【正文】 s work? 操作員是否有操作 2個(gè)或更多工站？ 5) Is there an aisle way and cart for the water strider? 物料員是否有專用通道和專用推車？ 6) Is there information being sent to the water strider in real time? 發(fā)送給物料員的信息是否實(shí)時(shí)？ 7) Is there an andon lamp installed? 有沒有安裝異常警示燈？ ( Andon lamp,異常警示燈 ) 36 Machine ( continue ) 設(shè)備 (續(xù)頁 ) 8) Is a production control board in place? 產(chǎn)線有沒有看板，易于及時(shí)且清楚地了解產(chǎn)線的狀況 ? 9) Can you separate internal setup from external setup and externalize internal setup? 你能區(qū)分內(nèi)部信息和外部信息，并使內(nèi)部信息具體化嗎？ 比如：換線時(shí)的內(nèi)部時(shí)間與外部時(shí)間 比如：某些機(jī)器的參數(shù)我們自己可以設(shè)定，有些需要求助于供應(yīng)商 10) Be sure that material flows in one direction. 確保物流同方向，不迂回 . 11) Is your machine 6 Sigma Process Capability gauge R R done? 是否有對機(jī)器做 6σ制程能力分析，重復(fù)性與再現(xiàn)性分析？ 注： Gauge Repetition Reappearance 量具重復(fù)性與再現(xiàn)性分析。 2) Is the Takt board defined (on the board)? 節(jié)拍時(shí)間確定了嗎？ (把節(jié)拍時(shí)間寫在白板上 ) 3) Are the Standard WIP defined? 標(biāo)準(zhǔn) WIP有定義嗎 ? 4) Do you know how to separate manual (person39。 制程設(shè)計(jì)治具同時(shí)放置 4 塊 PCB板，則制程的節(jié)拍時(shí)間是 48 秒 /治具。 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 。 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，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。 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。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，有沒有選擇或?qū)ふ椅锪系葻o價(jià)值的動(dòng)作？ 42 Material ( continue ) 物料 (續(xù)頁 ) 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 ) 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? 針對缺料 ,有沒有逐級上報(bào)的流程？ 15) Is it possible to put more (material) than necessary? 有沒有存放多于所需的物料？ 16) Does the water spider have shortest walking path defined? 有沒有為物料員規(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 高庫存的 5個(gè)原因 1) Long lead time 前置時(shí)間 /周期時(shí)間長 2) Purchasing timing too early 采購時(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? 有沒有使用一步接著一步（ chakuchaku） 生產(chǎn)？ 2) Do you have implemented Hanedashi? 有沒有使用自動(dòng)彈出設(shè)計(jì)？ 3) Do you have implemented Nagare concept? 有沒有達(dá)到不間斷流動(dòng)生產(chǎn)？ 4) Do you have implemented TPM? 有沒有執(zhí)行全面生產(chǎn)維護(hù)？ 5) Do you have maintained free machine? 有沒有保養(yǎng)閑置的設(shè)備 ? 6) Do you have fast turn around time for Jigs and tools? 有沒有對治工具運(yùn)用最快換線時(shí)間？ 47 Option ( continue ) 連續(xù)性 (續(xù)頁 ) 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 更輕 c) Combine existing technology 現(xiàn)有技術(shù)的結(jié)合 d) Use existing technology to 將現(xiàn)有技術(shù)應(yīng)用于 i) mass produce 大批量生產(chǎn) ii) reduce defect and 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) ,使其保證完整無缺 (看板卡等同于鈔票或信用卡 ) 6) Kanban card must be taged with license n