【正文】 生產(chǎn)缺陷產(chǎn)品 Do Not Pass Along Defects 不傳送缺陷產(chǎn)品 Do Not Accept Defect 不接受缺陷產(chǎn)品 Defects are the Worst Kind of Waste 缺陷是 7大浪費(fèi)中最壞的 Single Piece Flow is intended to detect defects as they occur 單件流趨向于時(shí)時(shí)偵測(cè)正在出現(xiàn)的缺陷 3 Things to Remember …有３件事情要記住 Single Piece Flow 單件流 7 Types of Waste ? Defective Parts缺陷產(chǎn)品 ? Over Production過量生產(chǎn) ? Inventory庫(kù)存 ? Motion多余動(dòng)作 ? Transportation運(yùn)輸 ? Waiting等待 ? Over Processing過度加工 41 Building Quality into the Process在制程中品質(zhì)控制 The Next Process is the Customer … Never Send Defects !下個(gè)工序就是客戶．．．決不發(fā)送缺陷產(chǎn)品 Catches Defects too Late 發(fā)現(xiàn)缺陷時(shí)已經(jīng)晚了 ? How many more do you have? ? Where are they in the process? ? What is the root cause? Catches Defects Immediately 立即發(fā)現(xiàn)缺陷 ? You only have one ? You know where it occurred ? Resolve the root cause immediately Batch批量生產(chǎn) Single Piece Flow單件流 From: The Flextronics Lean Enterprise 42 Single Piece Flow 單件流 Good Cell Layout Makes Work Redistribution Easy 好的單元設(shè)計(jì)可使工作調(diào)整更容易 ? Place Workstations Close Together to Minimize Walking Distance 把工作站盡量靠近，使步行距離最小 ? Keep Inside Width of a Cell at 5 feet to Allow Flexibility in Work Redistribution保持單元內(nèi)距離在５步內(nèi)可使作業(yè)調(diào)整方面具有柔性 ? Locate the Leadoff and Final Processes Near one Another 把開始和結(jié)束工藝彼此靠近 ? Eliminate Spaces and Surface where WIP can Accumulate消除空閑的空間和可以堆積在制品的作業(yè)面 ? Use Dedicated Hand Tools and Gravity to Assist Operators 使用專業(yè)工具和重力原理去協(xié)助操作人員 ? Absolutely ensure Safety and Good Ergonomics絕對(duì)確保安全和經(jīng)濟(jì)原則 ? 5S Materials 物料供應(yīng) Machines 機(jī)器配置 Cell Layout 單元設(shè)計(jì) 單元設(shè)計(jì) 43 Single Piece Flow 單件流 機(jī)器配置原則 Good Machine Design Enables Operator Focus on Manual Content 好的機(jī)器配置可使操作員能夠全力投入手工作業(yè)中 ? Use small equipment dedicated to a single task使用小的設(shè)備去加工簡(jiǎn)單任務(wù) ? Introduce AutoEject When Operators Must Use Both Hands 當(dāng)操作員要用雙手操作時(shí)要引進(jìn)自動(dòng)卸料的機(jī)器 ? Install OneTouch Automation Where Possible盡可能安裝接觸性啟動(dòng)的機(jī)器 ? Incorporate Sensors to Signal Abnormal Conditions, so Operators Do not Need to Watch Machines During Cycle盡可能多采用感應(yīng)器來顯示異常情況， 不需要操作員在整個(gè)生產(chǎn)周期內(nèi)都要照看機(jī)器 ? Avoid Batching避免批量生產(chǎn) ? At Pacemaker, Strive to Devise Machine Changeover Between Different Assemblies Take Less than 1 TAKT Cycle 在節(jié)拍控制點(diǎn)處要全力去設(shè)計(jì)那種用低于 １個(gè)節(jié)拍就可以在不同裝配線間實(shí)現(xiàn)快速切換的機(jī)器 Materials 物料供應(yīng) Cell Layout 單元設(shè)計(jì) Machines 機(jī)器配置 44 Single Piece Flow 單件流 物料供應(yīng)原則 Good Material Flow Improves Productivity 好的物流可以提高生產(chǎn)效率 ? Present Parts as Close as Possible to the Point of Use 零件補(bǔ)充盡可能靠近零件使用點(diǎn) ? Present Parts so Operators can use Both Hand Simultaneously 零件補(bǔ)充要方便操作員可以同時(shí)使用雙手取 ? Do not Have Operators Get or Restock Their Own Parts 不要讓操作員自己取或再重新儲(chǔ)備自己的零件 ? Keep No More than 2 Hours of Material at the Point of Use 在每個(gè)使用點(diǎn)保持不要超過２個(gè)小時(shí)的物料 ? Do not Put Additional Parts Storage in or Near the Process 不要在工位上或旁邊設(shè)置多余的物料儲(chǔ)存庫(kù) ? Utilize Kanban to Regulate Parts Replenishment使用看板控制零件補(bǔ)充 ? Size Part Bin for the Convenience of the Operator, Not for the Convenience of the Material Handler or Supplying Process 設(shè)計(jì)盛零件的盒子要方便于操作員，而不是方便物料供應(yīng)者或提供過程 Machines 機(jī)器配置 Cell Layout 單元設(shè)計(jì) Materials 物料供應(yīng) 45 Single Piece Flow 單件流 18’ 14’ Assembly I Connector Preparation Assembly II angled to keep cell Inside Width about 5’ 安裝工位被調(diào)了個(gè)角度來保持單元在５步內(nèi) Parts materials presented on Flow racks from outside cell組件和原料從單元外面的傳送架提供進(jìn)來 Single piece of inprocess stock left In machine as operator moves on１個(gè)在制品被放在機(jī)器的左邊 使與操作員移動(dòng)方向一致 No obstruction in walking path在移動(dòng)路線上沒有阻礙物 No space for WIP accumulation沒有堆積在制品的空間 Assembly IV angled to bring cell start And end together裝配４被調(diào)了的角度使單元起點(diǎn)和終點(diǎn)靠近在一起 I 30 pcs /Container Example例子 Result : 5 Pieces in Process 效果：只有５個(gè)在制品 46 What is Standard Work? 什么是標(biāo)準(zhǔn)作業(yè)？ (1) TAKT Time節(jié)拍時(shí)間 (2) Work sequence (order of operations)作業(yè)順序 (操作規(guī)范 ) (3) Standard workinprocess標(biāo)準(zhǔn)在制品 Standard Work Definition標(biāo)準(zhǔn)作業(yè)定義 Three Elements of Standard Work標(biāo)準(zhǔn)作業(yè)３個(gè)要素 Standard Work is a bination of actions performed by humans and machines carrying out valueadded work in an efficient way in the right sequence right time, enabled by material information flow, using the right tools as required. It is the foundation for a lean enterprise. 標(biāo)準(zhǔn)作業(yè)是一個(gè)由人和機(jī)器執(zhí)行有附加價(jià)值的 ,使用一種有效方法的，采用正確的順序和正確的時(shí)間內(nèi)的，并使物流和信息能夠流動(dòng)的，且使用所需的正確工具下的多個(gè)工作的集合．它是精益企業(yè)的基礎(chǔ)． 47 Why Have Standard Work?為什么需要標(biāo)準(zhǔn)作業(yè) (1) To make manufacturing rules explicit使加工標(biāo)準(zhǔn)清晰 (2) Establish the methods for manual tasks with respect to safety, quality, quantity and ，品質(zhì)，數(shù)量和成本方面有關(guān)的手工作業(yè)的方法 (2) A tool for KAIZEN一種持續(xù)改善的工具 (3) Establish baseline for future improvement (4) 是建立未來改善的基準(zhǔn) Standard Work – Objective標(biāo)準(zhǔn)作業(yè)－目標(biāo) There Is No Improvement In The Absence Of Standards 沒有標(biāo)準(zhǔn)就沒有改善 48 TAKT Time節(jié)拍 The Heartbeat of the Business 企業(yè)的脈搏 1st Element of Standard Work標(biāo)準(zhǔn)作業(yè)要素之第一要素 Standard WIP標(biāo)準(zhǔn)在制品 Work Sequence 作業(yè)順序 TAKT Time 節(jié)拍 4 1 Available time Customer Forecast TAKT TIME = TAKT TIME is just Math, but is Fundamental to Lean 節(jié)拍雖說是個(gè)數(shù)字，但它是精益生產(chǎn)的基礎(chǔ) AVAILABLE TIME: Total amount of TIME allocated for production DEMAND: qty of scheduled parts for a given time frame ? each shift has ~ hrs available this is a constant! hrs is used to account for lunches, breaks, etc... EXAMPLE Available Time = 60 min/hr x hrs/shift x 2 shifts/day x 5 days/wk = 3900 min/wk Your customer demand is 90 pcs per week 3900 min/wk 90 pcs/wk = 43 min/pc TAKT Time = 49 Work Sequence作業(yè)順序 The order of operations in which a worker places parts on a machine or in an assembly. 操作規(guī)范就是規(guī)定一個(gè)工人把零件是放機(jī)器上還是放安裝工位上 The Same Thing, The Same Way, Every Time 對(duì)相同的工作，每次采用相同的工作方法 4 2Standard WIP 標(biāo)準(zhǔn)在制品 Work Sequence 作業(yè)順序