【正文】 raise yield 降低不良，提高良率 48 Kanban 看板系統(tǒng) 1) When Kanban card is detached from the product, it must be clear ?where Kanban card‘ should GO 當(dāng)產(chǎn)品的看板卡取下時(shí) ,一定要清楚看板應(yīng)該 去 哪兒 2) The product Kanban card must be transfer to address designated 看板卡一定要與所隨產(chǎn)品一起按要求轉(zhuǎn)送到指定地點(diǎn) 3) Kanban card should be transported the scheduled time to designated location 看板卡傳送時(shí)要按預(yù)定時(shí)間送到指定地方 4) Each box or product must have kanban card attached 每個(gè)運(yùn)輸盒 /產(chǎn)品上必須附其對(duì)應(yīng)看板卡 5) Kanban card has to be maintained all time and to be ensured no damage/ spoil/ loss (Kanban card is equivalent to cash or credit card) 看板卡要時(shí)時(shí)進(jìn)行跟蹤 ,維護(hù) ,使其保證完整無(wú)缺 (看板卡等同于鈔票或信用卡 ) 6) Kanban card must be taged with license number (serial number) 看板卡必須要有發(fā)行編號(hào) 49 Kanban ( continue ) 看板系統(tǒng) (續(xù)頁(yè) ) 7) No Kanban card = No production (Do not start any production without Kanban card) 看板卡上的數(shù)量等于生產(chǎn)數(shù)量 (沒(méi)有看板就不生產(chǎn) ) 8) Quantity in the Kanban card must match or equal to the physical quantity 看板卡上的數(shù)量一定要和實(shí)際生產(chǎn)數(shù)量相一致 9) No extra tray, no extra bin, no extra Kanban card in the Genba Supermarket at all time 在生產(chǎn)現(xiàn)場(chǎng)或超市不允許有多余的托盤，多余的盒子，多余的看板卡 10) All WIP / Inventory must be acpanied w。 41 Material 物料 1) Are parts provided 1 kit at a time (or less than 10 min.39。 RR是推進(jìn) 6 SIGMA及 QS 9000中常用的評(píng)價(jià)測(cè)定系統(tǒng)再現(xiàn)性及再生性的工具，被廣泛應(yīng)用于尺寸測(cè)定的工具上。 31 VSM 價(jià)值流圖 1) Do you have value stream done on your product? 1. 產(chǎn)線有沒(méi)有做價(jià)值流分析？ a) have you visualized improvements to the overall production flow, instead of spot improvements to single processes 有沒(méi)有把所有產(chǎn)線流程存在改善空間的地方明顯地標(biāo)識(shí)出來(lái)，而不是僅標(biāo)示某個(gè)地方。 5) When we set up new layout ,we must consider use the one piece flow. 當(dāng)建立新的生產(chǎn)線布局時(shí)，必須考慮使用單件流。 19) Do your work stations are in same height ? 工作臺(tái)都是同一個(gè)高度嗎？ 20) Do you carry out ―rope test‖ to validate the continuous value flow ? 有 實(shí)施“繩子測(cè)試”驗(yàn)證連續(xù)價(jià)值流嗎？ 26 Zero Defect 零缺陷 1) Can normal and abnormal be visually differentiated? 正常和異?，F(xiàn)象易于區(qū)分嗎 ? 2) Are the escalation paths well defined if abnormality occurs? 針對(duì)異常的發(fā)生 ,有沒(méi)有制定出逐級(jí)上報(bào)的流程 ? 3) Are the defects allowed to escape to down stream? – 有沒(méi)有不良流入下一工站 ? a) Do not pass defect ( Downstream Internal or To End Customer ) 不流出不良品 (內(nèi)部下游客戶或終端客戶 ) b) Do not make defect( In Own Process ) 不制造不良品 （自己的工位） c) Do not accept defect ( From Upstream) 不接收不良品 （從上游工序） d) Do not rework ( Not Build Product Via Rework ) 不允許返工 （不通過(guò)返工生產(chǎn)產(chǎn)品） 4) Do you have a mon area to view the defect (fish market)? 有沒(méi)有特定的地點(diǎn)來(lái)檢討不良 ?(fish market 魚(yú)市場(chǎng) ) 27 Zero Defect ( continue ) 零缺陷 (續(xù)頁(yè) ) 5) Do you apply 3 Gens? 有沒(méi)有做到三 現(xiàn) ? a) Genba Actual place 現(xiàn)場(chǎng) b) Genbutsu Actual product 現(xiàn)物 c) Genjitsu Actual fact 現(xiàn)實(shí) 6) Do you use 5 W ( who, what , where, when, why)+1H (how) where rule and regulation applied? 規(guī)章制度的制定有沒(méi)有運(yùn)用 5W+1H的方法 ? 7) Do you have hand free inspection station? 視檢工站 ,有沒(méi)有不需要用手的 ? 8) Do you have template with navigation or pointer to guide inspection operators? 有沒(méi)有模板來(lái)輔助視檢作業(yè)？ 28 Zero Defect ( continue ) 零缺陷 (續(xù)頁(yè) ) 9) Do you apply SDCA,PDCA? and for defects do you apply PDCA? (Problem,Display,Clear acknowledge) SDCA ( Standardize, Do, Check Action ) 工作中有沒(méi)有運(yùn)用 SDCA、 PDCA方法？針對(duì)不良現(xiàn)象，有沒(méi)有運(yùn)用 PDCA的方法？ 10) Do you have Kaizen Newspaper displayed? 改善活動(dòng)的海報(bào)有沒(méi)有展示出來(lái) ? 11) Do you have 1hr, 2hr, 4hr, 8hr tracking system on the floor? (lead to zero defect) 產(chǎn)線有沒(méi)有跟蹤系統(tǒng) ， 隨時(shí)了解每 1小時(shí)，每 2小時(shí)，每 4小時(shí)，每 8小時(shí)的狀況？ (向零缺陷靠近 ) 12) Identify POO POD to solve the problem 當(dāng)問(wèn)題發(fā)生時(shí) ,鑒別出問(wèn)題的起源 (POO)和問(wèn)題的發(fā)現(xiàn)點(diǎn) (POD)來(lái)解決問(wèn)題 . POO=point of origin (where is the first point are the cause problem) POD=point of detection (where the point the problem been captured) 13) Learn how to make the defect to understand root cause 研究如何會(huì)產(chǎn)生不良 , 從而了解根本原因。s) from auto (the machine39。制程 A根據(jù)生產(chǎn)能力需求，需要生產(chǎn) 2種產(chǎn)品。 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?；诠?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. 后段組裝線測(cè)試機(jī)的 WIP，制程時(shí)間 60 sec，節(jié)拍時(shí)間 30 sec. Standard WIP in the Test station = 60 sec/ 30 sec 測(cè)試工位的標(biāo)準(zhǔn) WIP = 2 pcs ? In other words, Standard WIP in order to fulfill the above 1), 2), 3) functions, It is the pulsory WIP in the machine / process before establish standard work for the process. 換句話說(shuō)，標(biāo)準(zhǔn) WIP能夠確保上述 1),2),3)達(dá)成，在建立標(biāo)準(zhǔn)作業(yè)前，標(biāo)準(zhǔn) WIP是機(jī)器和制程強(qiáng)制的 WIP。 ? 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)。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。 ?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。 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 。Lean Hand Book 精 益生產(chǎn)手冊(cè) 1 ? Defect : X 1/10 缺陷 降低 90% ? Inventory : 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