【導(dǎo)讀】Kaizenprogram. Schedulingprogram. Productionmanager,Productionmanager,Productionmanager,areamanagers,Businessneed. Productandprocess. Targetstatevision. Quantificationof. Proposedtactical. Focusonmajor. Stabilizationof. Process. Standardizedlabor. Definitionofcore. Performance. Controlled. Changeovertime. Controlledflow. Consistencyof. Demand-drivenpull. Directfeedback. Improved. (maintenance,Auditingprocess. Planforsustaining. Ongoing'check-up'Dedicateresources. Determinemetrics,plans&reviewprocess

　　

【正文】 based (coordinate with i2) on current practice – Pilot pull system (C) Component quality and supplier management – Review current evaluation system – Develop new score card system based on best practice – Deploy new measurement system to suppliers – Launch pilot 25 A. STEPS IN IMPROVING QUALITY PERFORMANCE MANAGEMENT AND ESTABLISH POLICY DEPLOYMENT SYSTEM AND CONTINUOUS IMPROVEMENT PROCESS Timing 2 weeks 23 weeks 23 weeks 34 weeks 34 weeks 12 months Ongoing Who BU head and production manager Production manager, Line managers BU head, CIteam Top management, CI team Production manager, quality managers, production team Production manager Top management, CI team Step Set pany level targets for quality improvement and break down to anization Install big white boards for line performance including product / ponent quality Set continuous improvement process and team Collect quality data and prioritize problems, set targets and develop roadmap Run problem solving cycles to solve prioritized problems Implement improved measures and coordinate with related departments to fix outside manufacturing quality problems Establish management feedback loops Source: McKinsey analysis 26 STEPS CAN BE TAKEN TO START A PROGRAM FOR IMPROVING SOURCE QUALITY AND WARRANTY REPAIRS Timing 48 weeks 12 weeks 23 weeks 28 weeks 23 days Who BU manager, service manager, quality manager, BU manager, service manager, quality manager Project leader, area manager Initiative team, area manager Initiative team, area manager Step Collect initial data ? Internal quality at each step ? Shortterm repairs ? Longterm warranty repairs Prioritize areas of focus and select improvement approaches amp。 target Pilot problem solving approach on priority issues Select and launch 23 initiative teams around other priority area(s) and implement countermeasures Measure results, prioritize next issues to address Repeat until initial “step change” targets are met* * Total time may be long due to time required for feedback from the field Source: McKinsey analysis 27 THE IMPROVEMENT STEPS SHOULD BE SEQUENCED CORRECTLY TO ASSURE PROPER IMPLEMENTATION Source: McKinsey analysis ? Perform 5S pilot in model area ? Establish 5S promotion team ? Select measurements for visual management ? Start measuring and visually displaying key KPI?s ? Analyze demand and production data in detail ? Design new system for production scheduling ? Analyze available data for customer returns and warranty repairs and prioritize biggest issues ? Set program targets ? Start data collection for unknown items ? Perform structured rootcause problem solving on highest priority items ? Establish review mechanisms for managing results ? Run problem solving in PDCA loop until targets are achieved ? Set inventory targets ? Implement new, highly standardized production scheduling process using pull principles on pilot area ? Stabilize and tweak new system ? Roll out system for all products ? Launch system across all products Start 5S and visual management program Design new pullbased scheduling process Improve inventory control。 continue 5S and visual management approach。 stabilize Pilot scheduling Launch program to reduce variability and warranty repair rates 1 Month ? 2 Months ? Months 28 CONTENTS ? Production system design ? Quality improvement program ? OEE improvement program ? Kaizen program ? Scheduling program ? Visual performance improvement ? Organizational/capability building 29 STEPS IN STARTING AN OEE IMPROVEMENT PROGRAM Timing 12 months 1 week 2 weeks 28 weeks 23 days Who Production manager, maintenance manager Production manager, maintenance manager, president Production manager, area manager Initiative team, area manager Initiative team, area manager Step Collect initial data ? Capacity ? OEE Prioritize areas of focus and select improvement approaches amp。 target Select and launch initiative teams around priority area(s) Perform improvement approach and measure results Summarize results Repeat until overall OEE target is met Source: McKinsey analysis 30 STEPS CAN BE TAKEN TO START A PROGRAM FOR IMPROVING OEE Timing 23 weeks 2 weeks 2 weeks 24 weeks 23 days Who Production manager, maintenance manager, OEE/TPM expert Production manager, maintenance manager, expert Production manager, area manager Initiative team, area manager, expert Initiative team, area manager Step Collect initial data on OEE for bottleneck or highestpriority equipment Prioritize losses to focus on and select improvement approaches (such as SMED or TPM) amp。 select targets Select and launch initiative teams around priority area(s) Perform improvement approaches and measure results Review results and reprioritize efforts Repeat until initial “step change” targets are met, and then attack next machines Source: McKinsey analysis 31 CONTENTS ? Production system design ? Quality improvement program ? OEE improvement program ? Kaizen program ? Scheduling program ? Visual performance improvement ? Organizational/capability building 32 STEPS CAN BE TAKEN TO