【正文】 evised based on KAIZEN and changes in production ,它是基于不斷改善修正和產(chǎn)量變化而變化的Roadmap To Standard Work標(biāo)準(zhǔn)作業(yè)的路標(biāo)Review of Standard Work標(biāo)準(zhǔn)作業(yè)回顧56Tools for Standard Work標(biāo)準(zhǔn)作業(yè)的工具 Time Measurement Sheet Capacity Sheet 時(shí)間測量表 產(chǎn)能分析表Combination Table Standard Work Chart Work Instruction作業(yè)組合表 標(biāo)準(zhǔn)作業(yè)表 作業(yè)指導(dǎo)書57Time Measurement Sheet時(shí)間測量表58Capacity Sheet產(chǎn)能分析表59Organization Area SupervisorNew / Rev Page of DateProduction LinePart NumberPart NameOperatorStandard Work SheetTo: Turns DPU39。sScope of OperationsFrom:Quality Check Safety Precaution Standard WorkinProcess Lots of Standard WorkinProcessTakt/Rate TimeTotal Manual Travel TimeMan/Travel TimeOperatorInspectionWaveHand LoadConnectorStageTestMarkStageTouch UpPCBA Bldg 3 Harjinder Bajwa1All PartsSun PCBA1 1CleanRaw materialConfigure100/DayICT5DXFunt Test2nd Qtr. ‘04PackOutside Cell27 avg lot = 6FlexFinished GoodsStandard Work Chart標(biāo)準(zhǔn)作業(yè)表60Standard Work Combination Table標(biāo)準(zhǔn)作業(yè)組合表Step No. Operation NameTimeManual Auto TravelProduction Req39。d Takt/Rate Time ManualAutoTravelWait ~~~~~~~~Organization Area SupervisorNew / Rev Page of Date Production LinePart NumberPart NameOperatorStandard Work Combination SheetTotals Operation TimeSec ( ) Min ( ) Hr ( ) Enter the travel timeEnter the unit of measured timeEnter Any machine Automatic Run Time. This operation!Enter the Any Manual Time(Hands On)Enter the operation NameScreen PrintOne sheet per Operator!!!x5 35 5T/T5 10 15 20 25 30 351 min12 SMT 10 0 23 Reflow 10 84 wait 0 0 0Op/Step numbers425 73 10Process Capacity Sheet Data1/09/03 SunRU18P03PCBA BoardA 1 11000Harjinder Bajwa61Work Instruction作業(yè)指導(dǎo)書62Work forms should be located in each work area各種工作文件會被掛在各個(gè)工作區(qū)域內(nèi)123654Work Capacity加工能力 Combination Table作業(yè)組合表Work instructions 作業(yè)指導(dǎo)書Standard Work Charts 標(biāo)準(zhǔn)作業(yè)表Worldclass work typically have a binder at each workstation with work forms and process instructions (., part drawings, engineering instructions, descriptions of final use). Work capacity and bination table are visually posted because they are real problemsolving forms used on a continuous basis 世界級的工廠都會在每個(gè)工位上掛作業(yè)指導(dǎo)書和工藝指導(dǎo) (如零件圖紙 ,工程指導(dǎo) ,終端使用說明等 ).加工能力和作業(yè)組合表都會被張貼在顯眼的位置 ,因?yàn)樗鼈冊诠ぷ鞒掷m(xù)改善上是能真正解決問題的文件 .Work Instruction作業(yè)指導(dǎo)書635. 拉動與看板拉動與看板 64? Withdraws needed parts from preceding process 后工序所需零件是從前工序來的? Preceding process “owns” Supermarket 前工序建立超市? “Purchasing” intervals derived from TAKT time 領(lǐng)取零件時(shí)間間隔是根據(jù)節(jié)拍來決定的? “Purchased” quantities in standardized amounts 按規(guī)定的標(biāo)準(zhǔn)數(shù)量進(jìn)行領(lǐng)取數(shù)量Tenants of Pull 拉動式生產(chǎn)的要點(diǎn)Consume Before Bringing More Material In在來料前消耗完零件651234Cell or ChakuChaku lineParts78910Supplier Material物料Information信息Supermarket超市Empty container空箱Full container滿箱Legend圖例說明1 Sequence / Timing順序 /定時(shí)Pull Methodology Sequence拉動式生產(chǎn)的方法和順序Assembly Line5666? Circulation of Information信息的循環(huán)? Cards are Like $ Used to “Buy” Parts from the Supermarket 看板卡要象美元一樣能從超市購買零件? Tool Used in Pull Production在拉動生產(chǎn)系統(tǒng)里所用到的工具Basics of The Kanban System看板系統(tǒng)的要素Kanban is Not Material . . . It is Information 看板不是物料 … 它是一種信息67There are 4 conditions that need to be met before you can introduce the Kanban effectively… 掌握了看板系統(tǒng) 4個(gè)條件后你就能更好地介紹看板了1. Stability of Preceding Process in Quality and Productivity前工序在品質(zhì)和產(chǎn)量方面的穩(wěn)定2. Leveled Production均衡化生產(chǎn)3. Takt Production / Pull System按節(jié)拍生產(chǎn) /拉動系統(tǒng)4. Team Member Education團(tuán)隊(duì)成員的培訓(xùn)Prerequisites of The Kanban System看板系統(tǒng)的先決條件Kanban Can Paralyze Without Satisfying These Conditions這些條件一旦沒有滿足看板系統(tǒng)就會癱瘓68? Physical Goods Control: Movement of Kanban corresponds to physical goods ? 實(shí)物掌控 :看板與實(shí)物對應(yīng)并一起移動? Instruction of Operation: What do you produce and how many?? ? 生產(chǎn)指示 :指導(dǎo)你生產(chǎn)什么和生產(chǎn)多少 ?? Tool for Kaizen: Easier to see material deficiencies? ? 改善的工具 :輕易地發(fā)現(xiàn)缺料Roles of Kanban看板的角色The Chain of Kanbans Spans From Customers to Suppliers 看板拉動鏈從客戶跨越到供應(yīng)商69Types of Kanban看板類型6 Types of Kanban can be classified as follows:看板能分成以下 6類 :1. Production Kanban生產(chǎn)看板 Specifies the type and quantity in which the previous process has to produce the 2. Withdraw Kanban拉動看板 Specifies the address where the parts need to Each Type for Specific Points in the Process在工序中每種看板都應(yīng)明確要點(diǎn)KanbanProduction Kanban生產(chǎn)看板InProcess Kanban工序生產(chǎn)看板Signal Kanban信號看板InterProcess Kanban工序拉動看板Supplier Kanban補(bǔ)充看板Withdraw Kanban拉動看板70Example of InProcess Kanban工序生產(chǎn)看板案例Kanban Gives Instruction for the Process to Produce 看板為工序提供了生產(chǎn)指導(dǎo)InProcess KanbanThe card is pulled from the containers to start the reorder “only” whenThe first part in the container is used僅當(dāng)容器中的第一個(gè)零件被使用后看板卡就會從容器中被取下來拿去開始重新生產(chǎn)71Example of Kanban看板系統(tǒng)案例Signal Kanban is Used when Changeover Time is Long 信號看板常用于換線時(shí)間長的情況InProcess Kanban工序生產(chǎn)看板Signal Kanban信號看板Reorder Point重新訂購點(diǎn)Stocking Height should not exceed the visual line for safety reason考慮安全的因素物料堆垛高度不要超過目視線StockingHeight72Example of Signal Kanban信號看板的案例Overproduction is the Mother of all Waste 過量生產(chǎn)是所有浪費(fèi)之母The card is placed when parts are withdrawn at the reorder point當(dāng)重新訂購點(diǎn)的零件被取走后卡片就會被放置在那里Qty/Palle