义及,7,种浪费,Lean Physical Transformation,精益的实体变革,Lean Management System,精益管理系统,Exercise:,By table/group come up with your definition of,揕,ean,练习：,按课桌,/,小组给出您对“精益”的定义,What is Lean?,什么是精益？,Lean,精益,lean,adj.,精益：形容词,1 a:lacking or deficient in flesh.b:containing little or no fat,a:,无肉或少肉,b:,少脂肪或无脂肪,2:lacking richness,不富裕,3:deficient in an essential or important quality or ingredient,在必要性、重要 性、质量或成分方面稀缺,4:charac-terized by economy of style or expression,文体或措辞简练,syn.,thin,skinny,lanky,scrawny,gaunt,bony,emaciated,svelte,lank,同义词：薄、极瘦、过分瘦长、骨瘦如柴、瘦削的、似骨的、消瘦的、细长的、瘦长的,ant.,fat,fleshy,overweight,flabby,obese,plump,chunky,corpulent,soft,反义词：肥胖的、多肉的、过重的、不结实的、过分肥胖的、丰满的、粗短的、肥大的、软的,What is Lean?-Womack,什么是精益,Define value precisely from the perspective of the end customer,从最终用户的角度准确地定义价值,Identify the entire value stream for each product or product family and eliminate waste,确定每一种产品或产品系列的整个价值流，消除浪费,Make the remaining value creating steps flow,理顺创造价值的步骤,Design and provide what the customer wants only when the customer wants it,只在客户需要时设计和提供他们所需的东西,5.Pursue perfection,追求完美,WHAT ARE THE OBJECTIVES OF LEAN?,精益的目的,Quality,质量,Cost,成本,On-time Delivery,及时交货,建立消除浪费的文化为我们的客户提供价值的最大化,目的,-,客户,&,股东,8,Customer Expectations,客户期望,Performs As Expected,按预期执行,Works when Needed,当需要时,既可用,Cost as Little as Possible,尽可能低的成本,Dont want to Wait,不想等待,“,Establishing a Culture of Relentless Waste Elimination to Deliver Customer Value”,Shareholder Expectations,股东期望,Use Minimum Assets,尽可能少的资产,Maximize Return on Investment,投资回报率最大化,Agenda,议程,The History of Lean-Toyota Production System,精益的历史与丰田生产系统,Lean Definition&7 Wastes,精益的定义及,7,种浪费,Lean Physical Transformation,精益的实体变革,Lean Management System,精益管理系统,History of Lean,历史,新郎重夫,大野,惠特丽,吉尔布雷思,泰勒,.,工业工程之父,Toyota Production System,Production Smoothing,Just,In,Time,Jidoka,通过减少成本消除浪费,How do we Define Value,如何定义价值,12,Value Add Activity,价值增值的活动,Transforming of Raw Materials and Information Into Parts or Products in a Way the Customer Values(Willing to Pay For),任何将信息和原材料转化为零件或产品,且客户愿意支付的活动,Examples:Milling,Boring,Drilling,Punching,Others?,例如,:,洗削,钻孔,冲压,Non-Value Add Activity,非价值增值的活动,Elements of the Process That Add Time,Effort,Cost,but No Value Also Called Waste,任何付出时间,努力,成本,但没有价值的活动,也叫浪费,Waste Are Symptoms of a Problem,Not Root Causes,浪费是问题的表像,非根本原因,Waste Identification,浪费辨识,Operation,加工,Seconds,秒,(Processing/Work),Transportation,运输,Minutes,分,Inspection,检验,Sec/Min,秒,/,分,Searching,寻找,Minutes/Hours,(Tools and Materials),分,/,小时,Storage,储存,Hours/Days/Months,(Waiting/Stops),小时,/,天,/,月,Time,Consumed,时间,What Customer,Pays For,客户支付,P,R,O,D,U,C,T,I,O,N,生,产,YES,NO,NO,NO,NO,Value Add-vs-Non-Value Add,价值增值及非增值,14,Typical Company,典型企业,Traditional Manufacturing,Improvement,传统制造改善,Lean Waste Reduction,精益的浪费减少,Original,Lead Time,最初的提前期,Major Improvement,较大的改善,NVA,非增值,NVA,非增值,NVA,非增值,VA,增值,VA,增值,VA,增值,Minor Improvement,较少的改善,Time,时间,Product Lead Time,提前期,1%to 5%,15,The History of Lean-Toyota Production System,精益的历史与丰田生产系统,Lean Definition&7 Wastes,精益的定义及,7,种浪费,Lean Physical Transformation,精益的实体变革,Lean Management System,精益管理系统,7 Wastes7,种浪费,16,Overproduction,过量生产,Motion,多余动作,Extra Processing,多余的加工,Material Transporation,物料周转,Inventory,库存,Correction,纠正错误,Waiting,等待,17,!,返工,库存堆积,!,机器故障,停工待料,寻找工具,?,生产过多和重复生产,Factory Situation,工厂的情景,Factory Situation,工厂内的情景,.,仓库,临时库房,?,清点部件数量,将库存数据人工输入电脑,观看机器运转,部件远距离运输,Waste of Overproduction,过度生产的浪费,19,Definition:,Producing MoreThan Needed,Producing Faster Than Needed,定义,:,生产超过了需求,生产快过了需求,Waste of Overproduction,过度生产的浪费,20,Characteristics,特点,:,Inventory Stockpiles,库存积压,Extra Equipment,额外的设备,Extra Storage Racks,额外的仓储架,Extra Manpower,额外的人力,Additional Floor Space,更多的工作场地,Causes,原因,:,Incapable Processes,过程能力低下,Lack of Communication,缺乏交流,Long Tool Changes,工具更换周期长,Lack of level Schedules,缺乏均衡生产,Misuse of automation,自动化的滥用,Low uptimes,劳动工时利用率低,21,Definition,:,Any movement of material that is not required for JIT production.,Waste of Material Transportation,材料移动,/,传送的浪费,定义,:,任何不是为了即时需要的物料移动。,22,Characteristics,特点,:,Extra Fork Trucks,额外的叉车,Multiple Storage Locations,多处储存地点,Extra Facility Space,额外的设施空间,Large lots,大批量,Lack of pull system,缺乏拉动系统,Causes,原因,:,Unleveled Schedules,计划安排不平衡,Long Change Over Times,更换品种时间长,Lack of Work Place Organization,工作场地缺乏组织,Improper Facility Layout,设备布局不当,Larger Buffer and Banks,缓冲库存区过大,Lack of address system,缺乏地址系统,Waste of Material Transportation,材料移动,/,传送的浪费,Waste of Motion,动作的浪费,23,Definition,定义,:,Any movement of people or machines which does not contribute value to the product or service.,任何对生产和服务没有带来价值的人员或机器的运动。,Waste of Motion,动作的浪费,24,Characteristics,特点,:,Looking for Tools,寻找工具,Excessive Reaching/Bending,过度伸展,/,弯腰,Machines/Material Too Far Apart(Walk Time),机器,/,材料距离过远（步行的时间,),Clutter w