Lean Manufacturing 4精益生产4英文.ppt

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1、leanmanufacturingtrainingweek4[]TPS–全程生产管理目视化管理稳定标准化过程标准生产(Heijunka)及时正确的零件,数量,时间生产节拍持续流程拉动体系快速切换完备物流Jidoka(现场质量)问题可见性自动停止暂停人与机器分离防错现场质量控制解决根本原因(5Why’s)高品质–低成本–短周期–更安全–高士气简化生产流程排除浪费leanmanufacturingfoundations个人&团队*选择*快速决定*共同目标*交叉培训减少浪费*GenchiGenbutsu*聚焦浪费

2、*5为什么*问题解决持续改进linebalanceadjustingthespreadofworkevenlybetweenoperatorstotherateofcustomerdemandremember:TAKTtime–availableworktime/customerdemandcycletime–actualtimetocompletethetaskslinebalancebenefits:improvethroughputofassemblylineencourageone-pieceflo

3、wincreaselabourutilisationreducecostlinebalanceYamazumi–Japanesewordliterallymeaningtostackupstackedbarchartthatshowsthebalanceofcycletimeworkloadsbetweenanumberofoperatorstypicallyinanassemblylineorworkcelllinebalanceeffectsofimbalanceexcessinventoryidlee

4、quipmentidlepeopleteamdissensionindividualfrustrationlinebalanceLineBalanceExerciseproblemsolvingwithinallorganisationsthereareanendlesssupplyofproblemstheinverseofaproblemisanopportunityproblemsoftenclassedasfailuresandthushiddenratherthanaddressed“everyp

5、roblemisanimprovementopportunity”problemsolvingtraditionalmethodofcorrectingproblemscorrectproblemsoff–lineinreworkareas/baysaddedlayersofinspectionreluctancetoidentifyproblems&solutionsnotexploredproblemscontinue,addedcosttocorrectlaterapplicationof6sigma

6、andSPCtosolveproblemsproblemsolvingnewapproach–stoppinglinetofixproblems(Jidoka)principle“getqualityrightthefirsttime”stoptofixproblemsdonotallowdefectstopassthroughtonextprocessurgencytofixproblems–challengespeopletothinkAndon,Jidoka,PokeYoke,StandardWork

7、,ProblemSolving,TrainingmotivationtoidentifyandsolveproblemsproblemsolvingProblemSolvingProcess1.DefineProblem2.Completerootcauseanalysis3.Considersolutionsthroughconsensus4.PDCA5.Reflectandlearnproblemsolving1.Definetheproblemgotowheretheproblemisandobser

8、vethesituationwithoutpreconceptioncomparetheactualsituationtothestandarduseParetoAnalysistoprioritiseanumberofdifferentproblemssettargetsforimprovement“Carefullyaimbeforefiring”problemsolvingParetoChart(80/20