优化生产基础之目视化工厂课件

,*, , , , , , ,目视化工厂,Fundamentals of Lean Manufacturing,VISUAL FACTORY,优化生产基础之,目视化工厂,Definition: Visual Factory,定义： 可视化工厂管理,Visual Factory is the use of visual controls that will enable an individual to immediately recognize the standard and any deviation from it.,可视化工厂是使用可视化控制手段，使个人能够依此立即识别标准及偏差,1,How the Visual Factory Can Help You,可视化工厂对你有什么帮助？,Reduce searching time.,减少寻找时间,Eliminate many frustrations.,排除许多挫挫折,.,Increase safety.,提高安全度,Improve communication.,增进了解,Increase job satisfaction.,提高工作满意度,2,Elements of the Visual Factory,可视工厂的要素,Workplace Organization and Standardization,工作场所的组织和标准化,Prevent Defects and Errors,防止不良和偏差,Visual Display,5,Keys,Visual Control,目视化控制,Visual Display,目视化展示,5,S,Share Information,分享信息,3,The Visual Factory Vision,可视化工厂一览,There is nothing extra.,没有任何例外,The environment is immaculate, safe, and self-cleaning.,环境优美，安全并自觉清扫。,Standards are easy to recognize and abnormal conditions are easier to correct.,标准易找，错误易改。,Performance and progress are readily apparent,工作与进程很明显,4,Visual Factory Foundation: Five Keys To Workplace Organization,目视化工厂的基础： 工作组织的5要点,Key 1: Sort (Organization),要点1：整理（组织）,Key 2: Stabilize (Orderliness),要点2：整顿（井然有序）,Key 3: Shine (Cleanliness),要点3：清洁（清洁）,Key 4: Standardize (Adherence),要点4：清扫（坚持）,Key 5: Sustain (Self-Discipline),要点5：,习惯化（自律）,5,Distinguish Between What Is and Is Not Needed,区分需要的与不需要的。,Key 1: Sort (Organization),要点1：整理 (组织,）,6,Key 1: Sort - Red Tagging,要点1：整理红色标签,A visible way to identify items that are not needed or are in the wrong place in the workplace.,用来识别工作现场不需要的与放在错误位置的东西的一种可视化方法,Obsolete, unneeded?,废旧的，不需要的？,Stored here, used elsewhere?,放在这里，在别的地方用吗？,Used infrequently?,不经常使用吗？,What the heck is THIS used for?,这是干什么用的？,7,Key 1: Sort - Red Tag Holding Areas,要点1：整理红色标签区,Temporary Storage,暂时存放,Local Holding Area,当地存放区,Central Holding Area,中心存放区,Holding Area Manager,存放域区经理,Timely Clearing,及时清扫,8,A Place For Everything,部件有地方放置,And,Everything In Its Place,物归其位,Key 2: Stabilize(Orderliness),要点2：整顿（井然有序）,9,Key2:Stabilize-LocationMapExample,要,点,点2,：,：,整,整,顿,顿,布,布,置,置,图,图,举,举,例,例,Extrude,Form,Cut,Cure,Pack,Office,PressDept.,挤,压,压,成,形,形,裁,断,断,压,榨,榨,包,装,装,办,公,公,室,室,硫,化,化,10,Key2:Stabilize-LocationIndicators,要,点,点2,：,：,整,整,顿,顿,布,布,置,置,指,指,示,示,Locationindicatorsare,usedtoindicatewhatis,locatedwhereandhow,manyaresupposedtobe,there.,区,域,域,指,指,示,示,是,是,用,用,来,来,指,指,明,明,什,什,么,么,东,东,西,西,放,放,在,在,哪,哪,里,里,及,及,应,应,放,放,多,多,少,少,。,。,11,Key2:Stabilize,要,点,点2,：,：,整,整,顿,顿,GuidelinesForLocationIndicators,区,域,域,指,指,示,示,指,指,导,导,方,方,针,针,ToIndicateLocations,指,明,明,区,区,域,域,AddressSignboards,地,址,址,板,板,LimitLines(Yellow),限,制,制,线,线,（,（,黄,色,色,）,）,LocationLines(White),区,域,域,线,线,（,（,白,白,色,色,）,）,Labels,标,鉴,鉴,ToSetLimits,设,定,定,限,限,制,制,ToIndicateDanger,标,明,明,危,危,险,险,HeightLines(Red),高,度,度,线,线,（,（,红,红,色,色,）,）,StandardContainerSizes,标准,集,集装,箱,箱尺,码,码,RedColoring,红色,标,标记,“Danger”Signs,危险,符,号,号,12,Key1:Sort&Key,要点2：1.,整,整理,和,和要,点,点,2:,Stabilize,2.,整顿,Summary,总结,Removingunneededitemsmakesiteasiertofindwhatyouneed.,去掉,不,不需,要,要的,东,东西,，,，使,你,你能,够,够容,易,易找,到,到需,要,要的,东,东西,。,。,Relocatingitemscanimproveworkflow.,重新,布,布置,可,可改,善,善工,作,作流,Identifyingitemlocationscanhelpyoufindthingsandputthemback.,确定,放,放置,区,区域,可,可以,帮,帮助,你,你找,到,到所,需,需要,的,的东,西,西并,放,放回,远,远处,Togetherthefirstandsecondkeysincreaseworkefficiency.,第一,点,点和,第,第二,点,点结,合,合可,以,以提,高,高工,作,作效,率,率,Theyalsomakeyourworkplaceamorepleasantplace.,他们,也,也可,以,以使,你,你的,工,工作,场,场所,更,更加,舒,舒适,13,Eliminateallformsofdirt.,清除,各,各种,灰,灰尘,。,。,Findwaystokeeptheworkplaceclean.,采取,措,措施,，,，保,持,持工,作,作场,所,所清,洁,洁,Adoptcleaningasaformofinspection.,把清,洁,洁作,为,为检,查,查的,一,一种,形,形式,Makecleaningpartofeverydaywork.,使清,洁,洁作,为,为日,常,常工,作,作的,一,一部,分,分,Key3:Shine(Cleanliness),要点3：,清,清洁,（,（清,洁,洁）,14,Check,检查,Standardize,标准,化,化,Maintain,维持,Monitor,监控,Improve,提高,MaintainandmonitorthefirstthreeKeys,维持,并,并监,控,控前3项,要,要点,Key4:Standardize(Adhere),清扫,（,（坚,持,持）,15,Requiresselfdiscipline,andcommitmentfrom,everyoneintheorganization,要有,自,自律,并,并且,组,组织,中,中的,每,每个,人,人都,要,要承,担,担义,务,务,Key5:Sustainingthe5Sprocess,维持5行,活,活动,每位,成,成员,养,养成,良,良好,的,的习,惯,惯，,并,并遵,守,守规,则,则做,事,事。,培,培养,主,主动,积,积极,的,的精,神,神,应遵,守,守出,勤,勤,作,作息,时,时间,；,；,工作,应,应保,持,持良,好,好的,状,状态(如,不,不可,以,以随,意,意谈,天,天说,笑,笑,离,离开,工,工作,岗,岗位,看,小,小说,、,、打,瞌,瞌睡,、,、吃,零,零食,等,等),；,；,服装,整,整齐,，,，待,好,好识,别,别卡,；,；,待人,接,接物,诚,诚恳,有,有礼,貌,貌；,爱护,公,公物,，,，用,完,完归,位,位；,保持,清,清洁,；,；,乐于,助,助人,；,16,5,S,含义,目的,做法示例,整理,将工作场所的任何物品区分为有必要与没有必要的，除了有必要的留下来以外，其它的都清除或放置在其它地方。它往往是5,S,的第一步。,腾出空间；,防止误用。,将物品分为几类（如）：,不再使用的；,使用频率很低的；,使用频率较低的；,经常使用的。,将第1类物品处理掉，第2、3类物品放置在储存处，第4类物品留置工作场所。,整顿,把留下来的必要用的物品定点定位放置，并放置整齐，必要时加以标识。它是提高效率的基础。,工作场所一目了然；,消除找寻物品的时间；,整整齐齐的工作环境；,对可供放置的场所进行规划；,将物品在上述场所摆放整齐；,必要时还应标识。,5,S,含义,总,总结,17,5,S,含义,总,总结,清扫,将工作场所及工作用的设备清扫干净，保持工作场所干净、亮丽,保持良好工作情绪；,稳定品质；,清扫从地面到墙板到天花板所有物品；,机器工具彻底清理、润滑；,杜绝污染源如水管漏水、噪音处理；,破损的物品修理,。,清洁,维持上面3,S,的成果,监督,检查表； 红牌子作战。,习惯化,每位成员养成良好的习惯，并遵守规则做事。培养主动积极的精神。,培养好习惯,遵守规则的员工；,营造良好的团队精神。,如：,应遵守出勤,作息时间；,工作应保持良好的状态(如不可以随意谈天说笑,离开工作岗位,看小说、打瞌睡、吃零食等)；,服装整齐，待好识别卡；,待人接物诚恳有礼貌；,爱护公物，用完归位；,保持清洁；,乐于助人；,18,1.,提,提,升,升企,业,业形,象,象；,整齐,清,清洁,的,的工,作,作环,境,境，,使,使顾,客,客有,信,信心,；,；,由于口碑,相,相传，会,成,成为学习,的,的对象。,2. 提,升,升员工归,属,属感；人,人,人变得有,素,素养；,员工从身,边,边小事得,变,变化上获,得,得成就感,；,；,对自己的,工,工作易付,出,出爱心与,耐,耐心。,3. 提,升,升效率；,物品摆放,有,有序，不,用,用花时间,寻,寻找；,好的工作,情,情绪。,4. 保,障,障品质,员,员工上下,形,形成做事,讲,讲究的风,气,气，品质,自,自然有保,障,障了。,机,机器设备,的,的故障减,少,少。,5. 减,少,少浪费；,场,场所的,浪,浪费减少,；,； 设备,、,、工具的,浪,浪费减少,5,S,的,作用,19,场所,检查对象,检查项目,记录,车间,通道,是否划线（整顿）,有没有无用的物品堆放（整理）,通道能否顺利通行（整顿）,地面是否平整（清扫,）,地面是否干净（清扫）,办公室,办公现场,办公现场有无无用物品；,使用频率低的物品是否放置储存处；,经常使用的物品是否摆放在办公现场；,物品摆放是否有合理规划，容易寻找；,物品摆放是否整齐；,抽屉、柜筒、文件类物品是否做有标识；,办公现场是否清洁；,办公设施是否干净,；,检查表（,检,检查表应,依,依据所出,台,台的5,S,书面规定,编,编制，示,例,例:,20,1、,成立推行,组,组织，制,订,订激励措,施,施；,2、 制,订,订实施规,划,划，形成,书,书面制度,；,；,3、 展,开,开宣传造,势,势，进行,教,教育训练,；,；,4、 全,面,面实施5,S，,实行区域,责,责任制；,5、 组,织,织检查，,采,采用红牌,子,子作战等,方,方法,进行督促,6,召开定期,会,会议，评,比,比,5S,结果,如何推行5,S,21,TheVisual Factory Pyramid,目视化工,厂,厂塔形图,Workplace Organization and Standardization,PreventDefectsandErrors,防止不良,和,和差错差,错,错,Visual Display,5,Keys,Visual Control,目视化控,制,制,Visual Display,目视化展,示,示,5,Keys,5,要点,Share Information,分享信息,工作场所,的,的组织和,标,标准化,22,Introduction: Visual Displays and Control,解释：目,视,视化展示,和,和控制,Visual displaysandcontrolsarea system ofdevices, information, color-coding,layouts, and signboards, standardized to createa common visuallanguage intheworkplace.,目视化展,示,示与控制,是,是一个以,设,设计，信,息,息，颜色,编,编码，布,置,置图，布,告,告板为手,段,段，通过,标,标准化在,工,工作场所,创,创造一个,通,通用的目,视,视化语言,的,的体系。,Theydistinguishpromptly between normalandabnormal conditions.,可以立即,区,区分正常,和,和非正常,状,状态,Theymake abnormalitiesandwaste obvious enoughforanyoneto recognize.,可以使任,何,何人明显,地,地识别出,不,不正常和,浪,浪费,Theyconstantlyexpose needsforimprovement.,可以不断,地,地暴露改,善,善的需要,。,。,23,Levels Of The VisualFactory,可视化工,厂,厂的层次,WORKPLACE ORGANIZATION,Share Information,Share Standards,at the Site,Build StandardsintotheWorkplace,Warnabout Abnormalities(Buildin alarms),StopAbnormalities,(Preventdefectsfrom movingon),PreventAbnormalities (Error-Proof),1,2,3,4,5,6,Sort, Set, Shine, Standardize, and Sustain,Workplace Organization,在车间形,成,成5行习,惯,惯,Visual Control,目视化控,制,制,Visual Display,目视化展,示,示,防止不正,常,常状态,（错误预,防,防）,制止不正,常,常状态,（防止不,良,良继续产,生,生）,预告非正,常,常状态,（设立警,报,报）,在工作现,场,场建立标,准,准,在现场共,享,享标准,分享信息,24,Definition:Visual Displays& Controls,定义：,目,目视化展,示,示和控制,Visual Displays.,目视化展,示,示,Communicateimportant information, but do not control what people ormachines do. Theymakeupthefirst two levelsofthepyramid.,交流重要信,息,息 ，但是,不,不控制人和,机,机器的行为,。,。他们形成,了,了金字塔的,前,前两,个层次,Visual Controls,目视化控制,Communicate information so that activities are performed according tostandards.Theymakeup the topfourlevels ofthepyramid.,交流信息，,使,使活动按照,标,标准进行。,他,他们形成了,金,金字塔上面,的,的4个层次,25,Levels OfVisual Control:Example,目视化控制,层,层次：举例,Itemto becontrolled,受控制的物,件,件,Ensuring that automobilelights areswitchedoff,whendriver cuts engine and leavescar,当司机停车,或,或离开车时,，,，保证车灯,是,是关闭的,Level1-Share information,层次1共,享,享信息,Level2-Share standards at,the site,层次2在,现,现场共享标,准,准,Level2-Build standards into,the workplace,层次2在,现,现场建立标,准,准,Level4-Warn about,Abnormalities,层次4非,正,正常状态警,告,告,Level5-Stop abnormalities,层次5停,止,止非正常状,态,态,Level6-Preventabnormalities,层次6防,止,止不正常状,态,态,Include instructionsto switchofflights before,turning engineoff in theowners manual,在车主手册,中,中包含关闭,前,前车灯的指,示,示,Pasteinstructions on cardashboardso they can easilybe seen bydriver “Switchofflights beforeleaving car”,在汽车的仪,表,表板上张贴,标,标志，使伺,机,机很容易看,见,见“离车前,关,关灯”的标,志,志,“,Switch offlights” comesup inredon controlpanel,whenthe ignition isswitchedoff,熄火时控制,板,板上出现“,关,关闭车灯”,的,的红灯,Bellsounds when cardooris openedif lightsareon,当车门开着,时,时，如果灯,开,开着就响起,铃,铃声,Keyscannot beremoved from ignition until lights,are switched off,如果车灯开,着,着，车钥匙,在,在发动过程,中,中拔不出来,Lights areautomaticallyswitched off when car engine,turnsoff,发动机关闭,时,时车灯自动,关,关闭,26,Visual Displays& Control,目视化展示& 控,制,制,Red tagging,红色标签,Whitelinedemarcations,用白线划分,Red line demarcations,用红线区分,27,Error-Proofing& TheVisual Factory,错误预防和,可,可视工厂,Error-proofingexpands the Visual Factory tool kitto include methodsthat,错误验证扩,展,展可视工厂,工,工具包括以,下,下方法：,Broadcastinformation toproblem solvers,为问题解决,者,者提供信息.,Prevent defectsandabnormalities from causing furtherproblems,and,防止不良和,不,不正常状态,带,带来更大的,问,问题.,Eliminatethe possibilityof certain problemsaltogether.,清除出现某,些,些问题的可,能,能性.,28,ErrorProofing& TheVisual Factory,错误预防和,可,可视工厂,Workplace Organization and Standardization,现场组织和标准化,Prevent Defects and Errors,Visual Display,5,Keys,Visual Control,Visual Display,5,Keys,Share Information,分享信息,目视化展示,五要点,防止不良和,差,差错,目视化控制,29,Common Electrical Devices,一般电器装,置,置,Common Mechanical Concepts,一般机械概,念,念,LimitSwitch,限位开关,ProximitySwitch,接近开关,Microswitch,微型开关,Define part positioning,for aprocess,对一个过程,确,确定位置的,配,配置,Allowonlycorrect parts,to pass for further,Processing,只允许好的,部,部件传入到,下,下一个工序,Enforce correctassembly,加强正确组,装,装,Error-ProofingDevices,预防错误的,装,装置,30,DefinitionOf VisualDisplay,目视化工厂,的,的定义,Everythingthatinforms,directs, warnstracks,所有的东西,都,都告知,指,示,示,警示,追,追踪,Communicates standards,交流标准,Showsgoals andresults of activities and improvements,说明活动以,及,及改善的目,标,标和结果,Communicates other information,交流其它信,息,息,31,AboutVisual Displays,关于目视化,展,展示,Communicate important information but,do not control,what peopleormachinesdo.,交流重,要,要信息,但,但并不,控,控制人,和,和机器,的,的行为,Fall intothe first twolevelsofthe VisualFactorypyramid.,属于目,视,视化工,厂,厂金字,塔,塔的前,两,两个层,次,次,VISUAL,DISPLAYS,目视化展示,32,IntegratingStandardsIntoTheWorkplace,在工作,现,现场整,合,合标准,Level1:,层次1,Standardsare indicatedseparately.Metersreadaccordingtoachecksheet.,标准单,独,独列示,按照,检,检查表,记,记录仪,表,表读数,Level2:,层次2,Standardsonlabels.Meterreadingscan be compared to labels.,标准在,标,标签上,说,说明,仪,仪表读,数,数可以,和,和标签,相,相对照,20 +/- 3,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,35 +/- 3,10 +/- 3,Month/Date,Check Sheet,33,Definition Of VisualControl,目视控,制,制的定,义,义,Communicateimportantinformationand standardsina waythat,controls,conformancetothosestandards.,通过控,制,制与标,准,准的一,致,致性,交,交流重,要,要信息,和,和标准.,Fall intothe topfour levelsoftheVisual Factorypyramid.,属于目,视,视化工,厂,厂金字,塔,塔的上,面,面的四,个,个层次,VISUAL,CONTROLS,目视化控制,34,VisualControls&TheVisual FactoryPyramid,目视化,控,控制和,目,目视化,工,工厂金,字,字塔,WORKPLACE ORGANIZATION,Share Information,Share Standards,at the Site,Build Standards into the Workplace,Warn about Abnormalities (Build in alarms),Stop Abnormalities,(Prevent defects from moving on),Prevent Abnormalities (Error-Proof),1,2,3,4,5,6,Sort, Set, Shine, Standardize, and Sustain,Workplace Organization,工作场所5,S,活动,Visual Control,Visual Display,目视化,控,控制,目视化,展,展示,防止不,正,正常状,态,态(预,防,防错误),停止非,正,正常状,态,态,(防止,不,不良继,续,续产生),警告非,正,正常状,态,态,(设立,警,警报),在工作,现,现场建,立,立标准,在工作,现,现场共,享,享标准,分享信,息,息,35,VisualControl,目视化,控,控制,Getthe correctinformation,orstandardasclosetothe,pointofactionaspossible.,在行动,场,场所尽,可,可能接,近,近的地,方,方获取,正,正确的,信,信息和,标,标准,Ideal,standardsare totallyintegratedwithactionsothat deviationsfromstandardareminimized.,理想的,标,标准与,行,行动完,全,全结合,在,在一起,，,，以便,减,减少与,标,标准的,偏,偏差.,36,IntegratingStandardsIntoTheWorkplace,在工作,现,现场融,入,入标准,Level1:,层次1:,Standardsare indicatedseparately.Meters readaccording to achecksheet,.,标准单,独,独列示,按照,检,检查表,进,进行仪,表,表读数.,Level2:,水平2:,Standardsonlabels.Meterreadingscan be compared to labels.,标准在,标,标签上,仪表,读,读数可,以,以和标,签,签相对,照,照.,20 +/- 3,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,10,20,30,40,50,35 +/- 3,10 +/- 3,Month/Date,Check Sheet,37,IntegratingStandardsIntoTheWorkplace,在工作,现,现场融,入,入标准,Level3:,层次3:,Visualindicator of standardsarebuiltintometers.Allconditionscanbeseenchecked at aglance,standardisat12oclock.,目视化,标,标准指,示,示器与,仪,仪表融,合,合,所,有,有的情,况,况都能,一,一眼看,出,出，标,准,准是在,刻,刻度12点上,.,Level4:,层次4:,A warningsignal willactivateinanon-standardconditions.,在非正,常,常状态,会,会出现,警,警告信,号,号.,20 +/- 3,10,20,30,40,50,15,25,35,45,55,40,50,10,20,30,50,10,20,30,40,15,25,35,45,55,40,50,10,20,30,35 +/- 3,10 +/- 3,Month/Date,Check Sheet,38,Reviewactual conditionontheshopfloor!,在现场,检,检查实,际,际情况,Look for,寻找,Levelof5SandVisual,Factory5S,层次和,目,目视化,工,工厂,Opportunities forimprovement,改善机,会,会,39,5,S,VisualDisplay,Visual,Control,Existing,现有,Opportunity,机会,VisualFactoryShop floor Exercise,目视化,工,工厂现,场,场演练,目视化,控,控制,目视化,展,展示,40,VisualControlsSummary,目视化,工,工厂控,制,制概述,VisualControls, likeVisual Displays,canresolvemany information andcommunication problems in theworkplace.,目视化,控,控制,象,象目视,化,化展示,一,一样,能,能够解,决,决很多,现,现场的,信,信息和,交,交流问,题,题.,Again,the resultisimprovedwork efficiencyand effectiveness.,结果是,提,提高了,工,工作效,率,率和效,能,能,Another importantresultisfewerworkfrustrationsand amoresatisfying workexperience.,另一个,重,重要结,果,果是减,少,少挫折,感,感和增,加,加了工,作,作满意,度,度.,41,谢谢观,看,看,/,欢迎下,载,载,BYFAITHI MEANAVISIONOFGOODONECHERISHES ANDTHEENTHUSIASMTHAT PUSHESONETOSEEKITSFULFILLMENTREGARDLESSOFOBSTACLES. BY FAITH IBYFAITH,