【正文】 Lean Systems implementation could spell Beware注意!46Direct LaborProductivity直接人工生產(chǎn)力HighLowDirect Labor Manpower直接人工 Indirect LaborManpower間接人工Sequencing排序Kitting成套R(shí)epacking在包裝Frequent Deliveries頻繁運(yùn)輸Kaizen Activities 持續(xù)改善Before and after Internal Lean Implementation內(nèi)部精益實(shí)施前后內(nèi)部精益實(shí)施前后After Internal Lean ImplementationBefore Internal 內(nèi)部精益實(shí)施前內(nèi)部精益實(shí)施前47Before and after External Lean Implementation 外外 部部 LEAN實(shí)現(xiàn)前后實(shí)現(xiàn)前后Direct LaborProductivity直接人工生產(chǎn)力HighLowDirect Labor Manpower直接人力 Indirect LaborManpower間接人工Indirect LaborProductivity間接人工生產(chǎn)力Standardize Workloads標(biāo)準(zhǔn)化工作負(fù)荷Standard Delivery Routes標(biāo)準(zhǔn)化運(yùn)輸路線Organized Storage 存儲(chǔ)有組織Outsource Storage外部存儲(chǔ)Suppliers Sequence供應(yīng)商排序Suppliers Kit供應(yīng)商配套Downsized Packaging減少包裝After External Lean ImplementationBefore External Lean Implementation外部精益實(shí)施前外部精益實(shí)施前48OperatorInside Out Not…Outside In!內(nèi)到外內(nèi)到外 ..不是外到內(nèi)不是外到內(nèi)? Support For The Operator支持員工– Involvement參與– Responsiveness快速反應(yīng)– Provide What’s Needed When 需要時(shí)提供 Needed (Not Before)（ 而不是之前）– Part Presentation傳送零件? Operator Optimization優(yōu)化人員– Balanced Operations平衡操作– Level Mix平衡產(chǎn)品系列– 65% Value Added Content增值 65%? Operation Effectiveness有效操作– Job Design工作設(shè)計(jì)– Compress Work Area縮小工作區(qū)– Operator Assist Devices員工幫助設(shè)備? Minimize Waste減少浪費(fèi)– Motion移動(dòng)– Processing加工– Waiting等待StartHere開始點(diǎn)Material Handling材料處理Maintenance 維護(hù)Inspection檢斂SupportPersonnel支持人員ThenHere Suppliers供應(yīng)商Logistics Providers物流供應(yīng)者TransportationCompanies運(yùn)輸公司ThenHere49EventProjectBlitzBlitzConnecting The DotsProject? Pull Systems拉動(dòng)系統(tǒng)? Window Receiving收料（定位）? Window Shipping發(fā)貨（定位）? Point Of Use Delivery靠近使用點(diǎn)? Milk Runs平凡使用緩沖區(qū)? Kitting Sequencing成套及排序? Dolly Exchange推車轉(zhuǎn)換? Electronic Kanban電子看板? Kanban Cards看板卡片? Standard Delivery Routes標(biāo)準(zhǔn)運(yùn)輸線路? Buffering Strategy緩沖區(qū)戰(zhàn)略? Small Lot Production小批量生產(chǎn)? Small Lot Containers小批量集裝箱? Standardized Work標(biāo)準(zhǔn)化工作? Leveled Mix均衡產(chǎn)品系列? Five ‘S’ 5S? Audio Visual Controls目視化管理? Andon System Andon系統(tǒng)? Error Proofing防錯(cuò)? Fixed Position Stops固定位置的停頓? Decoupling坼分（工序）? Self Direct Work Groups自我結(jié)果工作組? TPM? Quick Changeover快速換模Pockets of SuccessMarginal ProgressShort Term ApproachTotallyIntegratedSystemApproach全集成系統(tǒng)的方法 The Trap! The Trap!陷阱陷阱50Problem SolvingError ProofingAndonQuick SetUpJITTeam ConceptQuality CirclesTPMVisual ControlsThroughputTQMStandardized Work5’sWasteKaizenVS MappingWhat next?Let’s try...Click ClickWheel of FortuneLessons Learned? Cherry picking does not work?摘 桃 ,沒有解決問(wèn)題? Integrated Production System?集成化生產(chǎn)系統(tǒng)? Strategies are linked戰(zhàn)略聯(lián)系在一起? Focus on flow to create a system?關(guān)注流程產(chǎn)生系統(tǒng)? People System is the backbone?人力系統(tǒng)是骨架? JIT paces the process JIT決定 過(guò)程的 步調(diào)? Andon Error Proofing control quality?ANDON 及防措控制質(zhì)量? Standardized Work is the foundation?標(biāo)準(zhǔn)化工作是基礎(chǔ)? Problem Solving is the culture?解決問(wèn)題是文化? Continuous Improvement mentality?應(yīng)用持續(xù)改善思想 Lean Manufacturing SystemLessons Learned經(jīng)驗(yàn)經(jīng)驗(yàn)51StandardizationBuildInStationJustInTimePeople SystemContinuous ImprovementLean Opportunities機(jī)會(huì)機(jī)會(huì)Leadership領(lǐng)導(dǎo)Understanding理解Planning計(jì)劃Commitment承諾52What is the Lean Assessment Tool什么是精益評(píng)審工具？什么是精益評(píng)審工具？The Lean Assessment Tool精益評(píng)審工具精益評(píng)審工具This is a system that we use in all of our facilities to determine what level we are currently at in terms of lean deployment.是一種在我們工廠中使用的體系，用以是一種在我們工廠中使用的體系，用以 從從 LEAN的推廣的推廣 方面方面 確認(rèn)我們當(dāng)前確認(rèn)我們當(dāng)前 LEAN系統(tǒng)推廣系統(tǒng)推廣所處的水平所處的水平The system uses a questionnaire type audit along with a numerical scoring system When this is conducted, the entire facility is assessed for strengths and 數(shù)字的數(shù)字的 評(píng)分問(wèn)卷評(píng)審形式。評(píng)分問(wèn)卷評(píng)審形式。當(dāng)問(wèn)卷完成后，工廠的強(qiáng)項(xiàng)和弱項(xiàng)便一目了然了當(dāng)問(wèn)卷完成后，工廠的強(qiáng)項(xiàng)和弱項(xiàng)便一目了然了You will see later in this presentation how this toolcan be used to focus our efforts into the areas offacility that need it most. 在演示文稿的后面章節(jié)中，還可以看到如何使用這一工具集中力量到最需要改善的地方在演示文稿的后面章節(jié)中，還可以看到如何使用這一工具集中力量到最需要改善的地方53The Purpose of the Lean Assessment Tool精益評(píng)審工具的目的精益評(píng)審工具的目的The Lean Assessment Tool Essentiallyhas two purposes:精益評(píng)審工具有精益評(píng)審工具有 2個(gè)主要目的：個(gè)主要目的：1） Inventory of Lean best practices found throughout Plant 發(fā)現(xiàn)并推廣在公司內(nèi)發(fā)現(xiàn)的優(yōu)秀的 LEAN示例2） Provide awareness of Lean best practices not found in Plant or are not fully applied, and hence, should be considered for implementation 了解公司內(nèi)未發(fā)現(xiàn)或未完全應(yīng)用的 LEAN示例，并考慮實(shí)施54Who and when performs the Lean Assessment 由誰(shuí)及何時(shí)完成精益評(píng)審？由誰(shuí)及何時(shí)完成精益評(píng)審？WHO PERFORMS THE LEAN ASSESSMENT?由誰(shuí)完成精益評(píng)審？? THE LEAN FACILITATOR推廣人WHEN IS THE LEAN ASSESSMENT PERFORMED?何時(shí)完成精益評(píng)審？? ON A MONTHLY BASIS每月進(jìn)行55Lean Assessment Tool Contents15精益評(píng)審工具內(nèi)容The Lean Assessment Tool contains fifteen attribute worksheetsdescribing the Lean best practices that constitute the followingAttributes of Lean manufacturing:評(píng)審工具包含 15個(gè)要素工作表，描述組成下列精益生產(chǎn)要素的示例： 1. STANDARD WORK 標(biāo)準(zhǔn)化作業(yè) 8. LEAN CONTAINERS AND PACKAGING 精益容器及包裝 2. WORKPLACE ORGANISATION (5S’s) 車間組織（ 5S） 9. ANDON 3. AUDIO VISUAL CONTROLS聲音及目視控制 10. IN PROCESS QUALITY AUDIT制程質(zhì)量審核 4. OPERATION CERTIFICATION操作保嫜 11. CONTINUOUS IMPROVEMENT PROCESS (Kaizen) 持續(xù)改善過(guò)程 5. INTERNAL PULL MATERIAL CONVEYANCE 12. PROBLEM SOLVING (PDCA)用PDCA解決問(wèn)題 內(nèi)部拉動(dòng)及物料運(yùn)輸 6. EXTERNALL PULL TRANSPORTATION SYSTEM 13. TOTAL PRODUCTIVE MAINTENANCE (TPM) 外部拉動(dòng)及運(yùn)輸系統(tǒng) 全員性生產(chǎn)維護(hù) 7. CENTRAL MATERIAL STORAGE 14. ERROR PROOFING 防錯(cuò) 中央物料儲(chǔ)存15. QUICK CHANGEOVER (SMED)快速換模56演講完畢，謝謝觀