【文章內(nèi)容簡(jiǎn)介】 ： 在暗燈系統(tǒng)主看板上相應(yīng)區(qū)域的指示燈變成黃色，班組長對(duì)暗燈系統(tǒng)的信號(hào)做出反應(yīng),Step 3 Help comes immediately and problem solving begins. Team Leader takes the Andon responsibility 第三步：支持人員立刻到達(dá)并開始解決問題，班組長對(duì)此負(fù)責(zé),Andon Steps (Cont’d),Step 4 Line continues to move to fixed position stop 第四步：生產(chǎn)線繼續(xù)運(yùn)行直到定點(diǎn)停,,,,,,,,,,10,13,12,11,,FPS,FPS,FPS,FPS,,Zone 2,Andon Steps (Cont’d),,Step 5 Problem is addressed, Andon is deactivated by Team Leader to keep the line running. 第五步：?jiǎn)栴}解決，班組長解除暗燈信號(hào)以保持生產(chǎn)線繼續(xù)運(yùn)行。,,Andon Steps (Cont’d),Step 6 – If Andon is not deactivated by Team Leader when vehicle reaches FPS, line stops and board flashes red Downtime clock begins 第六步：如果車輛到達(dá)定點(diǎn)停時(shí)班組長仍然沒有解除暗燈信號(hào)，生產(chǎn)線停止并且主看板上紅燈開始閃爍，停線鈴開始響起,Downtime Clock,Andon Steps (Cont’d),,FPS,FPS,FPS,Set Line at 70% of Takt or Cycle Time amp。 Relate to Specific Step in Standardized Work,Pull the Andon as Early As Possible (at or before 70% Line) to Address Problems Before They Stop the Line!!! 在線停之前，盡早拉動(dòng)暗燈線宣告出現(xiàn)問題。（在70%線位或之前），,Purpose of “70% Line”,70% Line,Reaction Time,,Mgr,Group Leader,Team Leader,Team Member,,,Decision,Decision,Decision,Pull Andon,Support,Support,Support,Needs help,Function of everyone including managers and staff is to support production team members. 主管及所有人員都有職責(zé)支持生產(chǎn)一線的員工,班組成員,班組長,工段長,主管,尋求幫助,支持,支持,支持,決定,決定,決定,拉下暗燈拉索,Andon Concept,Role of Team Member Follow Standardized Work Actively Watch for OutofStandard Situations If an Abnormality or Defect Is Discovered That Cannot Be Immediately Corrected, Pull the Andon, and Continue With Rest of Cycle Until Support Arrives. Support Team Leader With Problem Solving As Required. 班組成員的職責(zé) 按照標(biāo)準(zhǔn)化要求作業(yè) 主動(dòng)查找超標(biāo)情況 如果發(fā)現(xiàn)了異常狀況或缺陷但無法及時(shí)解決，拉下暗燈拉索，并繼續(xù)做自己的工作直到支持人員到達(dá)。 支持的班組長按要求解決問題,Focus On Standardized Work!,Andon Concept,Role of Team Leader: Team Leader goes immediately to area of Andon call to investigate and support. Team Leader begins immediate correction of the problem. Team Leader releases the Andon when TL has determined a correction can be made. TL begins problem solving with support of TM. Team Leader manages the Andon system 班組長職責(zé) 在暗燈信號(hào)發(fā)出后立刻趕到發(fā)生問題的區(qū)域查明原因并實(shí)施支持 到達(dá)問題區(qū)域后立刻開始解決問題 當(dāng)班組長認(rèn)為可以把問題解決時(shí)解除暗燈信號(hào)。班組長與班組成員共同開始解決問題。 班組長管理暗燈系統(tǒng),Address NonStandard Conditions!,Andon Concept,Role of Group Leader Support Team Leader if (s)he is not able to countermeasure the problem, and get the line running as soon as possible. Call additional support as needed (i.e. maintenance, quality, etc.) Work with team leader to make sure root cause is identified and countermeasures implemented. Monitor downtime, identify problem areas and work with all available resources to eliminate problems. 工段長職責(zé) 當(dāng)班組長不能解決問題時(shí)要提供支持并盡快讓生產(chǎn)先運(yùn)轉(zhuǎn)起來 如果需要可以尋求外部支持（如：維修，質(zhì)量等部門人員） 與班組長一起確定問題的起因是否已經(jīng)被確認(rèn)出來并且保證解決措施得到實(shí)施 在停線時(shí)進(jìn)行監(jiān)控，確定問題區(qū)域并調(diào)動(dòng)一切可利用資源解決問題,Support The Team!,Andon Concept,Team Concept Small Team Size Standardized Work Clear Quality Standards Problem Solving Process Employee Training Mutual Trust/Respect Constant Takt Time Fixed Position Stop Decouplers/Buffers Process Capability,ENABLERS,Irreversible correction action Quality in station Inspection and Feedback Open Communication Teamwork Improved Productivity,BENEFITS,Motion Correction Waiting,團(tuán)隊(duì)概念 縮小團(tuán)隊(duì)規(guī)模 工作標(biāo)準(zhǔn)化(FPS) 明確質(zhì)量標(biāo)準(zhǔn) 職員培訓(xùn) 相互信任/尊重 保持單件工時(shí) 停線點(diǎn) 緩沖架 加工能力,好處,實(shí)施的糾正措施不能復(fù)原 在工位控制質(zhì)量 檢查和反饋 開放式交流 團(tuán)隊(duì)合作 提高生產(chǎn)力,Why is Andon Part of C.I.?,Use Andon Data to Continuously Improve by Identifying Bottlenecks and Issues Affecting Throughput 使用暗燈數(shù)據(jù)通過確定瓶頸及影響產(chǎn)出的問題來達(dá)到持續(xù)改進(jìn),TRIM 1 GROUP Andon Report 2003/1/24 Station 001R – 10’ Station 003L – 4’ Station 004R – 2’,Analyze Reports 分析報(bào)告,Discuss Countermeasures 討論對(duì)策,Improve!! 改進(jìn),Andon Is Not Just a System Of Wires and Lights 暗燈系統(tǒng)不僅僅是一個(gè)由電線和燈泡組成的系統(tǒng),It is a Concept of Calling For Help 它是一種尋求幫助的理念,Pull Your Andon!!! 在需要幫助時(shí)拉下拉索?。?！,EVERYONE HAS AN “ANDON CORD” 每個(gè)人都有一根“暗燈拉索”,Product Quality Standards,Quality System Management,InProcess Control amp。 Verification,Quality Feedback/ Feed forward,Visual Management,Management by TAKT Time,Work place Organization,Early Mfg. and Design Integration (DFM / DFA),Lean Design of Facilities, Equipment, Tooling and Layout,Total Productive Maintenance,Level Vehicle Order Schedules,Supply Chain Management,Internal Pull / Delivery,Health and Safety Priority,People Involvement,Values,Vision/ Mission,Shop Floor Management,Continuous Improvement,What Is a Problem? 什么可稱為問題? A Problem Is Defined As a Discrepancy Between an Existing Standard or Expectation and the Actual Situation 問題定義為現(xiàn)行的標(biāo)準(zhǔn)或期望與實(shí)際情況之間的差異,Standard,Actual,Discrepancy,TIME,LEVEL,標(biāo)準(zhǔn),實(shí)際,差異,水平,時(shí)間,Problem Solving 問題解決,Problem Solving 問題解決,Problems Are the Seeds for Improvement! 問題是進(jìn)行