【正文】 Downtime clock begins 第六步：如果 車輛 到 達(dá) 定點停 時 班 組長 仍然 沒 有解除暗燈信 號 ，生 產(chǎn)線 停止 并 且主看板上 紅 燈 開 始 閃爍 ，停 線鈴開 始 響 起 Downtime Clock SHORT CONV EQUIP FULL 5 4 1 2 3 TRIM 1 EQUIP Q1 Q2 Q3 Andon Steps (Cont’d) FPS FPS FPS Set Line at 70% of Takt or Cycle Time Relate to Specific Step in Standardized Work Pull the Andon as Early As Possible (at or before 70% Line) to Address Problems Before They Stop the Line!!! 在線停之前，盡早拉動暗燈線宣告出現(xiàn)問題。 Manufacturing Process Validation Quality System Management Quality Feedback/ Feed forward Standardized Work Visual Management Management by TAKT Time Work place Organization Andon Concept Problem Solving Continuous Improvement Process Business Plan Deployment Total Productive Maintenance Controlled External Transportation Scheduled Shipping / Receiving Level Vehicle Order Schedules Supply Chain Management Internal Pull / Delivery Simple Process Flow Small Lot Packaging Fixed Period Ordering System/ Order Parts Health and Safety Priority Team Concept People Involvement Open Communication Process Values Vision/ Mission Shop Floor Management Continuous Improvement Andon Concept 暗燈 概 念 Lean Design of Facilities, Equipment, Tooling and Layout InProcess Control and Verification What is an Andon System? 什 么 是暗燈系 統(tǒng) ? ? The ANDON System allows team members to pull the cord and call for help when there is a problem or out of standard situation. ? The ANDON System is an enabler to control quality while keeping the line running by pulling in support to address problems before they stop the line ? 暗燈系 統(tǒng) 允 許員 工在出 現(xiàn)問題 或有超 標(biāo) 情 況時 拉 繩 索以 尋 求 幫 助 ? 暗燈系 統(tǒng) 可以在保持流水 線繼續(xù)運 行的情 況 下， 員 工拉下 繩 索 尋 求支持人 員 在停 線 前到出 現(xiàn)問題 的工位解 決問題 ，以 滿 足 對質(zhì) 量的控制。 KEY BPD CONCEPTS BPD的核心理念 ? BPD a critical tool to achieve Continuous Improvement. BPD是 評 定是否 獲 得持 續(xù) 改 進(jìn) 的工具 Achieve targets and then “raise the bar”. 達(dá) 到了目 標(biāo) ，接著制定更高的目 標(biāo) 。 ? Visual Management … Status at a Glance 可 視 化管理 …… 讓 信息容易 讀 取 Makes out of standard condition highly visible. 突出超 標(biāo) 的情 況 。 ? Discuss as a team and report – Take 10 minutes 團(tuán)隊討論及匯報 十分鐘 Plan 計劃 Do 實 施 Check 檢查 Action 運 作 Grasp the Situation 了解情 況 PDCA is the foundation of BPD PDCA是 BPD的基 礎(chǔ) Below Expectations Needs Improvement Meets Expectation How does it work? Actions Annual Business Plan X Activities 行 動 PLAN DO PROBLEM SOLVING 問題 解 決 CHECK ACT 0501001st 3rdPDCA如何 運 作 ? 未完成 需要改 進(jìn) 完成 Regular Reviews Goals, Objectives, Targets, Methods Countermeasures 對 策 ? Open, Team Discussion ? Coaching Learning ? Get Support Resources ? Go To See BPD – We Will Be Successful When Everyone Focuses On What They Can Control! 當(dāng)每個人都集中力量做事，我們就一定能成功做到 BPD。Continuous Improvement GMS 持續(xù)改進(jìn) 員工參與 標(biāo)準(zhǔn)化 制造質(zhì)量 縮短制造周期 持續(xù)改進(jìn) 32 GMS Continuous Improvement BuiltIn Quality Short Lead Time People Involvement Standardization Continuous Improvement Health and Safety Priority Team Concept People Involvement Open Communication Process Controlled External Transportation Manufacturing Process Validation Product Quality Standards Quality System Management Scheduled Shipping / Receiving Level Vehicle Order Schedules Supply Chain Management Values Vision /Mission Shop Floor Management Internal Pull / Delivery Andon Concept Problem Solving Simple Process Flow Standardized Work Small Lot Packaging Quality Feedback/ Feed forward Visual Management Management by TAKT Time Work place Organization Continuous Improvement Process Lean Design of Facilities, Equipment, Tooling and Layout Business Plan Deployment Total Productive Maintenance Fixed Period Ordering System/ Order Parts Continuous Improvement Company持續(xù)改進(jìn)的公司 Small, steady improvements to constantly improve The Standard!! 從細(xì)小、穩(wěn)定的改進(jìn)到 標(biāo)準(zhǔn)的不斷提高 No Company Today Can Survive Without Having All Employees Focused on Continuous Improvement 沒有改進(jìn)就難以生存 Continuous Improvement What Is Absolutely Necessary Before Continuous Improvement Can Occur? 在能夠進(jìn)行持續(xù)改進(jìn)前什么工作是絕對必要的？ Stability Through Standardization! 通過標(biāo)準(zhǔn)化獲得穩(wěn)定發(fā)展 Standardization Improvement 改進(jìn) Standardization Standardization Standardization Improvement 改進(jìn) Improvement 改進(jìn) Continuous Improvement Standardization Before Continuous Improvement! 在進(jìn)行持續(xù)改進(jìn)前的標(biāo)準(zhǔn) 標(biāo)準(zhǔn)化 標(biāo)準(zhǔn)化 標(biāo)準(zhǔn)化 標(biāo)準(zhǔn)化 Plan 計劃 Do 實施 Check 檢查 Action 運作 Grasp the Situation 掌握情況 The PDCA Cycle PDCA The PDCA Cycle is One Of The Most Important Concepts In A Company… P D REACT P Poor panies do little planning, mostly doing, do not check their status and then react to everything… 沒有遠(yuǎn)見的公司很少做計劃，大多數(shù)情況是直接實施，從不檢查實施情況，此后對每件事都是如此 …… D C A WorldClass panies do excellent planning, always perform checks that enable to take corrective action and stay on schedule… 世界級的大公司會做非常周詳?shù)挠媱?，對每件工作進(jìn)行跟蹤檢查以便及時采取糾正措施并按進(jìn)度表運行 …… BAD GOOD Let’s go to Kyong Ju!!! Plan 計劃 Prepare for the trip Two days before leaving, check engine – OIL LEAK! Fix oil leak leave on time Our Family Has Not Had A Vacation In A Long Time! PDCA Can Be Used For Anything Do 實施 Grasp the Situation 掌握情況 Check 檢查 Action 運作 Manufacturing Process Validation Product Quality Standards Quality System Management Quality Feedback/ Feed forward Standardized Work Visual Management Management by TAKT Time Work place Organization Controlled External Transportation Scheduled Shippin