【正文】 info is required to move materials, what is the timing 信息 移動 /搬運物料時需要什么信息，什么時間點 e) People , Takt time 人流 標準作業(yè)，節(jié)拍時間 f) Equipment carts, conveyor, racks, andons, TPM 設(shè)備流 手推車，傳送帶，物料架， andons 異常停線系統(tǒng) ， 全面生產(chǎn)維護 (TPM=Total Productive Maintenance) g) Engineering quality, tooling, programs 工程 品質(zhì)，工具，程序 33 Moonshine Shop 月光工作室 1) Do you have moonshine capability in your plant? 工廠有沒有月光工作室可以自己動手制作治具或工具以及時滿足產(chǎn)能需求的能力 .? 34 Golf Score 動作評估表 1) Are the operators having to bent down? 操作員在作業(yè)過程中需要彎腰嗎 ? 2) Are operators having to reach high? 操作員的手需要伸到很高的位置 (獲取物料或工具 )來完成作業(yè)嗎？ 3) Are operators having to twist/turn? 操作員在作業(yè)過程中需要轉(zhuǎn)身嗎 ? 4) Are operators leaving work area? 操作員在作業(yè)過程中離開工作區(qū)嗎 ? 5) Are operators needing 3 arms?(hand being used as fixtures) 操作員必須依靠三只手才能完成作業(yè)嗎 ?（第三只指的是治具） 6) Is the C/T set at 90% or less of the Takt time? 周期時間是設(shè)定在節(jié)拍時間的 90%還是低于節(jié)拍時間？ C/T= cycle time， T/T=Takt time 7) Is there rework being done? 返工有沒有在做？ 35 Machine 設(shè)備 1) Are tools suspended above pointofuse? 工具有沒有懸掛在使用點 (觸手可及之處 )？ 2) Are proper gauges/fixtures used? 所用到的治具是否合適？ 3) Are distances between stations held at minimum? 工站間距離是否是最短的？ 4) Are there 2 or more stations for each operator39。 31 VSM 價值流圖 1) Do you have value stream done on your product? 1. 產(chǎn)線有沒有做價值流分析？ a) have you visualized improvements to the overall production flow, instead of spot improvements to single processes 有沒有把所有產(chǎn)線流程存在改善空間的地方明顯地標識出來，而不是僅標示某個地方。 7) The layout of ― Y‖ is better than the layout ― I I I ‖ series ―Y‖型布局比 ―I I I ‖型布局好。 5) When we set up new layout ,we must consider use the one piece flow. 當建立新的生產(chǎn)線布局時，必須考慮使用單件流。 17) Do you have mean test ? challenge the current state (Potential Problem Analysis) 有運用均值檢驗嗎 ? –對現(xiàn)狀進行尋根究底 (分析潛在的問題 ) 18) Do you use 5 Why analysis to understand the root cause? 有沒有運用 5個為什么來分析根本原因？ 19) Landscape concept – View from all angles (the mountain) ,Search for the truth (the forest), Look/Focus (the tree), See and fix it (the branch) 全局概念 全方位 遠看 (山 )，尋找真相 近觀 (森林 )，細看 (樹 )，深究并解決問題 (枝干 ) 30 One Piece Flow 單件流 1) One piece flow 單件流 2) Are the line visibility clear for the supervisor? ? Takt counter? Line flow? 對于管理者來說，產(chǎn)線狀況可視化嗎？有標準 WIP?節(jié)拍計數(shù)器？產(chǎn)線是流動的嗎？ 3) One piece flow which like as the eggs inside the chicken should be one by one flow ,but not in parallel. 單件流就像母雞肚里的雞蛋一樣是一個一個下蛋的，而不是一起下出來的。 19) Do your work stations are in same height ? 工作臺都是同一個高度嗎？ 20) Do you carry out ―rope test‖ to validate the continuous value flow ? 有 實施“繩子測試”驗證連續(xù)價值流嗎？ 26 Zero Defect 零缺陷 1) Can normal and abnormal be visually differentiated? 正常和異?，F(xiàn)象易于區(qū)分嗎 ? 2) Are the escalation paths well defined if abnormality occurs? 針對異常的發(fā)生 ,有沒有制定出逐級上報的流程 ? 3) Are the defects allowed to escape to down stream? – 有沒有不良流入下一工站 ? a) Do not pass defect ( Downstream Internal or To End Customer ) 不流出不良品 (內(nèi)部下游客戶或終端客戶 ) b) Do not make defect( In Own Process ) 不制造不良品 （自己的工位） c) Do not accept defect ( From Upstream) 不接收不良品 （從上游工序） d) Do not rework ( Not Build Product Via Rework ) 不允許返工 （不通過返工生產(chǎn)產(chǎn)品） 4) Do you have a mon area to view the defect (fish market)? 有沒有特定的地點來檢討不良 ?(fish market 魚市場 ) 27 Zero Defect ( continue ) 零缺陷 (續(xù)頁 ) 5) Do you apply 3 Gens? 有沒有做到三 現(xiàn) ? a) Genba Actual place 現(xiàn)場 b) Genbutsu Actual product 現(xiàn)物 c) Genjitsu Actual fact 現(xiàn)實 6) Do you use 5 W ( who, what , where, when, why)+1H (how) where rule and regulation applied? 規(guī)章制度的制定有沒有運用 5W+1H的方法 ? 7) Do you have hand free inspection station? 視檢工站 ,有沒有不需要用手的 ? 8) Do you have template with navigation or pointer to guide inspection operators? 有沒有模板來輔助視檢作業(yè)？ 28 Zero Defect ( continue ) 零缺陷 (續(xù)頁 ) 9) Do you apply SDCA,PDCA? and for defects do you apply PDCA? (Problem,Display,Clear acknowledge) SDCA ( Standardize, Do, Check Action ) 工作中有沒有運用 SDCA、 PDCA方法？針對不良現(xiàn)象，有沒有運用 PDCA的方法？ 10) Do you have Kaizen Newspaper displayed? 改善活動的海報有沒有展示出來 ? 11) Do you have 1hr, 2hr, 4hr, 8hr tracking system on the floor? (lead to zero defect) 產(chǎn)線有沒有跟蹤系統(tǒng) ， 隨時了解每 1小時，每 2小時，每 4小時，每 8小時的狀況？ (向零缺陷靠近 ) 12) Identify POO POD to solve the problem 當問題發(fā)生時 ,鑒別出問題的起源 (POO)和問題的發(fā)現(xiàn)點 (POD)來解決問題 . POO=point of origin (where is the first point are the cause problem) POD=point of detection (where the point the problem been captured) 13) Learn how to make the defect to understand root cause 研究如何會產(chǎn)生不良 , 從而了解根本原因。s not meet ―傳送帶 ‖的 4個功能， 如果不符合以下條件則不能使用 ―傳送帶 ‖ ? Function as a Pace Setter ( Takt Manufacturing ) 節(jié)拍調(diào)節(jié)器（節(jié)拍生產(chǎn)） b) Function as a Value adding work station ( Value being added as it moves) 增 值工位 （ 傳送帶移動時產(chǎn)品可以增值，如在傳送帶上作業(yè) ） c) Function as a Jidoka ( Stop every abnormal ) 自働化 （ 異常時停止作業(yè)） d) Function as a transportation mode ( 5% of the function ) 傳送作用 （只占 5%的功能） 22 Layout 布局 1) Insure the short walking distance. 確保產(chǎn)線行走距離短 . 2) Do you have 3 TEI implemented on your line? 產(chǎn)線有沒有對物品實施三定原則 ? a) Fix place 定點 b) Fix things 定位 /定物 c) Fix qty 定量 3) Is the safety aisle easily accessed by the operator? 安全通道是否易于員工通過 ? 4) Are there trash bins inside the cell? 單元生產(chǎn)線內(nèi)有沒有垃圾箱 ? 5) Do you have cell concept implemented on your line? 有沒有在生產(chǎn)線上應(yīng)用單元生產(chǎn)的概念 . 23 Layout ( continue ) 布局 (續(xù)頁 ) 6) The operator movement in a cell : is it counter clock wise(1) or clockwise(0). Counter clock wise is remended 操作員在 單元 內(nèi)的移動是逆時針還是順時針 (逆時針為佳 ) 7) The gap in a cell : is it wider(0) or narrower(1) (narrower remended). 單元