【正文】 Example : Break down machine maintenance/calibration task and cross check current manpower skill and develop them with required skills to minimize the cost. 例如 ：分解機器維護 /校準(zhǔn)作業(yè)，交叉檢查當(dāng)前的人員技能，提高人員需求的技能，減少成本。 8) As the quality feedback is fast and quick action taken. 品質(zhì)反饋速度快，能夠快速響應(yīng)采取行動。 10) Do you use 7 ways when designing tools, jigs, fixtures, layout or process? 在設(shè)計工具 ,夾具 ,治具 ,工廠布局和流程時有沒有采用 7種方法 (7 ways)? 11) Do you use Pugh matrix to evaluate 7ways? 有沒有使用 Pugh matrix來評估 7種方法 ? . 24 Layout ( continue ) 布局 (續(xù)頁 ) 12) Hand load station should meet the below requirements :手動作業(yè)工站應(yīng)該滿足以下要求 : a) Part presentation 物料擺放方式 b) Zero defect 物料品質(zhì)零缺陷 c) Layout /Ergonomic, 插件的順序 /根據(jù)人機工程學(xué)來安排 d) Both hands of operator have to be used during insertion 插件時要 雙手作業(yè) 13) Are the cables, wires and work using the overhead drop point for flexibility? 電線 ,網(wǎng)線 ,信號線是否架設(shè)在線體上端并連接到產(chǎn)線，易于靈活使用 ? 14) Do you use the Spaghetti Chart to do the layout, process, movement? 在設(shè)計 layout， 流程 ,行走路線時有沒有使用到 Spaghetti Chart(意大利面條圖 )工具 ,清晰的畫出人流、物流及產(chǎn)品流路線 ? 15) Is the line visibility clear for the supervisor? (boarder post defined for clear visibility) 對于管理者來說 ， 產(chǎn)線可視化嗎 ?(定義看板使其清晰可視化 ) 16) Do you use mockup layout? 有沒有模擬 layout實施后的情況嗎 ? 17) Tree and Branch – connecting sub assembly main assembly 主干和枝條 –主裝配線和輔助裝配線的合理銜接 25 Layout ( continue ) 布局 (續(xù)頁 ) 18) Short Takt time 1minute, multiply takt time by (x) factor and duplicate the backend cell accordingly 客戶節(jié)拍時間太短小于 1 分鐘時，增大節(jié)拍時間 X 倍并建立相應(yīng)數(shù)量的相同的單元產(chǎn)線。每個工位的標(biāo)準(zhǔn) WIP為 1pcs. 60 sec 51 45 58 43 Person Time A B C D 60 sec 60 60 60 12 Person Time A B C D variance After Before Process WIP = 3, Standard WIP = 1 Process WIP = 9, No standard WIP 13 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Process To Process WIP (PTP WIP) 制程 間 WIP ? WIP between 2 different processes with big gap cycle time 兩個周期時間相差很大的不同制程間的 WIP. ? PTP WIP Is needed due to changeover in upstream line. 上游制程需要 轉(zhuǎn) 拉， 則 需 設(shè) 定制程 間WIP. ? Not All line need PTP WIP. 不是所有產(chǎn)線都需要制程間 WIP. ? If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期時間小于下游制程的周期時間 Example 1: SMT Cycle time (30 sec) Less then Manual Insertion (60 sec) 例 1： SMT周期 時間 (30 sec)小于 MI插件周期 時間 (60 sec) CT (Upstream process) CT (Downstream) = Need PTP WIP 需要制程 間 WIP ? If Cycle time Upstream process is Equal or greater then Down stream process, No PTP WIP required. 如果上游制程的周期時間大于或等于下游制程的周期時間，不需要制程間 WIP. 節(jié)拍時間 前工序機器轉(zhuǎn)拉時間制程間 　　 T ime T akt Mac hine Prev ious of Cha nge ove r W IP W IPProc ess to Proc ess ?14 What is Standard WIP 什么是標(biāo)準(zhǔn) WIP Process To Process WIP 制程 間 WIP 節(jié)拍時間前工序機器轉(zhuǎn)拉時間程間 　　制 T ime T akt Mac hine Prev ious of Cha nge ove r W IP W IPProc ess to Proc ess ?Example 2: Process A cycle time 15 sec. It is faster then Process B cycle time 25sec. Process A is running 2 product models as capacity requirement. In order to Keep Process line running, process to process WIP is required between Process A and B. The calculation as below: 例 2： 制程 A周期時間是 15sec，比制程周期時間 25sec快。庫存從根本上說是“不好”的。每天工作小時是 22小時，一個月 20天。Lean Hand Book 精 益生產(chǎn)手冊 1 ? Defect : X 1/10 缺陷 降低 90% ? Inventory : X 189。 ?Takt Time calculation shall display all the variable and units to make clarity to all. 計算節(jié)拍時間時要顯示所有變量及單位，便于大家理解。 ? 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)。制程 A根據(jù)生產(chǎn)能力需求，需要生產(chǎn) 2種產(chǎn)品。 19) Do your work stations are in same height ? 工作臺都是同一個高度嗎？ 20) Do you carry out ―rope test‖ to validate the continuous value flow ? 有 實施“繩子測試”驗證連續(xù)價值流嗎？ 26 Zero Defect 零缺陷 1) Can normal and abnormal be visually differentiated? 正常和異常現(xiàn)象易于區(qū)分嗎 ? 2) Are the escalation paths well defined if abnormality occurs? 針對異常的發(fā)生 ,有沒有制定出逐級上報的流程 ? 3) Are the defects allowed to escape to down stream? – 有沒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 （不通過返工生產(chǎn)產(chǎn)品） 4) Do you have a mon area to view the defect (fish market)? 有沒有特定的地點來檢討不良 ?(fish market 魚市場 ) 27 Zero Defect ( continue ) 零缺陷 (續(xù)頁 ) 5) Do you apply 3 Gens? 有沒有做到三 現(xiàn) ? a) Genba Actual place 現(xiàn)場 b) Genbutsu Actual product 現(xiàn)物 c) Genjitsu Actual fact 現(xiàn)實 6) Do you use 5 W ( who, what , where, when, why)+1H (how) where rule and regulation applied? 規(guī)章制度的制定有沒有運用 5W+1H的方法 ? 7) Do you have hand free inspection station? 視檢工站 ,有沒有不需要用手的 ? 8) Do you have template with navigation or pointer to guide inspection operators? 有沒有模板來輔助視檢作業(yè)？ 28 Zero Defect ( continue ) 零缺陷 (續(xù)頁 ) 9) Do you apply SDCA,PDCA? and for defects do you apply PDCA? (Problem,Display,Clear acknowledge) SDCA ( Standardize, Do, Check Action ) 工作中有沒有運用 SDCA、 PDCA方法？針對不良現(xiàn)象，有沒有運用 PDCA的方法？ 10) Do you have Kaizen Newspaper displayed? 改善活動的海報有沒有展示出來 ? 11) Do you have 1hr, 2hr, 4hr, 8hr tracking system on the floor? (lead to zero defect) 產(chǎn)線有沒有跟蹤系統(tǒng) ， 隨時了解每 1小時，每 2小時，每 4小時，每 8小時的狀況？ (向零缺陷靠近 ) 12) Identify POO POD to solve the problem 當(dāng)問題發(fā)生時 ,鑒別出問題的起源 (POO)和問題的發(fā)現(xiàn)點 (POD)來解決問題 . 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 研究如何會產(chǎn)生不良 , 從而了解根本原因。 31 VSM 價值流圖 1) Do you have value stream done on your product? 1. 產(chǎn)線有沒有做價值流分析？ a) have you visualized improvements to the overall production flow, inste