【正文】 umber (serial number) 看板卡必須要有發(fā)行編號(hào) 49 Kanban ( continue ) 看板系統(tǒng) (續(xù)頁(yè) ) 7) No Kanban card = No production (Do not start any production without Kanban card) 看板卡上的數(shù)量等于生產(chǎn)數(shù)量 (沒(méi)有看板就不生產(chǎn) ) 8) Quantity in the Kanban card must match or equal to the physical quantity 看板卡上的數(shù)量一定要和實(shí)際生產(chǎn)數(shù)量相一致 9) No extra tray, no extra bin, no extra Kanban card in the Genba Supermarket at all time 在生產(chǎn)現(xiàn)場(chǎng)或超市不允許有多余的托盤(pán)，多余的盒子，多余的看板卡 10) All WIP / Inventory must。 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。 Key Note from Sensei: 老師的重要提示： ? To understand the above WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解 WIP定義，你需要去到現(xiàn)場(chǎng)在工作中實(shí)踐正確的 WIP數(shù)量。 生產(chǎn)周期減半 ? Scrap : X 1/10 報(bào)廢降低 90% ? Space : X 189。 Scenario 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec 情節(jié) 2：如果正反面產(chǎn)品同時(shí)在一條生產(chǎn)線生產(chǎn)，節(jié)拍時(shí)間則為一半， 48秒。s) work? 你知道如何區(qū)分手動(dòng)作業(yè)和自動(dòng)作業(yè)嗎 ? 5) Is the Work load leveling defined for man， machine and C/O? 人工 ,機(jī)器以及換線使用工作負(fù)荷均衡表分析了嗎？ 6) Is the H/C calculated based on Takt time? 人力的多少是根據(jù)節(jié)拍時(shí)間計(jì)算出來(lái)的嗎 ? 7) Is the Std work (front page) SWCS (back page) posted in front of each operator? 每個(gè)工站前都有標(biāo)準(zhǔn)作業(yè) (前頁(yè) )和標(biāo)準(zhǔn)作業(yè)合并表 SWCS(背頁(yè) )嗎 ? Operations 操作 17 Operations ( continue ) 操作 (續(xù)頁(yè) ) 8) Is the std work being followed by the operator? 操作員有沒(méi)有按照標(biāo)準(zhǔn)作業(yè)流程作業(yè) ? 9) Is the std work defined for water strider? 有沒(méi)有定義物料員的標(biāo)準(zhǔn)作業(yè) ? 10) Is the operator idle at the station? 在作業(yè)過(guò)程中 ,操作員是否有等待 ? 11) Does the operator search for ponents or tools? Locate all tools and parts within easy access or reach (Doctor Nurse). 在作業(yè)中 ,操作員有沒(méi)有尋找物料或工具的動(dòng)作 ? 工具或物料應(yīng)該放置在易于獲取的位置 ,定點(diǎn)定位 .(遵循醫(yī)生和護(hù)士概念： Doctor醫(yī)生 ,指直接作業(yè)的人員 ,nurse護(hù)士 ,指輔助作業(yè)人員 ,如物料員 ) 12) Do you have std work for inspection station? 檢查工站有沒(méi)有標(biāo)準(zhǔn)作業(yè)書(shū) ? 13) Do you have shortest cycle time for inspection? 對(duì)于檢查工站 ,有沒(méi)有定義最短周期時(shí)間 ? 18 Operations ( continue ) 操作 (續(xù)頁(yè) ) 14) At the hand load station, do you apply doctor and nurse concept? 在手工作業(yè)工站 ,有沒(méi)有運(yùn)用醫(yī)生和護(hù)士理念 ? 15) Do you meet the target of 3 sec per ponent during insertion at hand load? 在手插工站 ,有沒(méi)有達(dá)到每 3 秒一顆零件的插件速度 ? 16) SIC less at hand load station (with template). 手插工站不需要 SIC(用模板來(lái)顯示需要插件的位置 )? 17) Hand load manual CT Takt time nurse not required. Are there system in place to stop work when abnormal conditions arise? 當(dāng)手動(dòng)作業(yè)的周期時(shí)間小于節(jié)拍時(shí)間時(shí)，不需要 ” 護(hù)士 ” (護(hù)士 nurse:輔助作業(yè)人員 ) 當(dāng)異常情況出現(xiàn)時(shí) ， 有沒(méi)有系統(tǒng)來(lái)控制停止作業(yè) ? 18 ) Does the supervisor respond in a quick/crude manner? 當(dāng)異常發(fā)生時(shí) ， 管理人員的反映是快速還是遲鈍 ? 19) Do you have 6S implemented on your line? 線上有實(shí)行 6S嗎 ?(6S=5S+Safety) 19 Operations ( continue ) 操作 (續(xù)頁(yè) ) 20) Is the production qty for the day defined? 日 產(chǎn) 量有沒(méi)有定 義 ? 21) Is the Multi skill charts visible and available? 有沒(méi)有顯示和使用多技能培訓(xùn)表？ 22) Do you allow banana peeling on the line? 允許在線拆卸物料包裝嗎 ? 23) Are you able to detect bottleneck station at a glance? 瓶頸工站能一眼看出來(lái)嗎 ? 24) The operator must not reorient the part 操作員不允許重新調(diào)整零件方向 ,防止零件極性弄錯(cuò) .(這里操作員指輔助作業(yè)人員 ,即 nurse) 25) Change over : 快速換型 a) Internal time 內(nèi)部時(shí)間 d) Adjustment time 調(diào)整校準(zhǔn)時(shí)間 b) External time 外部時(shí)間 e) Clean 清潔 c) Trial run 試運(yùn)行 20 Operations ( continue )操作 (續(xù)頁(yè) ) 26) ETE Operation criteria: 端到端運(yùn)行標(biāo)準(zhǔn) a) The line should run based on Takt time 生產(chǎn)線必須按照客戶需求節(jié)拍合理安排生產(chǎn) b) The H/C should be loaded based on Takt time 生產(chǎn)線應(yīng)按客戶需求節(jié)拍時(shí)間合理安排人員 c) Material should be loaded based on Takt time 按客戶需求節(jié)拍時(shí)間備置原材料 d) The line should be configured to zero defects 配置生產(chǎn)線時(shí)需滿足零缺陷 e) Supermarket should meet all the 15 criteria 超市必須符合 15個(gè)設(shè)置準(zhǔn)則 27) ETE consists of : 端到端包括 : a) Productivity improvement (MLT,H/C, WIP, Space) 提高生產(chǎn)效率 (生產(chǎn)前置期 ,科學(xué)的人員配置 ,適當(dāng)?shù)脑诰€庫(kù)存 ,有效的空間利用 ) b) Material replenishment (Water strider, Min Max, Supermarket) 靈活精益的原材料供給方式 (水蜘蛛補(bǔ)貨原則，設(shè)置最低最高庫(kù)存，超市 ) c) Quality improvement (Zero defects) 提高質(zhì)量 (零缺陷 ) d) C/O (if the time more than 10 minutes) 換型時(shí)間 (如果時(shí)間超過(guò) 10分鐘 ) 21 Operations ( continue ) 操作 (續(xù)頁(yè) ) 28) 4 functions of ?Conveyor‘, Say NO to ?Conveyor‘ if below criteria39。 12) Is the Layout for machine and tools by process? 機(jī)臺(tái)和工具的擺放布局是根據(jù)流程來(lái)安排的嗎 ? 37 Machine ( continue ) 設(shè)備 (續(xù)頁(yè) ) 13) Are all the stations on wheels? 所有的工站是可移動(dòng)的嗎？ 14) Is the station load based on Takt time? 各工站的負(fù)荷是按節(jié)拍時(shí)間設(shè)計(jì)的嗎？ 15) Are the power cables suspended above the station for easy plug and play? 電源插頭是否是位于工站易于插拔的地方？ 16) Do you have work standard done for tester? 測(cè)試工位有沒(méi)有做 作業(yè)標(biāo)準(zhǔn) 指導(dǎo)書(shū)？ 17) Are there systems in place to stop work when abnormal conditions arise? Does the supervisor respond in a quick/crude manner? 當(dāng)異常發(fā)生時(shí)，有沒(méi)有系統(tǒng)會(huì)報(bào)警并自動(dòng)停止產(chǎn)線作業(yè)？管理人員對(duì)于異常的反映是迅速還是遲鈍 /拖延 ? 18) If a machine is identified as Bottleneck(no flow) create a flow by working on reducing the machine cycle time, manage the machine with eagle eyes or put up SM to create the flow. 如果某個(gè)機(jī)器是瓶頸工位，我們應(yīng)當(dāng)對(duì)該工位特別關(guān)注，研究并降低它的周期時(shí)間或者設(shè)立超市，建立出一個(gè)新的流 . 38 Machine ( continue )設(shè)備 (續(xù)頁(yè) ) 19) How many of y