【正文】 ne Does Not Come to Work and the Job Still Gets Done Safely, Efficiently and with Quality 真 正 經(jīng) 得 檢驗 的 標(biāo) 準(zhǔn)化工作是 當(dāng) 有人缺席 時 仍能 安全 、 有效 、 高 質(zhì) 地完成工作 What Do I Do? GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 51 GMS Manufacturing Process Validation Product Quality Standards Quality System Management Quality Feedback/ Feed forward Standardized Work Visual Management Management by TAKT Time Work place Organization Andon Concept Problem Solving Business Plan Deployment Total Productive Maintenance Scheduled Shipping / Receiving Level Vehicle Order Schedules Supply Chain Management Internal Pull / Delivery Simple Process Flow Small Lot Packaging Fixed Period Ordering System/ Order Parts Health and Safety Priority Team Concept People Involvement Open Communication Process Values Vision/ Mission Shop Floor Management Management by TAKT Time 生產(chǎn)節(jié)拍 管理 Standardization 標(biāo) 準(zhǔn)化 Lean Design of Facilities, Equipment, Tooling and Layout Controlled External Transportation Continuous Improvement Process GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 52 GMS Takt Time = Number of vehicles required per time period 此 階 段需要生 產(chǎn) 臺 數(shù) Weekly 周 Monthly 月 Yearly 年 Takt Time is Constant! TAKT TIME是不 變 的！ Takt Time: – Determines the speed of the line 決 定流水 線 速度 – The time available to produce a ponent or single unit. 生 產(chǎn) 一 個 部件或一 輛車 的 時間 – Determined by the number of vehicles required by the end of each day to meet the production target. 由需要 達(dá) 到的每日生 產(chǎn) 目 標(biāo) 的 車輛數(shù)決 定 Operational Time Per Period 某 階 段生 產(chǎn)時間 Management By Takt Time Takt Time管理 GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 53 GMS I Love Lucy Video Part II ?? ??? (Start video at Chocolate Assembly Line)錄 象 從 巧克力的生 產(chǎn)線開 始 GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 54 GMS I Love Lucy Video Part II Group Discussion 小 組討論 ? What GMS Standardization Principle concepts did we (not) see in the video? 在 錄 象看到或 沒 看到 哪 些 GMS的標(biāo) 準(zhǔn)化原 則 ? Discuss as an open forum – not by teams 論壇討論 —非小 組討論 GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 55 GMS I Love Lucy Video Discussion What did we see in the video: 從錄 象可我 們 看到： ?Lack of Standardized Work: 缺乏 標(biāo) 準(zhǔn)化工作 ? No documented standardized work on job 車 上 沒 有 標(biāo) 準(zhǔn)文件化 ? No standardized work to use as basis for training 沒 有 標(biāo) 準(zhǔn)化工作 作為 培 訓(xùn) 基 礎(chǔ) ? No quality standard for pleted chocolate 巧克力做完后 沒有 質(zhì) 量 標(biāo) 準(zhǔn) ?Lack Of Management By Takt Time: 缺乏 生產(chǎn)節(jié)拍 管理 ? Takt Time arbitrarily changed 主 觀 改 變 生產(chǎn)節(jié)拍 ? No munication or planning of Takt Time change 生產(chǎn)節(jié)拍 改 變沒 有 協(xié) 商或 計劃 ? No visual indication of workstation beginning and end 從頭 到尾都 沒 有工位的目 視 化 標(biāo)識 ?Others: ? No way to call for help ? No way to stop line or prevent defects from leaving station GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 56 GMS Example of Unlean Chocolate Factory 不精益的巧克力工 廠 例 子 ? Takt time slowed down TAKT TIME 減 慢 ? Cycle time not adjusted to the takt time 周期 時間與 TAKT TIME 不符 Wait Time! 等待時間 Cycle Time Lucy Ethel Actual Takt Time Team Member Cycle Time 5” 4” 3” 2” 1” Time Management By Takt Time Takt Time? ?? ?? Wait Time! 等待時間 GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 57 GMS Example of Unlean Chocolate Factory 不精益的巧克力工 廠 ? Takt Time Arbitrarily Speed Up TAKT TIME 隨 意加快 ? Cycle Time Not Adjusted to Takt Time 周期 時間與 TAKT TIME 不符 Cycle Time Lucy Ethel Takt Time Team Member Cycle Time 5” 4” 3” 2” 1” Time Overburden!! 負(fù)載過 重 Management By Takt Time Takt Time管理 GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 58 GMS Management By Takt Time Takt Time管理 When Takt Time Changes Arbitrarily Safety, Quality Efficiency Suffer! TAKT TIME隨意改變 —安全、質(zhì)量、效率 就會出問題 Standardization Is Impossible Without Constant Takt Time 若 沒 有 恒定 的生 產(chǎn)節(jié) 拍， 標(biāo) 準(zhǔn)化 則無法 實現(xiàn) Takt Time Changes Must Be Communicated Planned!!! Takt Time 的改 變 必 須經(jīng)過協(xié) 商或 計劃 !!! Just think of poor Lucy!! GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 59 GMS Example of Lean Chocolate Factory 精益的巧克力工 廠 ? Takt Time Is Constant, Based on Demand TAKT TIME 基于需求恒定 ? Cycle Time Is Adjusted to Takt Time 周期 時間與 TAKT TIME一致 Cycle Time Lucy Ethel Takt Time Team Member Cycle Time 5” 4” 3” 2” 1” Takt Time based on demand TAKT TIME 根據(jù)需求 Time Management By Takt Time Takt Time管理 GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 60 GMS 8 hours x 60 minutes 8 小時 x 60分 100 Units Scheduled 100 輛計劃 480 mins 47 mins. Breaks 480分 – 47分 (休息 ) = mins. 分 100 Units 100輛 ―OPTIMUM‖ TAKT TIME x Downtime Loss 停 線損 失 = 107 Units Needed Capacity 107輛產(chǎn) 量 107 Units 107臺 433 minutes 433分鐘 = mins. ACTUAL TAKT TIME (實際費時 ) OF WASTE 107 CAPACITY 107 產(chǎn) 量 100 Units REQUIRED 需求 100輛 = 7 UNITS 7輛 浪 費 = PLANT LOSS (工 廠損 失 ) The Effects of Waste (Downtime) GMS Orientation Standardization GMDAT/DIMC Confidential Version Date Slide 61 GMS “OPTIMAL” TAKT TIME最佳節(jié)拍 7% OVERSPEED (Downtime Loss) ACTUAL TAKT TIME 實際節(jié)拍 Cycle Time 433 100 = 43330 100 = Andon Stops: ? Operator Overburden ? Quality Is