【正文】 Lean Hand Book 精 益生產(chǎn)手冊(cè) 1 ? Defect : X 1/10 缺陷 降低 90% ? Inventory : X 189。 庫(kù)存減半 ? Productivity : X 2 生產(chǎn)效率翻倍 ? Lead Time : X 189。 生產(chǎn)周期減半 ? Scrap : X 1/10 報(bào)廢降低 90% ? Space : X 189。 面積減半 Goal : Add Value Eliminate Waste … Relentlessly for Our Customers 目標(biāo) : 減少浪費(fèi) 創(chuàng)造價(jià)值 全心全意為客戶服務(wù) ? ETE (End to End) Productivity Improvement 端到端 (從頭到尾 )產(chǎn)能提高 ? ETE Zero Defect (Quality, TPM, OEE etc.) 端到端 (從頭到尾 )零缺陷（質(zhì)量，全面生產(chǎn)維護(hù)，全局設(shè)備利用率等） ? Inventory Reductions 降低庫(kù)存 ? Lead Time Reductions 縮短生產(chǎn)前置期 ? Crew Size Optimization 優(yōu)化人員數(shù)量 ? Space Reduction 減少 使用面積 Double the Good 好的加倍 Halve the Bad 壞 的減半 Double the Speed 改善速度加倍 Kaizen Workshop Goal 改善目標(biāo) No Money 不投入更多金錢(qián) No Space 不占用更多面積 No Manpower 不使用更多人力 2 Standard Work Standard Combination Sheet 標(biāo)準(zhǔn)化作業(yè) 標(biāo)準(zhǔn)作業(yè)合并表 1) Standard work defined 標(biāo)準(zhǔn)作業(yè)定義 a) Takt time defined 節(jié)拍時(shí)間的定義 b) Work sequence defined 工序的定義 c) Standard WIP defined 標(biāo)準(zhǔn)在線庫(kù)存定義 d) Cycle time defined 周期時(shí)間定義 e) No of operators defined 操作員數(shù)量的定義 f) Safety 安全性 g) Multi skill 多技能 2) Standard work bination sheet defined 標(biāo)準(zhǔn) 作業(yè)合并表定義 a) Manual time 手動(dòng)時(shí)間 b) Auto time 機(jī)器 (自動(dòng) )時(shí)間 c) Walking time 走動(dòng)時(shí)間 d) Waiting time 等待時(shí)間 3) Is the Quality check legend defined on each process on std work sheet? 標(biāo)準(zhǔn)作業(yè)合并表上，有定義每個(gè)流程中的品質(zhì)管控的關(guān)鍵點(diǎn)嗎？ 3 Key Elements 3項(xiàng) 關(guān)鍵要素 3 3 Types of Standard Works 3種標(biāo)準(zhǔn)作業(yè) Ta k t Ti m e節(jié)拍時(shí)間S e qu e nc e順序S t a nd a r d W I P標(biāo)準(zhǔn)在制品1 YFe w很少Y Y Y N S W C S S M T2Fe w很少Y Y Y Y NW o r k L o a d L e v e l i n g C h a r t / S W C SH a n d L o a d A s s e m b l y手動(dòng)作業(yè)裝配W o r k S t a n d a r d作業(yè)標(biāo)準(zhǔn)3 Y Y N N Y YA n d o n異常報(bào)警系統(tǒng)R e c e i v i n g ,W a t e r S p i d e r ,HR,T e s t i n g收貨，水蜘蛛， HR ，測(cè)試S i gn a l Tri ge r r i ng信號(hào)觸發(fā)E x a m pl e s例子E l e m e nt s 要素S t a n d a r d W o r k標(biāo)準(zhǔn)作業(yè)Ty pe類型M a c hi ne機(jī)器M a n人To ol s工具4 3 Types of Standard Works 3種標(biāo)準(zhǔn)作業(yè) Type 1 : Standard Work to support machine (90%) man (10%) bination task. 類型 1：標(biāo)準(zhǔn)作業(yè)適用于 90%的機(jī)器作業(yè)和 10%的手動(dòng)作業(yè)的組合作業(yè)方式 。 Type 2 : Standard Work to support man (90%) machine (10%) bination task. 類型 2：標(biāo)準(zhǔn)作業(yè)適用于 90%手動(dòng)作業(yè) 和 10%機(jī)器作業(yè)的組合作業(yè)方式 。 Type 3 : Standard Work (also called as Work Standard) to support task carried out once signal is triggered. 類型 3：標(biāo)準(zhǔn)作業(yè)（也叫做作業(yè)標(biāo)準(zhǔn)）適用于當(dāng)信號(hào)產(chǎn)生時(shí)才去執(zhí)行相應(yīng)任務(wù)的作業(yè)方式 。 No Std Work means no Kaizen … Std Work is the Mother of all Kaizen 沒(méi)有標(biāo)準(zhǔn)作業(yè)就沒(méi)有改善 …… 標(biāo)準(zhǔn)作業(yè)是改善之母 5 How to start the Takt Time Calculation Based On Customer Demand 怎樣根據(jù)客戶需求計(jì)算節(jié)拍時(shí)間 ? Step 1: Calculate Takt time Based on Customer Demand 第一步：根據(jù)客戶需求計(jì)算節(jié)拍時(shí)間 ? Example 例如 : ? Customer Demand per Month 792K. Working hour per day is 22 hours, 20 days a month. 客戶每月需求量是 792K。每天工作小時(shí)是 22小時(shí)，一個(gè)月 20天。 ?Takt Time calculation shall display all the variable and units to make clarity to all. 計(jì)算節(jié)拍時(shí)間時(shí)要顯示所有變量及單位，便于大家理解。 sec 2792 ,0001,58 4,00 0pcs 792 ,000s 360 0 x days 20 x Hou rs 22 Deman d Custome r Time AvailableTime Takt????客戶需求有效時(shí)間6 How to start the Takt Time Calculation Based On Product and Process Design怎樣根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Step 2: Calculate Process Takt time Based on Product and Process Design 第二步：根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Based on Step 1, Takt Time is 2 second to produce 1 pcs. 根據(jù)步驟 1，節(jié)拍時(shí)間是每 2 秒生產(chǎn) 1 件產(chǎn)品。 7 How to start the Takt Time Calculation Based On Product and Process Design怎樣根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間 Scenario 1: Product design is 6 pcs per one PCB panel. The Process Takt Time will be every 12 second a panel. Besides, your process design is using a pallet to place 4 panels, then your Process Takt Time is 48 second a pallet. If 2 line running, process Takt time will be 96 sec. 情節(jié) 1：產(chǎn)品設(shè)計(jì)為每塊 PCB板由 6 塊小板組成，節(jié)拍時(shí)間是每塊 PCB板 12 秒 。 制程設(shè)計(jì)治具同時(shí)放置 4 塊 PCB板，則制程的節(jié)拍時(shí)間是 48 秒 /治具。如果同時(shí)有 2 條生產(chǎn)線生產(chǎn)，制程的節(jié)拍時(shí)間則為 96 秒。 Scenario 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec 情節(jié) 2：如果正反面產(chǎn)品同時(shí)在一條生產(chǎn)線生產(chǎn)，節(jié)拍時(shí)間則為一半， 48秒。 As such the Process Takt Time Calculation as following: 制程節(jié)拍時(shí)間計(jì)算如下： = Takt Time X Product Up x Process Up X Number of Line = 2 sec X 6 products per panel X 4 Panel per pallet X 2 Lines = 96 sec 8 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Various types of WIP in our manufacturing process 生產(chǎn)過(guò)程中存在各種類型的 WIP 1. Standard WIP 標(biāo)準(zhǔn) WIP 2. Process WIP 制程 WIP 3. Process To Process WIP 制程與制程間 WIP 4. Station To Station WIP 工位與工位間 WIP 9 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP ? WIP means INVENTORY. INVENTORY is Basically ‘bad’. WIP就是庫(kù)存。庫(kù)存從根本上說(shuō)是“不好”的。 ? Standard WIP is the Ideal or Should be conditions for WIP 標(biāo)準(zhǔn) WIP是理想 WIP或者是 WIP的應(yīng)有狀態(tài)。 ? However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and bottle neck 然而，在完全達(dá)到標(biāo)準(zhǔn) WIP數(shù)量前，你需要經(jīng)過(guò)不同的階段了解制程中的浪費(fèi)和瓶頸。 Key Note from Sensei: 老師的重要提示： ? To understand the above WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解 WIP定義，你需要去到現(xiàn)場(chǎng)在工作中實(shí)踐正確的 WIP數(shù)量。這是讓你理解這個(gè)定義的唯一方法。 10 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP The purpose of Standard WIP is: 標(biāo)準(zhǔn) WIP的目的： 1. Separation between machine job and man job 區(qū)分機(jī)器作業(yè)和手動(dòng)作業(yè) 2. Ensures quality requirements 確保質(zhì)量要求 3. Ensures smooth flow based on Takt time 確保基于節(jié)拍時(shí)間的連續(xù)流 Example 1: 例子 1 WIP in the reflow oven for curing with process time 6 min and Takt time 30 sec. 在回流焊爐中固化的 WIP，制程時(shí)間 6 min，節(jié)拍時(shí)間 30 sec. Standard WIP in the curing oven = Process Time / Takt Time 回流焊爐的標(biāo)準(zhǔn) WIP = 6 min / 30 sec = 12 Pcs 11 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Example 2: 例子 2 WIP in the tester at backend assembly with process time 60 sec and Takt Time 30 sec. 后段組裝線