【正文】 節(jié)拍時(shí)間 Cycle time Takt time ( 1 Station Process ) C/TTakt Time (1個(gè)工位） Cycle time than takt for single process (2 same stations needed) C/TTakt (需要2個(gè)相同工位 ) TAKT Time = 20s 10 20 30 40 Machine/Process A : St. 1 Machine/Process A : St. 2 Note注 : CT TT : No additional Machine/Man needed 不需要額外的機(jī)器 /人員 CT TT : Additional Machine/Man needed 需要額外的機(jī)器 /人員 It can be used to calculate 節(jié) 拍 時(shí)間 可以 計(jì) 算 ? Total Operators needed 員 工需求數(shù)量 ? Total machines needed 機(jī)器需求數(shù)量 ? Standard WIP needed Etc 標(biāo) 準(zhǔn) WIP需求數(shù)量，等 16 1) Is the Takt time visible (with counter and triggering point)? 節(jié)拍時(shí)間可以直觀地看出來(lái)嗎？有沒(méi)有借助工具 (計(jì)數(shù)器和觸發(fā)機(jī)制 ) 。 17) Do you have mean test ? challenge the current state (Potential Problem Analysis) 有運(yùn)用均值檢驗(yàn)嗎 ? –對(duì)現(xiàn)狀進(jìn)行尋根究底 (分析潛在的問(wèn)題 ) 18) Do you use 5 Why analysis to understand the root cause? 有沒(méi)有運(yùn)用 5個(gè)為什么來(lái)分析根本原因？ 19) Landscape concept – View from all angles (the mountain) ,Search for the truth (the forest), Look/Focus (the tree), See and fix it (the branch) 全局概念 全方位 遠(yuǎn)看 (山 )，尋找真相 近觀 (森林 )，細(xì)看 (樹(shù) )，深究并解決問(wèn)題 (枝干 ) 30 One Piece Flow 單件流 1) One piece flow 單件流 2) Are the line visibility clear for the supervisor? ? Takt counter? Line flow? 對(duì)于管理者來(lái)說(shuō)，產(chǎn)線狀況可視化嗎？有標(biāo)準(zhǔn) WIP?節(jié)拍計(jì)數(shù)器？產(chǎn)線是流動(dòng)的嗎？ 3) One piece flow which like as the eggs inside the chicken should be one by one flow ,but not in parallel. 單件流就像母雞肚里的雞蛋一樣是一個(gè)一個(gè)下蛋的，而不是一起下出來(lái)的。ideal state? 未來(lái)的情況 價(jià)值流圖表示出改善之后的理想狀況 e) 3D VSM for better visualization (for office kaizen) 3D價(jià)值流圖使流程更加直觀（針對(duì)辦公室改善） 32 VSM ( continue )價(jià)值流圖 (續(xù)頁(yè) ) 2) 7 types of flow must be clearly defined : 7大流程必須定義清楚 a) Material – Raw 物料 原材料 b) Material – WIP 物料 在線庫(kù)存 c) Material Finish Goods 物料 成品 d) Information what info is required to move materials, what is the timing 信息 移動(dòng) /搬運(yùn)物料時(shí)需要什么信息，什么時(shí)間點(diǎn) e) People , Takt time 人流 標(biāo)準(zhǔn)作業(yè)，節(jié)拍時(shí)間 f) Equipment carts, conveyor, racks, andons, TPM 設(shè)備流 手推車(chē)，傳送帶，物料架， andons 異常停線系統(tǒng) ， 全面生產(chǎn)維護(hù) (TPM=Total Productive Maintenance) g) Engineering quality, tooling, programs 工程 品質(zhì)，工具，程序 33 Moonshine Shop 月光工作室 1) Do you have moonshine capability in your plant? 工廠有沒(méi)有月光工作室可以自己動(dòng)手制作治具或工具以及時(shí)滿足產(chǎn)能需求的能力 .? 34 Golf Score 動(dòng)作評(píng)估表 1) Are the operators having to bent down? 操作員在作業(yè)過(guò)程中需要彎腰嗎 ? 2) Are operators having to reach high? 操作員的手需要伸到很高的位置 (獲取物料或工具 )來(lái)完成作業(yè)嗎？ 3) Are operators having to twist/turn? 操作員在作業(yè)過(guò)程中需要轉(zhuǎn)身嗎 ? 4) Are operators leaving work area? 操作員在作業(yè)過(guò)程中離開(kāi)工作區(qū)嗎 ? 5) Are operators needing 3 arms?(hand being used as fixtures) 操作員必須依靠三只手才能完成作業(yè)嗎 ?（第三只指的是治具） 6) Is the C/T set at 90% or less of the Takt time? 周期時(shí)間是設(shè)定在節(jié)拍時(shí)間的 90%還是低于節(jié)拍時(shí)間？ C/T= cycle time， T/T=Takt time 7) Is there rework being done? 返工有沒(méi)有在做？ 35 Machine 設(shè)備 1) Are tools suspended above pointofuse? 工具有沒(méi)有懸掛在使用點(diǎn) (觸手可及之處 )？ 2) Are proper gauges/fixtures used? 所用到的治具是否合適？ 3) Are distances between stations held at minimum? 工站間距離是否是最短的？ 4) Are there 2 or more stations for each operator39。s worth of material? 物料超市是不是設(shè)計(jì)成存放 1 小時(shí)物料的大?。? 4) Is the replenishment information being sent out? 補(bǔ)充物料的信息有及時(shí)送出嗎 ? 5) Are there defects being sent from upstream processes? 不良是從上游工站流出的嗎？ 6) Are operators selecting between or searching for parts? 操作員在作業(yè)中，有沒(méi)有選擇或?qū)ふ椅锪系葻o(wú)價(jià)值的動(dòng)作？ 42 Material ( continue ) 物料 (續(xù)頁(yè) ) 7) Is banana peeling allowed? 允許在產(chǎn)線拆除物料包裝嗎 ? 8) Do you have vertical storage, is it human reachable height? 有沒(méi)有立式的儲(chǔ)物空間，是否在可觸及的高度內(nèi)？ 9) Are the parts located as close as possible to POU? 物料擺放是否遵從 POU原則？ POU=point of use (where/when the material need to use) 10) Do you allow double and triple handling of materials? 是否允許一次雙倍或三倍地抓取物料？ 11) Are there any materials that not required NOW stored in the shop area? 當(dāng)前不用的物料有沒(méi)有存放在物料超市 12) Are the materials arranged properly based on FIFO? 物料擺放是否遵從先進(jìn)先出的原則？ (FIFO=first in first out) 43 Material ( continue ) 物料 (續(xù)頁(yè) ) 13) Are the materials required placed in ways that allow them to be removed immediately? 物料是否放置在易于快速移動(dòng)的位置 ? 14) Do you have material shortage escalation path? 針對(duì)缺料 ,有沒(méi)有逐級(jí)上報(bào)的流程？ 15) Is it possible to put more (material) than necessary? 有沒(méi)有存放多于所需的物料？ 16) Does the water spider have shortest walking path defined? 有沒(méi)有為物料員規(guī)劃 最短路徑？ 17) Do you have one Kanban card per box? 每個(gè)盒子是否都有物了看板卡？ 18) Are the parts located with single entry? (condominium conceptonly one entry point per unit) 物料放置是否設(shè)計(jì)成只有一個(gè)取放口 ? (公寓理念 — 每個(gè)單元只有一個(gè)入口 ) 44 5 Reasons for High Inventory 高庫(kù)存的 5個(gè)原因 1) Long lead time 前置時(shí)間 /周期時(shí)間長(zhǎng) 2) Purchasing timing too early 采購(gòu)時(shí)間太早 3) Lot size too big 批量太大 4) Consumption rate less than planned 實(shí)際消耗小于計(jì)劃 5) Customer cancelation Demand Change 定單取消或需求改變 45 Heijunka 均衡生產(chǎn) 1) 3 key elements in Heijunka :均衡化的三個(gè)重要因素 a) Heijunka Pull 均衡化拉動(dòng)生產(chǎn) b) Supermarket 物料超市 c) Replenishment 補(bǔ)料系統(tǒng) 46 Option 連續(xù)性 1) Do you have implemented chakuchaku? 有沒(méi)有使用一步接著一步（ chakuchaku） 生產(chǎn)？ 2) Do you have implemented Hanedashi? 有沒(méi)有使用自動(dòng)彈出設(shè)計(jì)？ 3) Do you have implemented Nagare concept? 有沒(méi)有達(dá)到不間斷流動(dòng)生產(chǎn)？ 4) Do you have implemented TPM? 有沒(méi)有執(zhí)行全面生產(chǎn)維護(hù)？ 5) Do you have maintained free machine? 有沒(méi)有保養(yǎng)閑置的設(shè)備 ? 6) Do you have fast turn around time for Jigs and tools? 有沒(méi)有對(duì)治工具運(yùn)用最快換線時(shí)間？ 47 Option ( continue ) 連續(xù)性 (續(xù)頁(yè) ) 7) Four categories of Technology: 四種技術(shù) /方法 : a) Original Technology 獨(dú)創(chuàng)技術(shù) /新技術(shù) b) Technology that is available to 以下三種適用的技術(shù) i) make smaller 更小 ii) make thinner 更薄 iii) make lighter