【正文】 s worth of material? 物料超市是不是設(shè)計成存放 1 小時物料的大?。? 4) Is the replenishment information being sent out? 補(bǔ)充物料的信息有及時送出嗎 ? 5) Are there defects being sent from upstream processes? 不良是從上游工站流出的嗎？ 6) Are operators selecting between or searching for parts? 操作員在作業(yè)中，有沒有選擇或?qū)ふ椅锪系葻o價值的動作？ 42 Material ( continue ) 物料 (續(xù)頁 ) 7) Is banana peeling allowed? 允許在產(chǎn)線拆除物料包裝嗎 ? 8) Do you have vertical storage, is it human reachable height? 有沒有立式的儲物空間，是否在可觸及的高度內(nèi)？ 9) Are the parts located as close as possible to POU? 物料擺放是否遵從 POU原則？ POU=point of use (where/when the material need to use) 10) Do you allow double and triple handling of materials? 是否允許一次雙倍或三倍地抓取物料？ 11) Are there any materials that not required NOW stored in the shop area? 當(dāng)前不用的物料有沒有存放在物料超市 12) Are the materials arranged properly based on FIFO? 物料擺放是否遵從先進(jìn)先出的原則？ (FIFO=first in first out) 43 Material ( continue ) 物料 (續(xù)頁 ) 13) Are the materials required placed in ways that allow them to be removed immediately? 物料是否放置在易于快速移動的位置 ? 14) Do you have material shortage escalation path? 針對缺料 ,有沒有逐級上報的流程？ 15) Is it possible to put more (material) than necessary? 有沒有存放多于所需的物料？ 16) Does the water spider have shortest walking path defined? 有沒有為物料員規(guī)劃 最短路徑？ 17) Do you have one Kanban card per box? 每個盒子是否都有物了看板卡？ 18) Are the parts located with single entry? (condominium conceptonly one entry point per unit) 物料放置是否設(shè)計成只有一個取放口 ? (公寓理念 — 每個單元只有一個入口 ) 44 5 Reasons for High Inventory 高庫存的 5個原因 1) Long lead time 前置時間 /周期時間長 2) Purchasing timing too early 采購時間太早 3) Lot size too big 批量太大 4) Consumption rate less than planned 實際消耗小于計劃 5) Customer cancelation Demand Change 定單取消或需求改變 45 Heijunka 均衡生產(chǎn) 1) 3 key elements in Heijunka :均衡化的三個重要因素 a) Heijunka Pull 均衡化拉動生產(chǎn) b) Supermarket 物料超市 c) Replenishment 補(bǔ)料系統(tǒng) 46 Option 連續(xù)性 1) Do you have implemented chakuchaku? 有沒有使用一步接著一步（ chakuchaku） 生產(chǎn)？ 2) Do you have implemented Hanedashi? 有沒有使用自動彈出設(shè)計？ 3) Do you have implemented Nagare concept? 有沒有達(dá)到不間斷流動生產(chǎn)？ 4) Do you have implemented TPM? 有沒有執(zhí)行全面生產(chǎn)維護(hù)？ 5) Do you have maintained free machine? 有沒有保養(yǎng)閑置的設(shè)備 ? 6) Do you have fast turn around time for Jigs and tools? 有沒有對治工具運(yùn)用最快換線時間？ 47 Option ( continue ) 連續(xù)性 (續(xù)頁 ) 7) Four categories of Technology: 四種技術(shù) /方法 : a) Original Technology 獨(dú)創(chuàng)技術(shù) /新技術(shù) b) Technology that is available to 以下三種適用的技術(shù) i) make smaller 更小 ii) make thinner 更薄 iii) make lighter 更輕 c) Combine existing technology 現(xiàn)有技術(shù)的結(jié)合 d) Use existing technology to 將現(xiàn)有技術(shù)應(yīng)用于 i) mass produce 大批量生產(chǎn) ii) reduce defect and raise yield 降低不良，提高良率 48 Kanban 看板系統(tǒng) 1) When Kanban card is detached from the product, it must be clear ?where Kanban card‘ should GO 當(dāng)產(chǎn)品的看板卡取下時 ,一定要清楚看板應(yīng)該 去 哪兒 2) The product Kanban card must be transfer to address designated 看板卡一定要與所隨產(chǎn)品一起按要求轉(zhuǎn)送到指定地點 3) Kanban card should be transported the scheduled time to designated location 看板卡傳送時要按預(yù)定時間送到指定地方 4) Each box or product must have kanban card attached 每個運(yùn)輸盒 /產(chǎn)品上必須附其對應(yīng)看板卡 5) Kanban card has to be maintained all time and to be ensured no damage/ spoil/ loss (Kanban card is equivalent to cash or credit card) 看板卡要時時進(jìn)行跟蹤 ,維護(hù) ,使其保證完整無缺 (看板卡等同于鈔票或信用卡 ) 6) Kanban card must be taged with license number (serial number) 看板卡必須要有發(fā)行編號 49 Kanban ( continue ) 看板系統(tǒng) (續(xù)頁 ) 7) No Kanban card = No production (Do not start any production without Kanban card) 看板卡上的數(shù)量等于生產(chǎn)數(shù)量 (沒有看板就不生產(chǎn) ) 8) Quantity in the Kanban card must match or equal to the physical quantity 看板卡上的數(shù)量一定要和實際生產(chǎn)數(shù)量相一致 9) No extra tray, no extra bin, no extra Kanban card in the Genba Supermarket at all time 在生產(chǎn)現(xiàn)場或超市不允許有多余的托盤，多余的盒子，多余的看板卡 10) All WIP / Inventory must。 41 Material 物料 1) Are parts provided 1 kit at a time (or less than 10 min.39。 24) Do you train your operator to act as sensor to machine problem? 有沒有把操作員培訓(xùn)成對機(jī)器的異常非常敏感？ 39 Machine ( continue )設(shè)備 (續(xù)頁 ) 25) Is your feeder color coded based on size? FEEDER有沒有根據(jù)其大小做顏色標(biāo)示？ 26) Do you build the fixture based on :有沒有根據(jù)以下要求來制作治具 : a) Reference points 治具的相關(guān)參數(shù) b) X and Y axis XY軸坐標(biāo) c) jig hands free 不需要手來輔助作業(yè) 40 Total Productivity Maintenance ( Skill Matrix ) 全面生產(chǎn)維護(hù)（技能表） A HU M aint enan ce S kil l M atrix Radz i Nadri G op i K ha i r i1 Chec k r un ni ng am p2 Ins pe c t g en eral c on di ti on 3 Chec k w ate r l ev el4 Chec k f l oa t s w i tc h5 Cl ea n i n f i l l 6 Cl ea n l ou v r e/s tr ai ne r /ba s i n 7 Chec k m oto r am p / greas i ng8 Chec k s prin k l e h ea d / f an c on di ti on / b el ti ng9 Chec k c he m i c al pu m p/c he m i c al l ev el10 Chec k m oto r / b el ti ng /p ul l ey11 Dy na m i c ba l an c i ngZero Knowledge 無相關(guān)知識 Apprenticeship under training 培訓(xùn)中 Full Knowledge 熟練 Full knowledge, able to lead 熟練 ， 能領(lǐng)導(dǎo)他人一起作業(yè) Full knowledge, able to lead, able to train 熟練，能引導(dǎo)他人，并且有能力培訓(xùn)人員 Skill Matrix – Good visual management tool to evaluate current anization strength and plan TPM development strategy. 技能 矩陣 —良好的可視化管理工具，用于評估當(dāng)前機(jī)制是否具有優(yōu)勢，計劃 TPM發(fā)展戰(zhàn)略。 RR是推進(jìn) 6 SIGMA及 QS 9000中常用的評價測定系統(tǒng)再現(xiàn)性及再生性的工具，被廣泛應(yīng)用于尺寸測定的工具上。ideal state? 未來的情況 價值流圖表示出改善之后的理想狀況 e) 3D VSM for better visualization (for office kaizen) 3D價值流圖使流程更加直觀（針對辦公室改善） 32 VSM ( continue )價值流圖 (續(xù)頁 ) 2) 7 types of flow must be clearly defined : 7大流程必須定義清楚 a) Material – Raw 物料 原材料 b) Material – WIP 物料 在線庫存 c) Material Finish Goods 物料 成品 d) Information what