【正文】 浪費 過量制造的浪費 搬運的浪費 制造次品的浪費 加工本身的浪費 等待的浪費 動作的浪費 PDCA Brainstorming 65 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng 5... WHY？ 1 HOW！ ? 查找原因，要查找出真正的原因。 66 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng ? 克服陳規(guī)漏習，倡導集思廣益。 Rules For Brainstorming 集思廣益規(guī)則 Habits can make us? 習慣使我們 ? Rigid 墨守陳規(guī) Unreceptive to change 難以接受變化 Not open to new possibilities 不愿開發(fā)新的可能性 Criticism Forbidden 禁止批評 Freewheeling Encouraged 鼓勵發(fā)揮 Quantity (going for a lot of uideas) 數量（提出許多想法） Combine and expand (Hitchhiking) 綜合發(fā)揮（借助 ) 67 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng 個人智慧，比不過集體智慧。 高 HIGH independent 自立 dependent 依賴 interdependent 互相協(xié)作 境界 Condition 難度 difficulty 低 LOW 高 HIGH 低 LOW ? 拋棄依賴，達到自立，從自立出發(fā)，進入互助新境界。 68 ? 改善現(xiàn)狀，永無止境。 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng 時間 Times 改進 Improverment Plan 計劃 Do 實施 Check 檢查 Action 行動 P D C A P D C A P D C A 69 Lean Organization 精益組織 精益生產研討實施總結。 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng Standardized 標準化 Operations 操作 Zero Defect 零缺陷 Zero Stock 零庫存 Quick Setup 快速換模 SPF 一物流 Pull Systems 拉動式生產 In Time Supply 及時供貨 More Variety多品種 ,小 Small Batch批量生產 Visual Controls 直觀控制與管理 Lead Time 縮短制 Reduction 造周期 Production 生產 Office 辦公室 Layout 布局 Error Proofing 防錯 eigonomics 人機工程 U Style Cell U型制造單元 DTD 門到門時間 Planned 計劃 Maintenance維護 JIT 準時化生產 5S 5S Smart Card 看板管理 Customer Requirement Rate 客戶需求率 TEM 預防性維修 70 、質量、工具管理和小修、工藝流程改善等等共同負責，定期對問題和改善措施進行集體討論。 TEAM的改善機會 80% Workplace Organization Management (ex) Implement Visual Factory and the 5 S抯 in the work area. (ex) Establish TEM in the area. (ex) Ensure the operators are part of the tool selection process? they will be the ones using them! 5% Product 5% Tooling 10% Equipment (ex) Ensure customer specifications are clearly municated to the team. 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng 71 狀態(tài)信息欄 FPS 監(jiān)測指標 BTS DTD Total Cost OEE FTT 日質量信息 。 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng 01020304050607080901stQ tr2 n dQ tr3 rdQ tr4 thQ trEa s tW e s tN o rth日生產信息 PRODUCED 0546 Tool Change Needs Help 10B 20 30 40 50A 50B 60 PROJECTED 0562 In Attendance WORK AREA Warning 10A Down Quality Check 72 Team Meeting Area, 及時商量工作 解決工作中發(fā)生的問題。 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng Safe Work Procedures Safety Award Corporate Announcement Defective Supplier Parts Problem Info 01020304050607080901stQtr 2ndQtr 3rdQtr 4thQtrEastWestNorth01020304050607080901 2 3 4 5 6 7 8 9Ea stMachining Line 3 Work Group Display Board 73 STANDARDISED OPERATIC THEET 標準作業(yè)單 （作業(yè)標準）是成文的、目前最好的、安全及有效 完成工作的方法。并達到必要的質量水準。 TIME MEASUREMENT SHEET 時間測量單 JOB ELEMENT SHEET 工作要素單 TIME FLUCTUATION WORKSHEET 時間波動工作單 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng Totals Quality Process Sheet KEY: Cycle Time Department/ Section Process Part Name Part Date: Worksheet Opr WGL Sup Maint Eng Safety OTHER ERROR PROOFING FORD Total Prod. Maint. VISUAL FACTORY QUICK CHANGE OVER QUALITY CHECK DELTA CRITICAL KEY SAFETY/ ERGO IN PROCESS STOCK Step Work Steps Time Elements Manual Auto Walk Plant Name Target Time Work Sequence Layout Page__1__ of__1__ C D T F P M Q C Possible Hazards Remended Safe Job Procedures Lock(s) Safety Glasses Safety Shoes Gloves Earplugs Other 53 sec. 43 sec . Welding 05 rear panel 3302246 41096 5140 1 2 3 4 5 6 7 8 Pick up bar Set bar and rear panel in welder Hold rear panel and reinforcement Place rear panel in robot welder Hold bracket Place bracket in robot welder Make (4) additional spot welds on rear panel Set rear panel in punch press and start press 2 8 2 1 3 12 2 2 0 12 0 0 0 21 8 11 1 1 1 1 2 1 3 1 watch for burrs on edges Wear Gloves welding glasses required welding glasses required welding glasses required 5 2 3 Punch Press Spot Welder Robotic Welder 8 7 8 1 Q C weldin g Kevlar Steel Toe 74 2. 標準化是改進的基線。標準化工作則是標準化和穩(wěn)定 性的基本方法。沒有標準化，我們不可能取得不斷的改進 。 World Class 世界級 Standardization 標 準 化 “ a baseline for continuous improvement “ 不 斷 改 進 的 基 準 線” Change 變 更 Standardization 標 準 化 Standardization 標 準 化 Improvement 改 進 Standardization 標 準 化 Standardization 標 準 化 Improvement 改 進 Improvement 改 進 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai YanFeng 75 ，工廠中主要集中于生產 操作、維修操作、更換工模具、物料供給。 Max Min Part Number F7C65467934AB Black Clip Part Description Line Side Address Minimum Q uantity Maximum Q uantity Smart Number 001423 Market Address C27N10 DTLA01 4 1 Op 20 Route A 標準作業(yè)單 Max Min Part Number F7C65467934AB Black Clip Part Description Minimum Quantity 12 Maximum Quantity 2 標準作業(yè)單 標準作業(yè)單 標準作業(yè)單 精益生產簡明培訓教材 Concise Training Material for Lean Manufacturing 上海延鋒 Shanghai Yan