【正文】 ion (hour by hour) 每小時(shí)生產(chǎn)狀態(tài)如型號(hào)、產(chǎn)量等 Down time 故障維修時(shí)間 Change over 換型次數(shù)和時(shí)間 Planned down time 計(jì)劃停機(jī)時(shí)間 Quality loss 質(zhì)量損失 Speed loss 速度損失 Other lost time， people， material， etc 其他損失時(shí)間 Production Reporting Charting 生產(chǎn)報(bào)告及圖示 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 88 Precision is our life L O S T T I M E ( J U N E )53411246162354140200400600800100012001400H y d .C l e a n u pW a i t f o rC a s t i n g sW e l d T i pC h a n g e sQ u a l i t yC h e c k sC l e a rB o w lF e e d e rD E P T . 2 3 0MINUTESM i n u t e sDOW N TIM E (JUNE)95542778634511340200400600800100012001400Prox. Sw itch Thermocouple Hyd. Leak BrokenGripperRepackBearingsDEPT. 230MINUTESMinutesTOP 5 根源分析 Improve Overall Equipment Effectiveness 改進(jìn) 總的設(shè)備有效性 PARETO 主次分析 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 89 Precision is our life Total Preventive Maintenance is the total activities of all employees work to increase uptime, improve quality of output, improve safety, and reduce costs through the continuous improvement of equipment operation 全員設(shè)備維護(hù)是所有的員工努力通過(guò)持續(xù)改善設(shè)備的運(yùn)行 來(lái)增加有效時(shí)間、提高產(chǎn)品質(zhì)量、加強(qiáng)安全性及減少設(shè)備 成本的全系統(tǒng)的活動(dòng) Total Preventive Maintenance 全員設(shè)備（預(yù)防）維護(hù) Copy Right By MacroBrain Co., Ltd. Jimmy Guo 90 Precision is our life TPM 的五大支柱 訓(xùn)練和技能 的發(fā)展 Training and Skill Development 早期設(shè)備管理 維護(hù)預(yù)防設(shè)計(jì) Early Equipment Management 自主性的維護(hù) Autonomous Maintenance 維護(hù)程序改善 Maintenance Process Improvement 系統(tǒng)的設(shè)備改善 Systematic Equipment Improvement 小組 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 91 Precision is our life ? Zero Defect Principle 零缺陷法則 隱藏的異?，F(xiàn)象 Hidden abnormalities 缺陷只是露在水面上的冰山一角 A failure is the tip of the iceberg! 暴露隱藏的異常現(xiàn)象，在它們發(fā)生之前預(yù)防品質(zhì)和功能的缺陷 Expose hidden abnormalities and prevent quality and functional failures before they happen FAILURES 缺陷 磨損、松動(dòng)、泄漏、污垢、灰塵 腐蝕、變形、原物料的粘連、表面缺陷 破裂、過(guò)熱、顫動(dòng)、噪音、及其它異常現(xiàn)象。 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 97 Precision is our life Flow Cell and “U” Shape Layout柔性生產(chǎn)單元及 U型布局 C u s t o m e rT a k t T i m eS y n c h o n i z e d P r o c e s s e sa n d S u p p l i e r s? TAKT及生產(chǎn)速度 ?“U” 型布局和連續(xù)流 ?負(fù)荷平衡 ?消除瓶頸和變差 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 98 Precision is our life Flow Cell Design Objective 流動(dòng)單元設(shè)計(jì) 目標(biāo) “ The objective of flow cell design is to create a manufacturing system... 使我們有這樣一個(gè)制造系統(tǒng)： ...which provides for the smooth, uninterrupted flow of people and material…讓資源流和物流平滑而不間斷地 ...from each value added operation to the next value added operation... 從增值工位到增值工位 ...at a rate equal to customer demand…以客戶需求速度流動(dòng) …with the lowest life cycle cost ” 并且，使產(chǎn)品的生命周期成本最低 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 101 Precision is our life TAKT Time and Line Rate （ 需求）節(jié)拍與生產(chǎn)線速度 ? TAKT Time determines the rate at which work must be acplished at each operation (Operational Cycle Time) based on the line rate. ? 節(jié)拍時(shí)間 確定了每一工位必須完成工作的速率 ? （操作周期時(shí)間） ? TAKT is the rhythm or beat of the flow line. ? 節(jié)拍時(shí)間是流動(dòng)線的 節(jié)奏 或 拍子 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 102 Precision is our life Takt 節(jié)拍時(shí)間 = 可用工作時(shí)間 客戶需求數(shù)量 爭(zhēng)取使 每一工位 每 3分 20秒生產(chǎn)一件 合格 品 Takt節(jié)拍時(shí)間 = (60 X 工作小時(shí) /天 ) 休息 午餐 其它停頓時(shí)間 = 258 件 例子 : 節(jié)拍時(shí)間 = (60 x ) ((15+15+30+20)x2) = 860 分鐘 258 件 = 860 分鐘 x 60 秒 /分 200 秒 /件 ABC 裝配線 節(jié)拍時(shí)間 每天客戶需求數(shù)量 258 件 TAKT Time and Line Rate （ 需求）節(jié)拍與生產(chǎn)線速度 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 103 Precision is our life Planning with a Workable Takt 設(shè)計(jì)一個(gè)好的節(jié)拍時(shí)間 Takt Time (seconds) 30 120 ? 改善余地小 ? 很難應(yīng)付變動(dòng) ? 緊張 ? 太長(zhǎng)的工作步驟，難以標(biāo)準(zhǔn)化 ? 操作崗位輪換不容易 ? 注意力分散 合適區(qū)域 節(jié)拍時(shí)間 復(fù)雜度 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 104 Precision is our life 1 2 3 4 5 6 10 9 8 7 1 2 10 9 3 4 8 5 6 7 U Shape Cell Layout and Continuous Flow “ U”型布局和連續(xù)流 ? Flexible Line Capacity ? One Piece Flow ? Communication ? Save Space 具有柔性生產(chǎn)能力 有利于單件流 便于員工溝通 節(jié)約場(chǎng)地 Why??? Copy Right By MacroBrain Co., Ltd. Jimmy Guo 105 Precision is our life U Shape Cell High Rate Status “U”型單元 高速生產(chǎn)狀態(tài) TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 1 2 3 4 5 6 10 9 8 7 1 2 10 9 3 4 8 5 6 7 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 106 Precision is our life U Shape Cell Middle Rate Status “U”型單元 中速生產(chǎn)狀態(tài) TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 TAKT 0 10 20 30 40 50 60 1 2 3 4 5 6 10 9 8 7 1 2 10 9 3 4 8 5 6 7 Copy Right By MacroBrain Co., Ltd. Jimmy Guo 107 Precision is our life U Shape Cell Middle Rate Status “U”型單元 低速生產(chǎn)狀態(tài) 1 2 3 4 5 6 10 9 8 7 1 2 3 4 5 6 10 9 8