SGMGMS-CONCEPT通用汽車精益生產(chǎn)系統(tǒng)概覽-2課件

1、Welcome！An Overview to GMS第1頁，共41頁。A Lean Manufacturing Management System是一個(gè)精益制造管理體系GMSGMSLike An Atom We Need All The Pieces Working Together!第2頁，共41頁。Background背景介紹第3頁，共41頁。 New Plant 新工廠+ New Product 新產(chǎn)品+ New Process新工藝= Quality Problems 質(zhì)量問題Not True with GMS !GMS決不會(huì)這樣！Vehicle Launch Concerns新車型啟

2、動(dòng)關(guān)注點(diǎn)During a Typical Launch一次典型的啟動(dòng):Why Global Manufacturing Systems?為什么要采用GMS (通用全球制造體系)?第4頁，共41頁。 New Plant 新工廠 + New Product新產(chǎn)品+ New Process新工藝= Quality Problems 質(zhì)量問題J. D. Power, Initial Quality StudyJ. D. Power, 初始質(zhì)量調(diào)查1999Mercedes-Benz2002Cadillac CTSYESNOMercedes-Benz 235 problems per 100 near t

3、he bottom of the survey 每100輛車235個(gè)問題 在調(diào)查中排名靠近末尾Cadillac CTS88 problems per 100 Ranked SILVER ! 每100輛車88個(gè)問題 排名第二！第5頁，共41頁。Quote from J. Smith ( Former Chairman):引自：J.史密斯（主席） All GM plants are part of the same company and must operate with one production system with common elements“所有通用工廠同屬于同一個(gè)公司并且必須在

4、共同的環(huán)境中在同一個(gè)生產(chǎn)體系下運(yùn)作”Assignment任務(wù):Summer 96 年夏Develop a Common Global Production System建立一個(gè)共同的全球生產(chǎn)體系Background背景第6頁，共41頁。The GM/Toyota Joint Venture GM/Toyota合資公司New United Motors Manufacturing Inc. 新的聯(lián)合汽車制造公司Est. February 1984 in Fremont, California1984年2月在加利弗尼亞，弗里蒙特成立GM wanted to learn the Toyota Pro

5、duction System (TPS) GM想學(xué)豐田生產(chǎn)體系（TPS)Toyota wanted to learn about manufacturing in the U.S. 豐田想學(xué)如何在美國造車Each GM unit was free to study TPS and implement as they saw fit 每個(gè)GM的工廠都可以學(xué)習(xí)TPS,并按需實(shí)施第7頁，共41頁。Creation of GM-GMSGMGMS的產(chǎn)生GM-GMSNUMMISATURNCAMI QNPSEisenachNAOGreen Book第8頁，共41頁。Five GM-GMS Principle

6、s五項(xiàng)原則人員參與不斷改進(jìn)縮短制造周期標(biāo)準(zhǔn)化制造質(zhì)量第9頁，共41頁。Thinking Way精益概念第10頁，共41頁。Traditional WayGMS WayPeople are hired handsCurrent State is embracedFunction-driven organisationGo to Office & GuessKnowing OrganisationQuality seen as a functionHide MistakesEgo-driven leadersComplex Sense - wastefulSpend time figuring o

7、ut itselfPeople are investment in mindsCurrent State is challengedCustomer-driven organisationGo To See & UnderstandLearning OrganisationQuality seen as a cultureLearn from MistakesProcess-driven leadersCommon Sense - simpleSpend time figuring out enemy Purpose of GMS is to make lean-thinking People

8、 & lean Processes to deliver lean Results for the Customer第11頁，共41頁。System Position系統(tǒng)所在的位置第12頁，共41頁。Goal Categories目標(biāo)種類 Safety安全People人員發(fā)展Quality質(zhì)量 Responsiveness響應(yīng) Cost成本How WE are MEASURED如何衡量我們的業(yè)績第13頁，共41頁。Plant Performance Score Card工廠績效考核卡第14頁，共41頁。Goals目標(biāo) =Method方法 =People Involvement人員參與 -Peo

9、ple Company人員參與的公司 Continuous Improvement Company持續(xù)改進(jìn)的公司Standard-ization 標(biāo)準(zhǔn)化Built In Quality 制造質(zhì)量ShortLeadtime縮短制 造周期Strong Leadership 強(qiáng)有力的領(lǐng)導(dǎo)GMS Supports Attaining Our Goals GMS 支持我們達(dá)到目標(biāo)Safety安全 People人員 Quality質(zhì)量 Responsiveness響應(yīng) Cost成本GM-GMS第15頁，共41頁。GMS StructureGoals目標(biāo)NAAPOPrinciples原則Core Requi

10、rements核心要素(calibration statements)Tools工具Tools工具Elements原理LAAMGMEMethods標(biāo)準(zhǔn)Tools工具Tools工具GlobalMust be Global Common to Have ONE GM-GMS必須是全球共同的一個(gè)GM-GMS第16頁，共41頁。Structure Explanation 結(jié)構(gòu)說明Goals目標(biāo)Principles 原則Elements 要素CoreRequirements 核心要求Tools 工具Goals: Describe the primary state which thecorporatio

11、n strives to achieve. Reaching thesegoals leads to the complete success of ourcompany 目標(biāo)：描述公司努力要達(dá)到的狀態(tài)。達(dá)到這些目標(biāo)可引導(dǎo)公司走向成功Principles: The leading concepts / philosophyof the company which guide our activities inthe pursuit of success for our company.原則：公司的主導(dǎo)理念，可指導(dǎo)我們的行為，追求公司的成功。Elements: Main strategies w

12、ithin each Principle,which must be implemented to ensure successof each principle. 要素：每個(gè)原則的主要策略，實(shí)施策略是每個(gè)原則成功的保證。Core requirements: Details which must befollowed to ensure the success of eachElement 核心要求：實(shí)現(xiàn)每個(gè)要素成功必須要遵循的細(xì)節(jié)Tools: Methods, activities and systemswhich are used to support the CoreRequiremen

13、ts. They may be used to support multiple Core Requirements. 工具：方法，行動(dòng)和體系用來支持核心要求，也可能用來支持多重的核心要求。Be the Safety Benchmark 確定安全基準(zhǔn)PeopleInvolvement人員參與Health and Safety Priority 健康和安全第一24 Hr. Incidentfollow up 24小時(shí)事故跟蹤Green Cross 綠十字第17頁，共41頁。GMS Principle and ElementGMS 原則與要素第18頁，共41頁。Each of the 5 GMS

14、Principles is supported by key elements. There are 33 GM-GMS Elements. GMS Principles GMS ElementsGlobal Manufacturing Goals of Safety, People, Quality, Responsiveness & Cost are supported by the GMS Principles. There are 5 GMS Principles: People Involvement 1.Vision/Mission5.Team Concept2.Values6.P

15、eople Involvement3.Health & Safety Process 7.Open Communication4.Qualified People8.Shop Floor ManagementStandardization9. Workplace Organization10. Management By Takt Time11. Standardized Work12. Visual ManagementBuilt-In Quality13. Product Quality Standards 17.Quality System Management14.Manufactur

16、ing Process Validation16.Quality Control & 15.In-Process Verification Feedback/FeedforwardShort Lead Time18. Simple Process Flow 23. Temporary Material 19. Small Lot Packaging Storage - CMA 20. Fixed Period Ordering 24. Pull Systems System/Order Parts 25. Level Vehicle Order Schedules 21. Controlled

17、 External Trans. 26. Supply Chain Management22. Scheduled Shipping/ReceivingContinuous Improvement27.Problem Solving31. Early DFM/DFA28.Business Plan Deployment32. Total Maintenance System29.Andon Concept 33. Continuous Improvement30.Lean Design of Facilities, Equipment, Tooling and Layout第19頁，共41頁。

18、 People Involvement Elements人員參與原理Vision，Value and Culture Priority愿景，價(jià)值觀與企業(yè)文化Mission 使命Health & Safety Priority 健康與安全第一Qualified People合格的人員People Support System/Team Concept 人員支持體系/團(tuán)隊(duì)精神People Involvement人員參與Open Communication Process開放式溝通流程Shop Floor Management車間現(xiàn)場(chǎng)管理 Definition: The process whereb

19、y our employees are engaged as enthusiastic participants and valued contributors to our success.定義：員工憑之熱情工作的程序和評(píng)估貢獻(xiàn)的程序Purpose: People are our Companys most valuable asset. Our people and our company culture represent the healthy roots and trunk which support the methods and tools of our plant. Witho

20、ut involved people, the methods and tools will not be successful.目的：人員是我們公司最寶貴的資產(chǎn)。我們的人員和我們的公司文化代表的是健康的根和樹干，可以用來支持我們這顆大樹的方法和工具。沒有人員的參與，就不會(huì)有方法和工具People Involvement人員參與Leaves = ToolsSOSStandardized WorkTrunk = PeopleProblem SolvingTPMRoots = CultureOne Pc.Flow5SBranches = Methods第20頁，共41頁。Green cross S

21、heetManufacturing Safety Performance WallBPD- Group Information Board Nerve Center - Group Leader MeetingArea BPD Visualization 第21頁，共41頁。Safety Lockout ProcedureGroup AreaOpen Office Flexibility Chart第22頁，共41頁。Standardization標(biāo)準(zhǔn)化Definition: Standardization is a dynamic process by which we set standa

22、rds of terminology, principles, methods, and processes within our organization. 定義：標(biāo)準(zhǔn)化是我們?cè)谧约旱慕M織中建立術(shù)語、原則、方法和程序標(biāo)準(zhǔn)的動(dòng)態(tài)的程序Purpose: The purpose of standardization is to stabilize, so as to achieve a base from which to grow and improve.目的：標(biāo)準(zhǔn)化的目的是為了達(dá)到穩(wěn)定以完成可以用來發(fā)展和改進(jìn)的基礎(chǔ)Standardization標(biāo)準(zhǔn)化WorldClass世界級(jí)Continuou

23、s Improvement不斷改進(jìn)Change改變 Standardization Elements標(biāo)準(zhǔn)化原理Management by Takt Time時(shí)間管理Workplace Organization工作現(xiàn)場(chǎng)管理Standardized Work標(biāo)準(zhǔn)化作業(yè)Visual Management目視化管理第23頁，共41頁。Safety VisualizationVisual Management- Air, water flowTeam member operation certification boardWorkplace organization- 5S 第24頁，共41頁。 Fix

24、ed Position Stop ( Marked On Shop Floor )Trim Line Final Process AreaCode 1 Control Process第25頁，共41頁。 Built-In Quality Elements制造質(zhì)量原理Product Quality Standards產(chǎn)品質(zhì)量標(biāo)準(zhǔn)Manufacturing Process Validation 制造工藝驗(yàn)證In-Process Control & Verification 流程中控制和驗(yàn)證Quality Feedback/Feedforward質(zhì)量反饋/前饋Quality System Manag

25、ement質(zhì)量體系管理Built In Quality制造質(zhì)量Definition: The methods by which quality is built into the manufacturing process, in a way that defects are prevented, detected, and countermeasures are implemented to prevent recurrence.定義：在制造過程中制造質(zhì)量、防止缺陷、檢測(cè)和實(shí)施防止問題再次發(fā)生的對(duì)策的方法Purpose: To ensure that defects are not pass

26、ed to the customer.3目的：確保有缺陷的產(chǎn)品不會(huì)達(dá)到客戶手中Do not不要Accept允許Build制造Ship傳遞a Defect! 缺陷Solve problems through teamwork!通過團(tuán)隊(duì)合作解決問題Satisfy your Customer. . . 使客戶滿意The Built-In-Quality Motto制造質(zhì)量格言第26頁，共41頁。In house stamping panel inspection Boundary Sample - Visualization CARE Line Quality CheckError Proofing

27、第27頁，共41頁。QCOS Trend Control SheetANDON-Quality CallFinal Process Area Code 1 Control ProcessQCOS Sheet第28頁，共41頁。Short Lead Time縮短制造周期Definition: The movement of product or material in the right quantity, at the right time, to the right location, with the right equipment, using the shortest lead tim

28、e and the lowest possible cost for both the supplier and the customer.定義：讓供應(yīng)商和客戶在最短的制造周期內(nèi)用盡可能低的成本，在正確的地點(diǎn)使用正確的設(shè)備生產(chǎn)出正確的數(shù)量的產(chǎn)品或物料的運(yùn)作Purpose: To achieve customer enthusiasm by delivering the customer his/her product more quickly, while maintaining good quality. Ultimately, our Company benefits through co

29、st reduction and increased customer loyalty. 目的：保證優(yōu)質(zhì)質(zhì)量的同時(shí)，通過更快傳遞客戶產(chǎn)品來獲得客戶熱誠。最終，我們的公司會(huì)受益于降低的成本和提升的客戶忠誠。 Short Lead Time Elements 縮短制造周期要素Small Lot Packaging小包裝Fixed Period Ordering System 固定周期訂單體系Controlled External Transportation受到控制的外部交通Simple Process Flow簡單的流程Scheduled Shipping/Receiving有計(jì)劃的運(yùn)送/接收T

30、emporary Material Storage臨時(shí)物料儲(chǔ)存Internal Pull/Delivery內(nèi)部拉動(dòng)/運(yùn)送Level Vehicle Order Schedules水平車輛訂單計(jì)劃Supply Chain Management供應(yīng)鏈管理long lead-timeshort lead-time 第29頁，共41頁。Material Andon Light BoardKANBAN PostKanbanMaterial ANDON第30頁，共41頁。Continuous Improvement不斷改進(jìn)Definition: A process based on standardiza

31、tion, whereby improvement is made, through a series of small improvements.定義：一個(gè)基于標(biāo)準(zhǔn)化，通過一系列小的改進(jìn)來達(dá)到改進(jìn)的程序。Purpose: To always advance ahead towards an ever more challenging target and make progress in Safety, People Involvement, Quality, Responsiveness, and Cost through the elimination of waste. 目的:不斷向前

32、挑戰(zhàn)更多的目標(biāo)并且通過減少浪費(fèi)在安全、人員參與、質(zhì)量、響應(yīng)和成本方面取得進(jìn)步 Continuous Improvement Elements不斷改進(jìn)要素Problem Solving 問題解決Business Plan Deployment 業(yè)務(wù)計(jì)劃部署Andon Concept 暗燈原理Lean Design of Facilities, Equipment, Tooling and Layout 設(shè)施、設(shè)備、工具和平面布置的精益設(shè)計(jì)Early Manufacturing and Design Integration (DFM/DFA) 制造和設(shè)計(jì)的早期結(jié)合（制造能力設(shè)計(jì)、裝配設(shè)計(jì)）Tota

33、l Maintenance System/Total Productive Maintenance 全員維護(hù)體系/全員生產(chǎn)性維修Continuous Improvement Process 持續(xù)改進(jìn)流程The diagram above shows how each time an improvement is implemented, it creates temporary instability. There will be a short period of instability until new standards are set, and applied. Only once

34、the situation is truly stable, can new improvements be implemented.上面這張圖表顯示出每次改進(jìn)之后，都會(huì)帶來暫時(shí)的穩(wěn)定。而后會(huì)有一段短時(shí)間的不穩(wěn)定，直到建立并應(yīng)用新的標(biāo)準(zhǔn)。只有當(dāng)情況真正穩(wěn)定了，新的標(biāo)準(zhǔn)才能實(shí)施。改進(jìn)改進(jìn)改進(jìn)標(biāo)準(zhǔn)化標(biāo)準(zhǔn)化標(biāo)準(zhǔn)化標(biāo)準(zhǔn)化第31頁，共41頁。ANDON BoardSGM Line Balance Wall Pilot Area ( Building Line Balance Wall ) Creform Assembly Aid第32頁，共41頁。GMS In SGM全球制造體系在上海通用汽車第33頁，

35、共41頁。My Understanding of GMSExperience ShareQ&A第34頁，共41頁。Thanks!第35頁，共41頁。上海通用汽車的宗旨依靠一支訓(xùn)練有素、富有使命感和團(tuán)隊(duì)精神的員工隊(duì)伍，貫徹精益管理原則，注重不斷學(xué)習(xí)和積極創(chuàng)新。安全地為顧客提供高質(zhì)量的產(chǎn)品和服務(wù)，使上海通用汽車成為面向二十一世紀(jì)，國內(nèi)領(lǐng)先、在國際上有競爭力的汽車公司”。上海通用汽車的宗旨中包含愿景、使命與方法：愿景：使上海通用汽車成為面向二十一世紀(jì)，國內(nèi)領(lǐng)先、在國際上有競爭力的汽車公司使命：安全地為顧客提供高質(zhì)量的產(chǎn)品和服務(wù)方法：依靠一支訓(xùn)練有素、富有使命感和團(tuán)隊(duì)精神的員工隊(duì)伍，貫徹精益管理原則，

36、注重不斷學(xué)習(xí)和積極創(chuàng)新。第36頁，共41頁。Shanghai General Motors Core Values 上海通用汽車的核心價(jià)值以客戶為中心 Customer Focus以滿足客戶需求的程度作為衡量工作成效的標(biāo)準(zhǔn) We will measure our performance by determining whether it has met customers satisfaction安全 Safety充分關(guān)注人的安全和健康以及環(huán)境安全 We will pay full attention to peoples safety and health as well as the sa

37、fety of environment充分授權(quán)的團(tuán)隊(duì)合作 Empowered Teamwork創(chuàng)造良好氛圍，積極發(fā)揮員工與合作伙伴特點(diǎn)、 長處 We will promote an environment in which the unique qualities of each employee and partner can be employed to win.誠信正直 Integrity成為值得信賴的公司和員工 We will be a trustworthy organization and employee持續(xù)改進(jìn)與創(chuàng)新 Continuous Improvement & Innov

38、ation更好、更快、更有效，更多運(yùn)用新思維 We will do things better, faster, more effective and implement more new ideas第37頁，共41頁。People Involvement Elements 1Corporate Vision, Values, & Cultural PrioritiesDefinition: The Corporations desired state as well as attitudes, mindsets, beliefs, and behaviors each of which is

39、 critical to the success of the organization.Purpose: To guide individual behavior and organizational decisions, creating a process and results focused culture.MissionDefinition: A local statement that conveys a mental image of the goal or desired state for a specific plant or function.Purpose: To m

40、otivate/inspire people to act and help the entire workforce visualize, understand, and relate to the organizations competitive goals and objectives.第38頁，共41頁。People Involvement Elements 2Health and Safety PriorityDefinition: Implementation of behaviors, actions, policies, and practices that help our

41、 employees realize a healthy, injury free environment.Purpose: To ensure we protect the well being of our people through actions consistent with the belief that safety is our overriding priority and all accidents are preventable.Qualified PeopleDefinition: People at all levels of the organization that possess the required profile and skills to perform, thrive, and grow within a competitive manufacturing environment.Purpose: To ensure the best possible fit of peoples abilities with the expectations of the competitive manuf