康明斯目視管理法(1)

1、康明斯目視管理法Cummins Visible Controls 1Cummins 目視管理 Visible Controls 目的 Objectives闡述目視管理: 目標，定義，和標準 Describe Visible Controls: goal, definition, and criteria 了解如何運用 Understand how to use them講解4種做法 Define the 4 categories展示與持續(xù)改進的聯(lián)系 Show connection to Continuous Improvement Process2Cummins 目視管理 Visible Co

2、ntrols 與CPS*的聯(lián)系 CPS Connection隱藏問題，不能使問題受到重視并得到解決。我們必須能夠很快地標識問題，并立即做出反應(yīng)。問題點必須可以一目了然。 CPS 員工手冊 1991，24頁 *CPS-康明斯生產(chǎn)系統(tǒng)“Hidden problems will not get attention and will not be fixed. We must be able to identify problems quickly and respond to them immediately. Trouble spots must be obvious at a glance.”

3、CPS Employee Manual, 1991, pg. 243Cummins 目視管理 Visible Controls . 注意！ATTENTION！下面兩種方法對于信息運用管理可能會有很大的區(qū)別： How information is organized is perhaps the most distinguishing feature between 信息共享 目視交流 Information Sharing Visible Communication4Cummins 目視管理 Visible Controls 目視管理目標 Visible Controls Goal1. CPS

4、 質(zhì)量目標是： “使過程成效指標和問題均目視化” A CPS quality objective is to “make performance to processes and problems visible.”2. 持續(xù)改進是我們的生存之道 Continuos Improvement is a way of life3. 建立發(fā)展一個部門區(qū)域間交互責(zé)任的體系 Developing a system of overlapping responsibilities between functional area 5Cummins 目視管理 Visible Controls 目視管理 VISI

5、BLE CONTROL DEFINITION 目視管理就是信息展示，全面直觀地、方便地 能看見，以便對其做出反應(yīng)，進行調(diào)整控制。 A visible control is defined as a display of information devised to be in full view or readily seen in order to allow reaction or regulation to the source or cause of information.6Cummins 目視管理 Visible Controls 基本準則 Essential Criteria 使

6、重要的信息以最快的速度方便地傳遞到?jīng)Q策和措施制定的地方 They are used to facilitate the transfer of important information as quickly as possible at the point where decision and action can be made.1、簡潔陳述 Simplicity of presentation 2、可視測評 Visibility of measurements情況目視通報到每位員工 situation are visible to everyone 目標和責(zé)任目視通報到每位員工 goal

7、 and rules are visible to everyone 7Cummins 目視管理 Visible Controls 基本準則 Essential Criteria3、每位員工進行參與 Everyones involvement 4、基礎(chǔ)信息數(shù)據(jù)的真實收集 Undistorted collection of primary information 5、重要數(shù)據(jù)的直接測評（至關(guān)重要的幾個） The straightforward measurement of whats important (The Vital Few)6、對緊急情況有全面的了解掌握 Achieve an over

8、all feel of urgency 7、針對變異有完善計劃和受訓(xùn)練的反映 Planned and disciplined response to abnormalities8Cummins 目視管理 Visible Controls 行GO停STOP我該如何做？ What should I do?9Cummins 目視管理 Visible Controls 出口Exit 96目視信息-不好 Visible Information -Bad Example10Cummins 目視管理 Visible Controls 目視信息-好 Visible Information-Good Examp

9、le.出口Exit 9611Cummins 目視管理 Visible Controls 共同負責(zé) Shared Responsibility工廠質(zhì)量水平 Plant Level公司目標 Company Goals:*世界級 World class*CPS*通告Inform visitors班組板塊區(qū)Teams Territory班組目標Group Goal:*用戶/供應(yīng)商 customer/supplier*成本/質(zhì)量/發(fā)運 cost/quality/delivery*問題 problem獨立工作站Individual Workstation工序說明 Operation Specific:*工

10、藝文件 Process doc.*標準工作圖示 Std work charts*維護 Maintenance*環(huán)境管理 Housekeeping12Cummins 目視管理 Visible Controls 工廠質(zhì)量水平 Plant Level 團隊班組板塊區(qū)TeamsTerritory 用戶Customer 支持 Support 方法 Methods規(guī)范 Specification用戶 Customer工廠測評 Plant measure過程測評 Process measures供應(yīng)商 Supplier維護 Maintenance 安全 Safety獨立工作站 Individual Work

11、station供應(yīng)商 Supplier 計劃 Plans安全Safety13Cummins 目視管理 Visible Controls 目視管理準則The Rule of Visible Controls 班組必須審核和認可目視管理 The team has to review and approve any visible control“提交目視管理文件進行公開評議使員工獲得認知，提供員工發(fā)表建設(shè)性意見的機會”“submitting a visible control document to a process of public scrutiny -result in better ow

12、nership of the knowledge and opportunities for constructive criticism.”14Cummins 目視管理 Visible Controls 公開式傳達信息Openness of Communication問題狀況的明確展示使每位員工知道目前過程的狀態(tài)“Visible display of problem status lets everyone know the current status of the process.”度假, 一周后返回On vacation Return in 1week15Cummins 目視管理 Vi

13、sible Controls 生產(chǎn)計劃展示 例1 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #116Cummins 目視管理 Visible Controls 生產(chǎn)計劃展示例2 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #217Cummins 目視管理 Visible Controls 人力計劃舉例 Handout Solution for Situation 1 -Workfor

14、ce Planing A工廠 Plant A B工廠 Plant B18Cummins 目視管理 Visible Controls 四種展示 The Four Categories目視生產(chǎn)控制 Visible Production Control目視質(zhì)量控制 Visible quality control過程指示 Process indicators進程顯示 Making Progress Visible改進 Improvement ： 節(jié)拍 cycle time實際 Actual: 3.5 min reduction19Cummins 目視管理 Visible Controls 生產(chǎn)管理 P

15、roduction Control(過程狀態(tài)一目了然 understanding the process at a glance.)看板或拉料卡顯示材料狀態(tài) Chanson or Pull Cards showing material status 工作標準化 Standardized work charts瓶頸工序標識出 Bottleneck operations identified工序流程圖 Process flow charts預(yù)先確定場所 Predetermined locations整潔、工裝和設(shè)備定置擺放 clear, designated tool& equipment loc

16、ations20Cummins 目視管理 Visible Controls 生產(chǎn)管理 Production Control材料存儲標識完善 well marked material storage 材料過量堆積 overflow areas警示燈顯示問題或異常情況 Andon displays to indicate problems or abnormal situations生產(chǎn)量計數(shù) Production count status 發(fā)交狀況 Delivery status料箱（架）限制零件裝載量 Containers limiting the amount of parts21Cummi

17、ns 目視管理 Visible Controls 料架滿裝指示舉例Example of Production ControlInstructions for filling a container錯誤 No 正確 Yes滿裝線Fill line22Cummins 目視管理 Visible Controls 警示燈板 Andon (a lighting panel)發(fā)生故障傳送信息的裝置 Which is an “information transfer device for trouble occurrence”.同時可指示停止或故障解除警示Also reference to as stop

18、alarms, uptime lights23Cummins 目視管理 Visible Controls 生產(chǎn)管理警示板 Production Control Board -Andon Board目標 345Target實際 345Actual時間損失 8minLoss time最新消息：工作站 3材料短缺， 工作站 6有質(zhì)量問題Status update:Station 3 has a material shortage, Station 6 has a quality problem 6789101234524Cummins 目視管理 Visible Controls 生產(chǎn)警示燈有如下表示

19、：Example of Production: Andon Lights-紅色 Red : 生產(chǎn)線停止Line Stop -黃色Yellow: 請求支持援助 Worker has called for help-綠色Green: 正常 Normal operation25Cummins 目視管理 Visible Controls 警示燈有如下表示：Example : Andon Lights-紅色Red: 設(shè)備故障 Machine trouble -白色White: 生產(chǎn)終止 end of production run-綠色Green: 材料短缺停產(chǎn) no work shortage of m

20、at.-蘭色Blue: 有問題 defective unit-黃色Yellow: 要求調(diào)整 set-up required26Cummins 目視管理 Visible Controls 過程指示 Process Indicators (用于監(jiān)控工作進程的設(shè)施 devices for monitoring work progress)設(shè)備機油消耗 Machine oil consumption班組培訓(xùn)矩陣表(技能水平/培訓(xùn)項目) Team training matrix (skill level/training)安全成效 Safety results 內(nèi)部環(huán)境管理維護成效 Housekeepi

21、ng results庫存周轉(zhuǎn) Inventory turns色彩編碼任務(wù) 時間安排卡片 Color coded job scheduling cards在制品 Line side storage 節(jié)拍 Tat time, cycle time調(diào)整時間 Set-up TimeSPC 圖 SPC charts27Cummins 目視管理 Visible Controls 過程標示舉例: 發(fā)動機掛旗Example of process indicators:Engine Flags 紅色 - 發(fā)動機質(zhì)量問題要拆檢 Red - Engine Quality Teardown黃色 - 缺“自制”件 Ye

22、llow - Shortage of “made in works” part蘭色 - 缺“外協(xié)”件 Blue -Shortage of “bought out finished “ part綠色 - 發(fā)動機準備做試驗 Green -Engine ready for test白色 - 等待檢查 White -Awaiting inspection 28Cummins 目視管理 Visible Controls 質(zhì)量管理 Quality Control (質(zhì)量狀況一目了然 understand quality status at a glance) 用戶質(zhì)量水平 Customer Quality

23、 Levels工序控制紀錄 Process Control RecordsSPC圖 SPC chartsCPC情況 CPC status (CPC triangles)量檢具檢定狀況 Gauge calibration status接受/不可接受標樣 Boundary Samples referencing acceptable/non-acceptable quality供應(yīng)商質(zhì)量成效 Supplier results規(guī)定明確的不合格品區(qū) Clearly defined non-conforming area工藝文件 Process Documentation檢查計劃 Inspection

24、plans 29Cummins 目視管理 Visible Controls 工作場地一目了然A VISIBLE WORKPLACE產(chǎn)品陳列Product display用戶反饋Customer Feedback成效展示Results displayed30Cummins 目視管理 Visible Controls 工作場地一目了然A VISIBLE WORKPLACE1814131211101098716172619543211542031Cummins 目視管理 Visible Controls 32Cummins 目視管理 Visible Controls 33Cummins 目視管理 V

25、isible Controls 34Cummins 目視管理 Visible Controls 35Cummins 目視管理 Visible Controls 36Cummins 目視管理 Visible Controls 37Cummins 目視管理 Visible Controls 38Cummins 目視管理 Visible Controls 39Cummins 目視管理 Visible Controls 40Cummins 目視管理 Visible Controls 41Cummins 目視管理 Visible Controls 42Cummins 目視管理 Visible Contr

26、ols 工作場地一目了然 A VISIBLE WORKPLACE談?wù)撘曈X圖像信息卻不用圖片，似乎有些似是而非。這就是展示車間目視管理圖片的原因。 It would be somewhat paradox to speak of visual communication without relying on an image. This is the reason for presenting a visual workplace.上張圖示不是固定不變的逐條要遵循的實際例子，每個工廠有各自不同的實際操作運行情況。沒有理由完全按照圖示中每個項目去實施。其他內(nèi)容或展示可能更適合具體的情況。這里主要是

27、提供目視交流、管理的一種思路。The workplace depicted is not a practical example to be followed literally. Each firm has its own constraints and operating structure. There is no reason automatically to include everything appearing in this sketch. Conversely, other elements-or other forms of presentation-maybe more

28、suitable for certain situation. In this portrayal, the intent is to present significant visual communication themes.43Cummins 目視管理 Visible Controls 工作場地一目了然 A VISIBLE WORKPLACE班組板塊 The Teams Territory1.板塊標識 Identify territory2.標識活動、資源和產(chǎn)品 Identify activities, resource,& product.3.班組園地 Identify the te

29、am4.地面標記 Marking floor5.標識工裝和工位器具 Marking of tools and racks6.技術(shù)區(qū)域 Technical area7.交流和休息區(qū)域 Communication & rest area8.信息和指示 Info. & instruction 9.清掃工具 Neatness (broom)目視文件 Visual Doc.10.生產(chǎn)指導(dǎo)和技術(shù)程序Manufacture Instruction & tech. procedure44Cummins 目視管理 Visible Controls 工作場地一目了然 A VISIBLE WORKPLACE目視生產(chǎn)

30、管理 Visual production control11.計算機終端 Computer terminal12.生產(chǎn)計劃 Production schedule13.維修計劃 Maintenance schedule14.零標識 Identification of components目視質(zhì)量管理 Visual quality control15.設(shè)備監(jiān)控信號 Machine monitor signals16.SPC17.記錄指標展示 Display Indicators18.目標、結(jié)果和差距Objectives, results, and differences進展 Rendering

31、Progress Visible19.改進活動 Improvement activities20.公司方針、計劃和任務(wù) Company policy, project & mission 45Cummins 目視管理 Visible Controls 實施改進 Making Improvements（目視板可使每個員工追蹤改進工作的進展）(Display so that anyone can follow improvement work as it progresses)用戶滿意 Customer satisfaction 用戶/供應(yīng)商合作協(xié)議Customer/supplier workin

32、g agreements項目和狀況 Projects and status改進活動 Improvement activities之前/之后 Before/After培訓(xùn)計劃 Training matrices改進板 Improvement boards問題解決過程 Problem solving process status庫存降低騰空場地 Floor space freed up due to inventory reduction 預(yù)防性維護計劃 Preventative maintenance schedule46Cummins 目視管理 Visible Controls 合適的搬運擺放

33、作業(yè)指導(dǎo)Instructions for Proper Stacking Procedure不在正確 No 正確Yes47Cummins 目視管理 Visible Controls 預(yù)防問題重新設(shè)計Re-design for prevention of problem 目視管理的實施Levels of Visible Controls Implementation工藝文件 Process documentation環(huán)境維護管理 Housekeeping duties圖表-發(fā)交 ,員工培訓(xùn)計劃 Charts - parts shipped, - operator training matrice

34、s檢查計劃 Inspection plans不合格品報告 Reject reports色斑材料區(qū) Color striped material zonesSPC 圖 SPC charts控制限 Boundary samples發(fā)動機試驗 Engine test活塞環(huán)顏色碼 piston ring color code特殊力矩復(fù)檢 specialized torque overchecks預(yù)防 PREVENTION發(fā)現(xiàn) DETECTION停線 燈machine down lights裝配紅燈 assembly red lights2預(yù)通道無線系統(tǒng) 2-way radio system最初展示運行

35、狀態(tài)Initial display of operational status質(zhì)量信息和規(guī)范Quality information &specification工作環(huán)境探測異常Work environment for abnormality detection問題可視或可見警示Visual or audible alerts to problem防錯 Failsafing自動Automation48Cummins 目視管理 Visible Controls “標準是一個參照點, 提供給班組追隨的目標, 同時也提供了出發(fā)的起點.”“A standard is a point reference that simultaneously provides the group with a point to adhere to and a point of departure.” 通過信息展