上海通用汽车生产系统SGMGMSCONCE.ppt

Welcome！,An Overview to GMS,A Lean Manufacturing Management System 是一个精益制造管理体系,GMS,Like An Atom We Need All The Pieces Working Together!,Background 背景介绍,New Plant 新工厂 + New Product 新产品 + New Process新工艺 = Quality Problems 质量问题,Not True with GMS ! GMS决不会这样！,Vehicle Launch Concerns 新车型启动关注点,During a Typical Launch一次典型的启动:,Why Global Manufacturing Systems?为什么要采用GMS (通用全球制造体系)?,New Plant 新工厂 + New Product新产品 + New Process新工艺 = Quality Problems 质量问题,J. D. Power, Initial Quality Study J. D. Power, 初始质量调查,1999 Mercedes-Benz,2002 Cadillac CTS,YES,NO,Mercedes-Benz 235 problems per 100 near the bottom of the survey 每100辆车235个问题 在调查中排名靠近末尾 Cadillac CTS 88 problems per 100 Ranked SILVER ! 每100辆车88个问题 排名第二！,Background背景,The GM/Toyota Joint Venture GM/Toyota合资公司,New United Motors Manufacturing Inc. 新的联合汽车制造公司 Est. February 1984 in Fremont, California 1984年2月在加利弗尼亚，弗里蒙特成立 GM wanted to learn the Toyota Production System (TPS) GM想学丰田生产体系（TPS) Toyota wanted to learn about manufacturing in the U.S. 丰田想学如何在美国造车 Each GM unit was free to study TPS and implement as they saw fit 每个GM的工厂都可以学习TPS,并按需实施,Creation of GM-GMS GMGMS的产生,Five GM-GMS Principles 五项原则,Thinking Way 精益概念,Traditional Way,GMS Way,People are hired hands Current State is embraced Function-driven organisation Go to Office & Guess Knowing Organisation Quality seen as a function Hide Mistakes Ego-driven leaders Complex Sense - wasteful Spend time figuring out itself,People are investment in minds Current State is challenged Customer-driven organisation Go To See & Understand Learning Organisation Quality seen as a culture Learn from Mistakes Process-driven leaders Common Sense - simple Spend time figuring out enemy,Purpose of GMS is to make lean-thinking People & lean Processes to deliver lean Results for the Customer,System Position 系统所在的位置,Goal Categories 目标种类,How WE are MEASURED 如何衡量我们的业绩,Plant Performance Score Card工厂绩效考核卡,Goals目标 =,Method方法 =,People Involvement人员参与 -People Company人员参与的公司,Continuous Improvement Company持续改进的公司,Standard- ization 标准化,Built In Quality 制造质量,Short Leadtime缩短制 造周期,Strong Leadership 强有力的领导,GMS Supports Attaining Our Goals GMS 支持我们达到目标,Safety安全 People人员 Quality质量 Responsiveness响应 Cost成本,GM-GMS,GMS Structure,Goals目标,NA,APO,Principles原则,Core Requirements核心要素 (calibration statements),Tools工具,Tools工具,Elements原理,LAAM,GME,Methods标准,Tools工具,Tools工具,Global,Must be Global Common to Have ONE GM-GMS 必须是全球共同的 一个GM-GMS,Structure Explanation 结构说明,Goals 目标,Principles 原则,Elements 要素,Core Requirements 核心要求,Tools 工具,Goals: Describe the primary state which the corporation strives to achieve. Reaching these goals leads to the complete success of our company 目标：描述公司努力要达到的状态。达到这些 目标可引导公司走向成功,Principles: The leading concepts / philosophy of the company which guide our activities in the pursuit of success for our company. 原则：公司的主导理念，可指导我们的行为，追求公司的成功。,Elements: Main strategies within each Principle, which must be implemented to ensure success of each principle. 要素：每个原则的主要策略，实施策略是每个原则成功的保证。,Core requirements: Details which must be followed to ensure the success of each Element 核心要求：实现每个要素成功必须要遵循的细节,Tools: Methods, activities and systems which are used to support the Core Requirements. They may be used to support multiple Core Requirements. 工具：方法，行动和体系用来支持核心要求，也可能用来支持多重的核心要求。,Be the Safety Benchmark 确定安全基准,People Involvement 人员参与,Health and Safety Priority 健康和安全第一,24 Hr. Incident follow up 24小时事故跟踪,Green Cross 绿十字,GMS Principle and Element GMS 原则与要素,Each of the 5 GMS Principles is supported by key elements. There are 33 GM-GMS Elements.,GMS Principles,GMS Elements,Global Manufacturing Goals of Safety, People, Quality, Responsiveness & Cost are supported by the GMS Principles. There are 5 GMS Principles:,People Involvement 1. Vision/Mission 5. Team Concept 2. Values 6. People Involvement 3. Health & Safety Process 7. Open Communication 4. Qualified People 8. Shop Floor Management Standardization 9. Workplace Organization 10. Management By Takt Time 11. Standardized Work 12. Visual Management Built-In Quality 13. Product Quality Standards 17. Quality System Management 14. Manufacturing Process Validation 16. Quality Control & 15. In-Process Verification Feedback/Feedforward Short Lead Time 18. Simple Process Flow 23. Temporary Material 19. Small Lot Packaging Storage - CMA 20. Fixed Period Ordering 24. Pull Systems System/Order Parts 25. Level Vehicle Order Schedules 21. Controlled External Trans. 26. Supply Chain Management 22. Scheduled Shipping/Receiving Continuous Improvement 27. Problem Solving 31. Early DFM/DFA 28. Business Plan Deployment 32. Total Maintenance System 29. Andon Concept 33. Continuous Improvement 30. Lean Design of Facilities, Equipment, Tooling and Layout,People Involvement Elements人员参与原理 Vision，Value and Culture Priority 愿景，价值观与企业文化 Mission 使命 Health & Safety Priority 健康与安全第一 Qualified People合格的人员,People Support System/Team Concept 人员支持体系/团队精神 People Involvement人员参与 Open Communication Process开放式沟通流程 Shop Floor Management车间现场管理,Branches = Methods,Green cross Sheet,Manufacturing Safety Performance Wall,BPD- Group Information Board,Nerve Center - Group Leader Meeting Area BPD Visualization,Safety Lockout Procedure,Group Area,Open Office,Flexibility Chart,Standardization标准化 Definition: Standardization is a dynamic process by which we set standards of terminology, principles, methods, and processes within our organization. 定义：标准化是我们在自己的组织中建立术语、原则、方法和程序标准的动态的程序 Purpose: The purpose of standardization is to stabilize, so as to achieve a base from which to grow and improve. 目的：标准化的目的是为了达到稳定以完成可以用来发展和改进的基础,Standardization标准化,World Class 世界级,Continuous Improvement 不断改进,Change 改变,Standardization Elements标准化原理 Management by Takt Time时间管理 Workplace Organization工作现场管理 Standardized Work标准化作业 Visual Management目视化管理,Safety Visualization,Visual Management- Air, water flow,Team member operation certification board,Workplace organization- 5S,Fixed Position Stop ( Marked On Shop Floor ) Trim Line,Final Process Area Code 1 Control Process,Built-In Quality Elements制造质量原理 Product Quality Standards产品质量标准 Manufacturing Process Validation 制造工艺验证 In-Process Control & Verification 流程中控制和验证 Quality Feedback/Feedforward质量反馈/前馈 Quality System Management质量体系管理,Built In Quality制造质量 Definition: The methods by which quality is built into the manufacturing process, in a way that defects are prevented, detected, and countermeasures are implemented to prevent recurrence.定义：在制造过程中制造质量、防止缺陷、检测和实施防止问题再次发生的对策的方法 Purpose: To ensure that defects are not passed to the customer.3 目的：确保有缺陷的产品不会达到客户手中,Solve problems through teamwork! 通过团队合作解决问题,Satisfy your Customer. . . 使客户满意,The Built-In-Quality Motto 制造质量格言,In house stamping panel inspection,Boundary Sample - Visualization,CARE Line Quality Check,Error Proofing,QCOS Trend Control Sheet,ANDON-Quality Call,Final Process Area Code 1 Control Process,QCOS Sheet,Short Lead Time缩短制造周期 Definition: The movement of product or material in the right quantity, at the right time, to the right location, with the right equipment, using the shortest lead time and the lowest possible cost for both the supplier and the customer.定义：让供应商和客户在最短的制造周期内用尽可能低的成本，在正确的地点使用正确的设备生产出正确的数量的产品或物料的运作 Purpose: To achieve customer enthusiasm by delivering the customer his/her product more quickly, while maintaining good quality. Ultimately, our Company benefits through cost reduction and increased customer loyalty. 目的：保证优质质量的同时，通过更快传递客户产品来获得客户热诚。最终，我们的公司会受益于降低的成本和提升的客户忠诚。,Short Lead Time Elements 缩短制造周期要素 Small Lot Packaging小包装 Fixed Period Ordering System 固定周期订单体系 Controlled External Transportation受到控制的外部交通 Simple Process Flow简单的流程 Scheduled Shipping/Receiving有计划的运送/接收,Temporary Material Storage临时物料储存 Internal Pull/Delivery内部拉动/运送 Level Vehicle Order Schedules水平车辆订单计划 Supply Chain Management供应链管理,Material Andon Light Board,KANBAN Post,Kanban,Material ANDON,Continuous Improvement不断改进 Definition: A process based on standardization, whereby improvement is made, through a series of small improvements.定义：一个基于标准化，通过一系列小的改进来达到改进的程序。 Purpose: To always advance ahead towards an ever more challenging target and make progress in Safety, People Involvement, Quality, Responsiveness, and Cost through the elimination of waste. 目的:不断向前挑战更多的目标并且通过减少浪费在安全、人员参与、质量、响应和成本方面取得进步,Continuous Improvement Elements不断改进要素 Problem Solving 问题解决 Business Plan Deployment 业务计划部署 Andon Concept 暗灯原理 Lean Design of Facilities, Equipment, Tooling and Layout 设施、设备、工具和平面布置的精益设计 Early Manufacturing and Design Integration (DFM/DFA) 制造和设计的早期结合（制造能力设计、装配设计） Total Maintenance System/Total Productive Maintenance 全员维护体系/全员生产性维修 Continuous Improvement Process 持续改进流程,The diagram above shows how each time an improvement is implemented, it creates temporary instability. There will be a short period of instability until new standards are set, and applied. Only once the situation is truly stable, can new improvements be implemented.上面这张图表显示出每次改进之后，都会带来暂时的稳定。而后会有一段短时间的不稳定，直到建立并应用新的标准。只有当情况真正稳定了，新的标准才能实施。,改进,改进,改进,标准化,标准化,标准化,标准化,ANDON Board,SGM Line Balance Wall,Pilot Area ( Building Line Balance Wall ),Creform Assembly Aid,GMS In SGM 全球制造体系在上海通用汽车,My Understanding of GMS Experience Share Q&A,Thanks!,上海通用汽车的宗旨,依靠一支训练有素、富有使命感和团队精神的员工队伍，贯彻精益管理原则，注重不断学习和积极创新。安全地为顾客提供高质量的产品和服务，使上海通用汽车成为面向二十一世纪，国内领先、在国际上有竞争力的汽车公司”。,上海通用汽车的宗旨中包含愿景、使命与方法： 愿景：使上海通用汽车成为面向二十一世纪，国内领先、在国际上有竞争力的汽车公司 使命：安全地为顾客提供高质量的产品和服务 方法：依靠一支训练有素、富有使命感和团队精神的员工队伍，贯彻精益管理原则，注重不断学习和积极创新。,Shanghai General Motors Core Values 上海通用汽车的核心价值,以客户为中心 Customer Focus 以满足客户需求的程度作为衡量工作成效的标准 We will measure our performance by determining whether it has met customers satisfaction 安全 Safety 充分关注人的安全和健康以及环境安全 We will pay full attention to peoples safety and health as well as the safety of environment 充分授权的团队合作 Empowered Teamwork 创造良好氛围，积极发挥员工与合作伙伴特点、 长处 We will promote an environment in which the unique qualities of each employee and partner can be employed to win. 诚信正直 Integrity 成为值得信赖的公司和员工 We will be a trustworthy organization and employee 持续改进与创新 Continuous Improvement & Innovation 更好、更快、更有效，更多运用新思维 We will do things better, faster, more effective and implement more new ideas,People Involvement Elements 1,Corporate Vision, Values, & Cultural Priorities Definition: The Corporations desired state as well as attitudes, mindsets, beliefs, and behaviors each of which is critical to the success of the organization. Purpose: To guide individual behavior and organizational decisions, creating a process and results focused culture. Mission Definition: A local statement that conveys a mental image of the goal or desired state for a specific plant or function. Purpose: To motivate/inspire people to act and help the entire workforce visualize, understand, and relate to the organizations competitive goals and objectives.,People Involvement Elements 2,Health and Safety Priority Definition: Implementation of behaviors, actions, policies, and practices that help our employees realize a healthy, injury free environment. Purpose: To ensure we protect the well being of our people through actions consistent with the belief that safety is our overriding priority and all accidents are preventable. Qualified People Definition: People at all levels of the organization that possess the required profile and skills to perform, thrive, and grow within a competitive manufacturing environment. Purpose: To ensure the best possible fit of peoples abilities with the expectations of the competitive manufacturing roles and responsibilities.,People Involvement Elements 3,People Support System / Team Concept Definition: Small groups of employees that are empowered to function as the owners and basic work unit who share common tasks, support each other, and achieve common goals through continuous improvement. Purpose: To involve employees in the work process to continuously improve performance, product quality, and working conditions through teamwork. To develop employee pride, job satisfaction, and personal growth. People Involvement Definition: Systems, procedures, practices, and programs that involve all employees as active participants in continuous improvement activities. Purpose: Create and maintain an environment which fosters a “spirit of pride.“,People Involvement Elements 4,Open Communication Process Definition: Behaviors and practices that create an environment that fosters a free and open flow of communication at all levels. Purpose: To exchange information that helps people at all levels make informed decisions and improve organizational performance. Shop Floor Management Definition: The behavior of management and support groups to go to where the work is performed, to understand, support, and manage the operations. Purpose: To ensure that decisions are made at the work site by utilizing relevant, factual, accurate, and first-hand information.,