精益制造概括

OverviewLeanManufacturing精益制造概括Itisaintegratedsystemofmutuallydependentstrategiesthatwhencombinedtogethermaximizeoperatingperformancebyeliminationofwastefulmanufacturingpractices.它是通過消除浪費(fèi)性制造來達(dá)到最大運(yùn)營業(yè)績的相互依賴的戰(zhàn)略綜合集成系統(tǒng)。Notaprogram!不是一個(gè)項(xiàng)目！Notaproject!也不是一個(gè)工程！Notanevent!不是一個(gè)事件！Whatis“Lean”Manufacturing?精益制造是什么？Whatis“Lean”Manufacturing?精益制造是什么？Whatarethe“objectives”ofLeanManufacturing?什么是精益制造的目的？Achievementofbusinessgoalsinsafety,quality,responsiveness,costanddeliveryby:達(dá)到安全,質(zhì)量,響應(yīng),成本及運(yùn)輸?shù)臉I(yè)務(wù)目標(biāo)，通過：

makingonlywhatisneeded僅需要時(shí)制造

providingonlywhenneeded提供僅僅需要的

involvingemployees員工參予

focusingoncontinuousimprovement致力于持續(xù)改善

exposing&solvingproblemsrapidly快速暴露和解決問題

makingthestatusobvious使?fàn)顟B(tài)明顯

eliminatingconstraintsandbottlenecks消除限制和瓶頸

improvingfactoryflow改善工廠流程

LeanWhatarethe“objectives”?目的是什么？1.Craft手工藝-Oneproductmadecompleteby1person每人生產(chǎn)一件產(chǎn)品-Eachproductunique每一件產(chǎn)品都是唯一的-Partsnotinterchangeable零部件不能互換-Highquality,butexpensive高質(zhì)量,但價(jià)格昂貴

2.BatchManufacturing批量生產(chǎn)-Oneproductmadebymanypeople多人生產(chǎn)一件產(chǎn)品-Standardizedparts標(biāo)準(zhǔn)化的零部件-Partscouldbeinterchanged零部件可以互換-Assemblersmovetoproduct產(chǎn)品由零件組裝3.AssemblyLine/Mass裝配線/規(guī)模-Largemassofpeopleinvolved由大量的人參與-Vehiclesmovetoassembler運(yùn)輸工具運(yùn)送到裝配者-Lowskilllevel低水平技能-Acceptableleveldefects可接受一定水平的缺陷-Profit,delivery,quality利潤,交付,質(zhì)量4.LeanManufacturing精益生產(chǎn)-Workcells工作單元-J.I.T.components

J.I.T元件-Multifunctionalskilllevel多技能水平-Zerodefects零缺陷-Quality,delivery,profit質(zhì)量,交付,利潤5.FutureManufacturing未來制造BriefHistoryofManufacturing生產(chǎn)方式發(fā)展史LEARLeanManufacturingSystemTransforming精益制造系統(tǒng)轉(zhuǎn)變工廠精益制造的關(guān)鍵性概念零浪費(fèi)消除任何體系中存在的不必要的浪費(fèi)。簡言之，其目的在于力求完善。穩(wěn)定的生產(chǎn)環(huán)境只有在穩(wěn)定的生產(chǎn)環(huán)境中才能生產(chǎn)出優(yōu)質(zhì)的產(chǎn)品。存在的問題即是種種不穩(wěn)定性。對于這些不穩(wěn)定性必須迫其迅速出現(xiàn)，并永久地解決。穩(wěn)定的生產(chǎn)環(huán)境的目標(biāo)為：標(biāo)準(zhǔn)化、連貫性、預(yù)見性及重復(fù)性?？蛻舻睦瓌?dòng)/即時(shí)體系產(chǎn)品生產(chǎn)必須符合客戶的需求。僅生產(chǎn)客戶想要的產(chǎn)品，并按時(shí)發(fā)運(yùn)優(yōu)質(zhì)貨物。這種方法可以充分發(fā)揮公司內(nèi)各種資源的優(yōu)勢，為公司帶來更可觀的經(jīng)濟(jì)效益，并確保工作的安全。ThedifferentroleswithintheContinuous

ImprovementGroup持續(xù)改善團(tuán)隊(duì)不同的角色ExecutiveManagement執(zhí)行管理層DeploymentChampion實(shí)施倡導(dǎo)者M(jìn)asterBlackBelt黑帶大師BlackBelt黑帶LeanFacilitatorLEAN推廣人MajorResponsibilities主要責(zé)任WorkwithPlantManagementteamtoidentifyLeanprojectopportunities和公司管理層一道識別LEAN項(xiàng)目機(jī)會Co-ordinatethecreation,monitorandreportprogressofleanroadmapsandactivity協(xié)調(diào)生產(chǎn)、監(jiān)控及報(bào)告LEAN路線圖及LEAN活動(dòng)的進(jìn)展情況FacilitateLeanworkshopsinlinewithCorporategoals/BusinessMetrics和公司目標(biāo)/業(yè)務(wù)目標(biāo)/業(yè)績保持一致地推動(dòng)LEAN車間Makesignificantcontributionstotheplantfinancialsavingsbycompletingworkshopsandclosingoutfollowupactions通過車間實(shí)施和關(guān)閉跟進(jìn)行動(dòng)來為公司財(cái)務(wù)節(jié)省作出較大貢獻(xiàn)LeanFacilitator

Jobspecification

LEAN推廣人的工作說明MajorResponsibilities主要責(zé)任WorkwithPlantManagementteamtoidentifyLeanprojectopportunities和公司管理層一道識別LEAN項(xiàng)目機(jī)會Co-ordinatethecreation,monitorandreportprogressofleanroadmapsandactivity協(xié)調(diào)生產(chǎn)、監(jiān)控及報(bào)告LEAN路線圖及LEAN活動(dòng)的進(jìn)展情況FacilitateLeanworkshopsinlinewithCorporategoals/BusinessMetrics和公司目標(biāo)/業(yè)務(wù)目標(biāo)/業(yè)績保持一致地推動(dòng)LEAN車間Makesignificantcontributionstotheplantfinancialsavingsbycompletingworkshopsandclosingoutfollowupactions通過車間實(shí)施和關(guān)閉跟進(jìn)行動(dòng)來為公司財(cái)務(wù)節(jié)省作出較大貢獻(xiàn)LeanFacilitator

Jobspecification

LEAN推廣人的工作說明Weknowleanworks,sowhyarewenot

having

moresuccess?

我們知道LEAN怎樣工作，為什么我們沒有取得更大的成功？Exercise-1SuccessFactorsforLeadingChange領(lǐng)導(dǎo)改變的成功因素Vision愿望Skills技巧Incentives激勵(lì)Resources資源ActionPlan行動(dòng)計(jì)劃Change改變SkillsIncentivesResourcesActionPlanConfusion糊涂VisionIncentivesResourcesActionPlanAnxiety焦慮VisionSkillsResourcesActionPlanNoChange無變化VisionSkillsIncentivesActionPlanFrustration受挫VisionSkillsIncentivesResourcesFalseStarts錯(cuò)誤的開始始SuccessFactorsforLeadingChange領(lǐng)導(dǎo)變化的的成功因素素Past過去Internal/self內(nèi)部/自己External/

environment外部環(huán)境Future將來Explore開拓Resist抵抗Commit承諾Deny否定Re:Scott&Jaffe,1989“Anotherflavourofthemonth””嚼上另一種種味道“ReadytoDoIt”準(zhǔn)備做“Everyoneelsehasaproblembutme!”除了我每每個(gè)人都有問問題“Starttoseeit”開始看一看看PersonalChangeJourney個(gè)人的變化化歷程EXPECTRESISTANCE:希望的抵抗抗“Thedevilyouknowisbetterthantheoneyoudon’t!”你知道的壞壞事情比你你不知道的的壞事情要要好Openresistanceisalwayseasiertodealwiththanpassiveresistance.公開的抗拒拒比不公開開抗拒容易易處理Inordertomanageresistanceandreduceit,youhavetoknowwhatitisbeforeyoucanchangeit.為了管理和和降低抵抗抗,在你改變它它之前你必必須知道它它是什么？？EXPECTRESISTANCE所希望的抵抵抗PeoplearetheRealAssets人是真正的的財(cái)富PEOPLE人Needtoknow&understandbusinessobjectives&goals需要知道和和理解業(yè)務(wù)務(wù)目標(biāo)及目目的Needtoknowhowthiswillrelatetotheirroleintheorganization需要知道他他們在組織織中的角色色相關(guān)程度度“Whatwillhappentothem?”對他們將會會發(fā)生什么么？NeedtoknowwhatchangestheywillberequiredtoMake需要知道他他們需要作什么變化化Needtoknowwhatnewskillstheywillrequiretodothejob做工作時(shí)需需要知道他他們需要什什么技能ByRESPECTINGpeoplewecancreatetheCLIMATEFORCHANGE通過尊重人人才我們就就能夠產(chǎn)生生一個(gè)變化化的環(huán)境氣氣候LeanJourneyLeanvilleorbust!NOUTURNStrategicDirection戰(zhàn)略方向TrainingProcess培訓(xùn)過程Deployment推廣LeanOverview總結(jié)精益之路Whyarewehere?為何我們在在這里ToLearn去學(xué)習(xí)15LeanToolContents

15精益工具內(nèi)內(nèi)容TheLeanAssessmentToolcontainsfifteenattributeworksheetsdescribingtheLeanbestpracticesthatconstitutethefollowingAttributesofLeanmanufacturing:評審工具包包含15個(gè)個(gè)要素工作作表，描述述組成下列列精益生產(chǎn)產(chǎn)要素的示示例：1.STANDARDWORK標(biāo)準(zhǔn)化作業(yè)業(yè)8.LEANCONTAINERSANDPACKAGING精益容器及及包裝2.WORKPLACEORGANISATION(5S’s)車間組織（（5S）9.ANDON3.AUDIO&VISUALCONTROLS聲音及目視視控制10.INPROCESSQUALITYAUDIT制程質(zhì)量審審核4.OPERATIONCERTIFICATION操作保嫜11.CONTINUOUSIMPROVEMENTPROCESS(Kaizen)持續(xù)續(xù)改改善善過過程程5.INTERNALPULL&MATERIALCONVEYANCE12.PROBLEMSOLVING(PDCA)用PDCA解決決問問題題內(nèi)內(nèi)部部拉拉動(dòng)動(dòng)及及物物料料運(yùn)運(yùn)輸輸6.EXTERNALLPULL&TRANSPORTATIONSYSTEM13.TOTALPRODUCTIVEMAINTENANCE(TPM)外部部拉拉動(dòng)動(dòng)及及運(yùn)運(yùn)輸輸系系統(tǒng)統(tǒng)全全員員性性生生產(chǎn)產(chǎn)維維護(hù)護(hù)7.CENTRALMATERIALSTORAGE14.ERRORPROOFING防錯(cuò)錯(cuò)中央央物物料料儲儲存存15.QUICKCHANGEOVER(SMED)快速速換換模模HigherValueStandards更高高的的價(jià)價(jià)值值標(biāo)標(biāo)準(zhǔn)準(zhǔn)Inreality...現(xiàn)實(shí)實(shí)中中......itisnot:它不不是是...Insteaditis:取而而代代之之的的是是:JIT/17(Cost)+(Profit)=(SellingPrice)成本本+利潤潤=賣價(jià)價(jià)(SellingPrice)-(Cost)=(Profit)賣價(jià)-成本=利潤增值”的的含義增值”的的含義1在改充產(chǎn)產(chǎn)品的根根本性質(zhì)質(zhì)時(shí)，即即為對產(chǎn)產(chǎn)品增加加了價(jià)值值。例如如：截取取一段鋼鋼質(zhì)卷材材，經(jīng)過過沖壓后后制成支支架；或或如：將將一把椅椅子的兩兩只座墊墊組裝到到一起。。2其他的東東西即為為非增值值的產(chǎn)品品或浪費(fèi)費(fèi)。兩種類型型的浪費(fèi)費(fèi)：第一種——或稱“必必要”浪浪費(fèi)——為使產(chǎn)品品接近客客戶的要要求而必必須進(jìn)行行的非增增值行為為。例：發(fā)運(yùn)并不不增加價(jià)價(jià)值，卻卻又是必必需的。。第二種——或稱“不不必要””浪費(fèi)——是指那種種我們現(xiàn)現(xiàn)在就可可以合并并、減少少或消除除的非增增值行為為。零浪費(fèi)意意思是：將第一類類浪費(fèi)轉(zhuǎn)轉(zhuǎn)化為第第2類。合并、減減少或者者消除第2類浪費(fèi)。。WasteWalk“The7Wastes””浪費(fèi)行走走”7種浪費(fèi)7種浪費(fèi)等待過量生產(chǎn)產(chǎn)返工移動(dòng)過量加工工庫存運(yùn)輸TypeofWaste浪費(fèi)類型型Description描述1.WasteofOverProduction:Producingovercustomerrequirements,producingunnecessarymaterials/products,orproducingtosoon.過量生產(chǎn)產(chǎn)的浪費(fèi)費(fèi)生生產(chǎn)多多于客戶戶需求，，生產(chǎn)不不必要的的材料/產(chǎn)品或生生產(chǎn)多一一點(diǎn)2.WasteinWaiting(Time):Timedelays,idletime(nonvalueaddedtime)等待浪費(fèi)費(fèi)時(shí)時(shí)間延遲遲，呆時(shí)時(shí)間(不增值)3.WasteinTransportation:Multiplehandling,delayinmaterialhandling,unnecessaryhandlingortransportation(nonvalueaddedconveyance).運(yùn)輸浪費(fèi)費(fèi)多多次搬搬運(yùn)，材材料處理理延遲，，不必要要搬運(yùn)或或運(yùn)輸（（非增值值運(yùn)輸））4.WasteinProcessing:Unnecessaryprocessing,stepsorworkelements/procedures(nonvalueaddedwork).加工的的浪費(fèi)費(fèi)不不必必要的的加工工，步步驟或或工作作單元元，程程序（（不增增值））5.WasteofInventory:Producingunnecessaryinventory,holdingorpurchasingunnecessaryinventory,RS,WIP,FG.庫存的的浪費(fèi)費(fèi)產(chǎn)產(chǎn)生不不必要要的庫庫存，，保留留或采采購不不必要要的庫庫存，，原材材料、、WIP、成品品6.WasteofMotion:Wasteofmotions,excessivehandling,unnecessarystepsofmotion(nonvalueaddedmotions).移動(dòng)浪浪費(fèi)移移動(dòng)動(dòng)浪費(fèi)費(fèi)，過過度搬搬運(yùn)，，不必必要的的移動(dòng)動(dòng)步驟驟（非非增值值）7.WasteofProducingFailures:Correctionoferrorsorrework,scrap(qualityproblems)產(chǎn)生失失敗的的浪費(fèi)費(fèi)錯(cuò)錯(cuò)誤校校正、、返工工、報(bào)報(bào)廢（（質(zhì)量量問題題）WasteWalk““The7Wastes””Definitions浪費(fèi)行行走”7種浪費(fèi)費(fèi)”定義三種不不同的的公司司3第三等等級的的公司司每個(gè)人人都隨隨處亂亂扔垃垃圾而而沒有有人揀揀起來來第二等等級的的公司司有專人人將別別人亂亂扔的的垃圾圾揀起起來第一等等級的的公司司每個(gè)人人都自自覺維維護(hù)環(huán)環(huán)境的的清潔潔，沒沒人亂亂扔垃圾。。存在的的問題題●工廠廠變得得愈加加擁擠擠；●在員員工中中間一一些不不必要要的儲儲藏箱箱子、、料架架、貨貨架等等堆積積成山山，阻阻礙了了交流流；●時(shí)間間在尋尋找零零件和和工具具中浪浪費(fèi)掉掉；●過多多的現(xiàn)現(xiàn)場物物品隱隱藏了了其他他生產(chǎn)產(chǎn)問題題；●不需需要的的零件件和設(shè)設(shè)備使使得工工藝流流程更更困難難；KeyCharacteristicsina5SEnvironment5S環(huán)境的的關(guān)鍵鍵特征征Aneasilyunderstandablelayout簡單易易懂的的布局局圖Anopenview視野開開放Acleanatmosphere清潔的的環(huán)境境Activemanagement靈活的的管理理DAILYACTIVITY日常性性活動(dòng)動(dòng)5S:WorkplaceOrganisation工場組織TheFoundationoftheVisualWorkplace建立車車間目目視管管理基基礎(chǔ)1S-SORT-----------------------------Eliminatewhatisnotneeded整理(分類)除去不不需要要的東東西2S-STRAIGHTEN--Aplaceforeverythingandeverythinginitsplace整頓(系統(tǒng)安安排)物有其其位物物歸其其位3S-SHINE-------------Cleaningandlookingforwaystokeepitclean清潔清清潔潔并設(shè)設(shè)法保保持清清潔4S––STANDARDISE------------Maintainandmonitorthefirst3S’’s標(biāo)準(zhǔn)化化保保持并并監(jiān)控控前三三個(gè)S5S-SUSTAIN------------------------------------Sticktotherules5S-素養(yǎng)形形式式規(guī)則則85sIMPLEMENTATION5S實(shí)施ContinuouslyimproveourcompetitivepositionbydeployingkeyLeanpracticesthatwill:通過應(yīng)用主主要的精益益實(shí)例來持續(xù)改改善我們的的競爭地位位：Organizetheworkplace工廠組織(5s)Enablestatusataglance(VisualManagement)建立一目了了然的狀況況（目視管管理）Eliminatewaste,redundanciesandnon-valueaddedpractices消除浪費(fèi)、、多余的及及不增值作作法IncreaseValueAddedWorkactivities增加增值工工作活動(dòng)Improvefloorspaceutilization提高面積利利用Improvedirectandindirectlaborefficiency提高直接和和間接勞動(dòng)動(dòng)力效率Reduceoperatingcosts降低營運(yùn)成成本Freefloorspacefornewbusiness為新業(yè)務(wù)釋放放面積EstablishJust-In-Time/PullSystems建立JIT拉動(dòng)系統(tǒng)Reduceinventory,WIPandFGI減少庫存WIP及成品庫存Improvefactoryflow(material,peopleandinformation)改善工廠流程程（材料、人人員及信息））Improveresponsiveness(MTTRandMTBF)提高響應(yīng)（平平均故障時(shí)間間及故障間隔隔時(shí)間）Enablebuild-in-station崗位做好品質(zhì)質(zhì)（一次做好好品質(zhì)）Solveandpreventproblems解決和預(yù)防問問題Levelandreducevariation均衡及降低變變異Engageandempowertheworkforce勞動(dòng)力參予及及授權(quán)LeanDeploymentGoals精益應(yīng)用目的的LeanLeanManufacturingSystemUtilizehands-onplantfloorresultsbasedcoretrainingworkshopstoaccelerateimplementationandunderstanding:基于主要的培培訓(xùn)車間利用用實(shí)習(xí)工廠(現(xiàn)狀)來加速實(shí)施和和理解：ValueStreamMapping價(jià)值流LeanManufacturingOverview精益制造全貌貌StandardizedWork/MethodsImprovement標(biāo)準(zhǔn)化工作及及方法改善Five‘‘S’:WorkplaceOrganization5S:工廠組織Audio&VisualManagement聲頻及目視管管理PracticalProblemSolving/PDCA實(shí)際問題解決決/PDCAJIT/PullSystems準(zhǔn)時(shí)化生產(chǎn)/拉動(dòng)系統(tǒng)TotalPreventive&PredictiveMaintenance(TPM)全面預(yù)防性和和預(yù)測性維護(hù)護(hù)Andon&ErrorProofingAndon及防錯(cuò)Identification&EliminationofWaste識別及消除浪浪費(fèi)MasterPlanning總體規(guī)劃LeanTrainingRoll-OutProcess:精益培訓(xùn)的滾滾動(dòng)過程Train:Executives,OperationsDirectors,PlantStaffs,SixSigmaBlackBelts,IndustrialEngineers,ManufacturingEngineersShopFloorLeaders,UnionLeaders,HourlyWorkforce培訓(xùn)：執(zhí)行總總裁、營運(yùn)總總監(jiān)、工廠管管理人員、6西格瑪黑帶、、工業(yè)工程師師、制造工程程師、車間主主管、工會領(lǐng)領(lǐng)導(dǎo)、計(jì)時(shí)工工Facilitatorscascadetrainingtoplantworkforce推廣者將培訓(xùn)訓(xùn)滾動(dòng)到員工工LeanEducationApproach精益教育方法法Direct指導(dǎo)ExecutiveSteeringCommittee行動(dòng)指導(dǎo)委員會

ProvideStrategicDirection提供戰(zhàn)略方向

ProvideResource提供資源

MakeDecisions做決定

MeetRegularly經(jīng)常碰頭(開會)GuideDeployment指導(dǎo)應(yīng)用Plan計(jì)劃HeadquartersLeanSupportTeam總部精益支持團(tuán)隊(duì)

ProvideTacticalDirection提供戰(zhàn)術(shù)方向

CoordinatePlanning協(xié)調(diào)計(jì)劃

DevelopTrainingMaterial開發(fā)培訓(xùn)材料

CoordinateTraining協(xié)調(diào)培訓(xùn)

DevelopOperatingStandards開發(fā)運(yùn)作標(biāo)準(zhǔn)

ProvideLeanExpertise提供精益專家

SupportImplementation支持實(shí)施

AssessProgress評估進(jìn)展Implement實(shí)施PlantLeanFacilitators工廠精益推廣者

Develop&IntegratePlans開發(fā)并有機(jī)結(jié)合計(jì)劃

ExecutePlans執(zhí)行計(jì)劃

ConductTraining開展培訓(xùn)

AssistImplementation幫助實(shí)施

LeanResidentResource精益必有資源

ConductAssessmentProcess進(jìn)行過程評估Establishastructuretodriveimplementationinacommonapproach.用同種方法建建立結(jié)構(gòu)（組組織）來驅(qū)動(dòng)動(dòng)完成LeanDeployment精益部署OwnerSubjectPurposeStandardRequirementsLinksOwnerSubjectPurposeStandardRequirementsLinksOwner所有者Subject主題Purpose目的Standard標(biāo)準(zhǔn)Requirements要求Links連接LearLeanPeopleEmpowerment人力授權(quán)LeanVision精益遠(yuǎn)景觀念念WellPreparedPeople準(zhǔn)備好人SelfDirectedWorkGroups自我指導(dǎo)工作作組Education&TrainingProcess教育培訓(xùn)過程程CommunicationProcess溝通過程Standardization標(biāo)準(zhǔn)化StandardizedWork標(biāo)準(zhǔn)化工作-Scrolling(MovingLine)滾動(dòng)（移動(dòng)線線）-WorkFlowDiagramming工作流程圖LevelMix&BuildRestrictions均衡產(chǎn)品系列列和制造限制制LineBalanceProcess線平衡過程WorkplaceOrganization(Five‘S’)工廠5S組織Audio&VisualControls聲頻及目視管管理OperationCertification操作證書QualitySystem質(zhì)量系統(tǒng)Andon(Build-In-Station)Andon（崗位做好））ErrorProofing防錯(cuò)ProductQualityStandards產(chǎn)品質(zhì)量標(biāo)準(zhǔn)準(zhǔn)In-ProcessControl&Verification制程控制和驗(yàn)驗(yàn)證QualitySystemManagement質(zhì)量系統(tǒng)管理理ContinuousImprovement持續(xù)改進(jìn)ContinuousImprovementProcess持續(xù)改進(jìn)過程程ProblemSolving/PDCA問題解決/PDCAJust-In-TimeSystem準(zhǔn)時(shí)化系統(tǒng)LevelSchedules&Volume平衡計(jì)劃及數(shù)數(shù)量ScheduledShipping/Receiving有計(jì)劃運(yùn)輸及及接收FixedPeriodOrderingSystem定期時(shí)訂購系系統(tǒng)LeanContainers&Packaging精益容器及包包裝Kitting&Sequencing成套及成系列列TemporaryMaterialStorage暫時(shí)材料存儲儲InternalPull&MaterialConveyance內(nèi)部拉動(dòng)及材材料運(yùn)輸ExternalPull&TransportationSystem外部拉動(dòng)及材材料運(yùn)輸SupplyChainManagement供應(yīng)鏈管理LeanDesigns精益設(shè)計(jì)LeanTools,Equipment&Fixtures精益工具，設(shè)設(shè)備及夾具LeanFacility&Layouts精益工廠&平面布置DesignForLean(DFL)為精益而設(shè)計(jì)計(jì)TotalPreventiveMaintenance全員預(yù)防維護(hù)護(hù)LeanLeadership精益領(lǐng)導(dǎo)LeanMasterPlanning精益總體規(guī)劃劃LeanPlanningTeam精益計(jì)劃團(tuán)隊(duì)隊(duì)LeanSteeringCommittee精益方向指導(dǎo)導(dǎo)委員會ShopFloorManagement車間管理ManagementByTakt節(jié)拍管理OperatingStandards操作標(biāo)準(zhǔn)LearLMSStrategies李爾精益制造造系統(tǒng)戰(zhàn)略GlobalMarket全球ChangingConditions不斷變化的情情況FierceCompetition激烈的競爭?CustomersExpect:顧客期望ShortLeadTimes短的時(shí)間周期期100%Quality質(zhì)量100％好Just-In-TimeDelivery及時(shí)化運(yùn)輸AnnualCostReductions每年的成本降降低StrategicCollaboration&Partnership戰(zhàn)略合作及伙伙伴Innovativesolutions創(chuàng)造性的方法法FlawlessPerformance無缺點(diǎn)績效SuperiorServiceandSupport更優(yōu)服務(wù)及支支持?ImprovedEmployeeSkillsRequired提高雇員技能能的需要Multi-Skilled多功能Flexible靈活WhyLean?為什么用精益益？GrowTheBusiness增長生意AchieveOurVision完成我們的遠(yuǎn)景Why?Why?為什么？SatisfyCustomers,Employees&Stockholders使客戶、雇員及股東滿意Why?Why?為什么？SafetyQualityResponsivenessCostsWhyLean?AchieveBusinessObjectives完成業(yè)務(wù)目標(biāo)Why?Why?為什么？EliminateWaste消除浪費(fèi)Why?Why?為什么？LeanStrategies李爾戰(zhàn)略Why?Why?為什么？WhyLean?為什么要做精精益？Howdowe…我們怎樣做takeittothenextlevel把它現(xiàn)狀帶到到下一階段growthebusiness增加生意reducecosts降低成本achievebusinessobjectives完成業(yè)務(wù)目標(biāo)標(biāo)satisfythecustomer滿足客戶makemoney賺錢engagetheworkforce員工積極參與與Howdowe我們怎樣做…Paintedinacorner!從一角涂起LeanManufacturingSystem精益制造系統(tǒng)統(tǒng)ValueStreamMapping價(jià)值流ProblemSolving問題解決SelfDirectedWorkGroups自我管理工作作團(tuán)隊(duì)VisualManagement目視管理WorkplaceOrganization工廠組織AndonSystemAndon系統(tǒng)ErrorProofing防錯(cuò)StandardizedWork標(biāo)準(zhǔn)化工作JITPullSystemJIT拉動(dòng)系統(tǒng)Kitting&Sequencing成套及成系列列SmallLotProduction小批批量量生生產(chǎn)產(chǎn)QuickSet-Up快速速設(shè)設(shè)置置LeadTime周期期時(shí)時(shí)間間HighCosts高成成本本QualityIssues質(zhì)量量問問題題LeanCompetition精益益競競爭爭ExcessInventory過量量庫庫存存Inefficiencies低效效率率CashFlow現(xiàn)金金流流Overtime加班班Uptime運(yùn)行行時(shí)時(shí)間間FloorSpace車間間面面積積ThisWayOut這是出口Dowhatwe’’vealwaysdone(itgotuswhereweare).做我我們們通通常?？偪傇谠谧鲎龅牡模ǎㄋ故刮椅覀儌兊降竭_(dá)達(dá)我我們們所所在在的的位位置置））Donothingnew,justworkharder.不做新東西，，只是工作努努力一些Dowhat’sbestfortheemployees.做對雇員最好好的事Dowhat’srightforthelongevityofthebusiness.做對生意的長長期性正確的的事Dowhatourcustomer’’swant.做我們客戶想想做的事BreakingTheBusinessAsUsual““DoLoop”打破經(jīng)常做循循環(huán)的常規(guī)Dowhatthestockholdersneed.做股東需要的的事LeanDowhatsomebodyelsedoes.做其他人也做做的事LeanManufacturingSystemBreakingTheBusiness打破常規(guī)FlowInformation信息流FlowMaterial材料流FullEmptyWalkInstallWalkWalkWalkInstall安裝InstallInstallFlowOperations操作FlowProcess過程流FIFOFIFOCashFlowIt’sallaboutflow!它都是關(guān)于流流程的現(xiàn)金LeanLink精益連接SixSigmaProjects6西格瑪項(xiàng)目Processes精益過程ReduceCost降低成本ImproveQuality改善質(zhì)量OnTimeDelivery及時(shí)運(yùn)輸EliminateWaste消除浪費(fèi)InvolvePeople人員參予SolveProblems解決問題PreventProblems預(yù)防問題ApplyLeanTechniques應(yīng)用精益技術(shù)術(shù)ContinuousImprovement持續(xù)改進(jìn)PullSystem拉式系統(tǒng)AndonErrorProofing防錯(cuò)TPM全面預(yù)防維護(hù)護(hù)FTQSystem一次成材SelfDirectedWorkGroups自我指導(dǎo)工作作組StandardizedWork標(biāo)準(zhǔn)化工作WorkBalancing工作平衡LevelScheduling計(jì)劃均衡PracticalProblemSolving實(shí)際問題解決決Five‘‘S”/WPO(WorkPlaceOrg.)5S（工廠組織））Audio&VisualControls聲頻及目視管管理LeanPlantLayouts精益工廠平面面布置LeanEquipmentDesign精益設(shè)備設(shè)計(jì)計(jì)LeanPartDesign精益零件設(shè)計(jì)計(jì)ProblemSolvingProjects解決問題的項(xiàng)項(xiàng)目StatisticalProcessControl統(tǒng)計(jì)過程控制制RootCauseAnalysis根原因分析VariationReduction減少變異DesignOfExperiments試驗(yàn)設(shè)計(jì)RegressionAnalysis回歸分析FMEA故障模式分析析GageR&RMeasurement重復(fù)性和再現(xiàn)現(xiàn)性測量CommonGoals共同目的LEANLeanLink精益連接StructuralBackbonePlantDesignProcessLayoutToolDesignEquipmentDesignConnectiveTissuePeopleSystemMaterialSystemQualitySystemMaintenanceSystemInformationSystemManagementSystemPolicyDeploymentWorkMethodsLEANTHINKINGDNACustomer客戶Transportation運(yùn)輸Receiving接收Transportation運(yùn)輸Storage儲存Inspection檢查Assembly總裝Shipping運(yùn)送Suppliers供應(yīng)商PhysicalCharacteristics實(shí)際特征“Howthingsaredesignedandbuilt”實(shí)際事情怎樣樣設(shè)計(jì)及制造造Strategic&TacticalCharacteristics戰(zhàn)略及戰(zhàn)術(shù)特特征“Howworkisdone”怎樣做工作TheLEARLeanManufacturingSystems李爾精益制造造系統(tǒng)

PeopleInvolvement&Ownership員工參與SupportTheOperator支持員工ContinuousImprovementMentality支持改善思想RelentlessFocusOnWaste無情地關(guān)注浪費(fèi)FocusOnFlow關(guān)注流程Flexibility:People&Processes靈活性:人員和制程QualityBuild-In-Station:control崗位做好品質(zhì):質(zhì)量控制StatusAtAGlance一目了然的狀況RapidResponse快速反應(yīng)FTQGates:Control&Communicate一次材:控制&溝通ProduceOnDemand需要時(shí)生產(chǎn)SmallLotProduction小批量生產(chǎn)QuickChangeCapability快速改變能力MachineAvailability機(jī)器利用率FrequentDeliveries頻繁傳送ReplenishOnDemand需要時(shí)補(bǔ)充APlaceForEverything…每件東西有一個(gè)地方EverythingInIt’sPlace每件東西放在自己的位置上ErrorPrevention/Avoidance防/避免錯(cuò)ProblemResolution&Prevention解決問題/防止問題SupplierInvolvement&Relationship供應(yīng)商參與及關(guān)系VariationReduction:Schedule,Volume,Mix減少變化:計(jì)劃、容量,品種Standardization:Jobs,Processes,Facilities標(biāo)準(zhǔn)化:工作,制程及設(shè)施LeadTimeReduction減少交貨時(shí)間CommonSystem:Nationally&Worldwide共同系統(tǒng)：國內(nèi)/際通用KeyFeatures主要特征

TeamConcept/Projects/Meetings團(tuán)隊(duì)概念及會議PilotTeams領(lǐng)導(dǎo)團(tuán)隊(duì)KaizenEvents持續(xù)改善DesignForLean(EaseofBuild)設(shè)計(jì)考慮精益(易于生產(chǎn))LeanInfrastructure(LeanLayouts)精益基礎(chǔ)(精益平面布置)LeanFacilities(FactoryDesign&Shape)精益設(shè)施(工廠設(shè)計(jì)及成形)OneTouchEquipmentDesign一次觸動(dòng)的設(shè)備設(shè)計(jì)Automation:IntelligentMachines自動(dòng)化:智能機(jī)器SynchronousOperatorAssistDevices同步員工幫助設(shè)施AndonSystem系統(tǒng)Decoupling&Buffering緩沖區(qū)StandardizedWork標(biāo)準(zhǔn)化工作Five‘S’Process5SSingleMinuteExchangeofDies(SMED)快速換模Kanban(AllTypes)看板WindowDelivery&Shipping窗口傳送及發(fā)貨TotalPreventiveMaintenance預(yù)防性維護(hù)PracticalProblemSolving實(shí)際問題解決ValueStreamMapping價(jià)值流程圖LeanManufacturingTrainingProcess精益制造培訓(xùn)過程SupplierDevelopment(Worldwide)供應(yīng)商開發(fā)FastVDPStrategy快速數(shù)據(jù)處理戰(zhàn)略KeyEnablers能動(dòng)因素SixSigma,Lean,orKaizenProject?項(xiàng)目LeanSixSigmaTilt-O-MeterTILTTILT傾斜的拍子Thisisafamiliarquestionthatisoftenaddressedbyorganizations.Infact,it’sthewrongquestion.Theseconceptsarenothingmorethantoolsinyourmanagementtoolbox.Youdon’’tfixawatchwithahammer,andyougetthesameresultswhenyoudeploySixSigma,Lean,andKaizenincorrectly.這是組織經(jīng)常常提出的類似似提問，事實(shí)實(shí)上這是一個(gè)個(gè)錯(cuò)誤的提問問，(6西格瑪、精益益和快速閃電電戰(zhàn))這些概念都只只是你的管理理工具箱中的的工具而已。。你沒有用錘錘子修表，在在你沒有正確確地采用6西格瑪、精益益和持續(xù)改善善閃電戰(zhàn)時(shí)，，你就會得出出同樣的(以下)結(jié)論。PeoplespendmonthsdrillingtheSixSigmaprocessandstatisticaltoolsintotheirheadsuntiltheylookateverysituationasaSixSigmaproblem.人們花了幾個(gè)個(gè)月時(shí)間動(dòng)腦腦筋鉆研6西格瑪過程及及統(tǒng)計(jì)工具,最后他們把每每一件事情都都看成6西格瑪問題Ontheotherextreme,somehighanxietymanagerstendtolookatverycomplexprocessvariationorlargescalestrategicproblemasAKaizenBlitzthatcanbefixedbytomorrow.另一個(gè)極端則則是一些非常常焦急的經(jīng)理理往往把非常常復(fù)雜的過程程變異或大規(guī)規(guī)模的戰(zhàn)略問問題看成是明明天就可以一一揮而蹴的一一次持續(xù)改善善閃電戰(zhàn)SixSigma,Lean,orKaizenProject?項(xiàng)目？Information信息Understanding理解Commitment承諾Action行動(dòng)DevelopAVision創(chuàng)造遠(yuǎn)景EstablishStructureForChange建立改變組織結(jié)構(gòu)ProvideLeanExpertise提供LEAN專門技術(shù)知識DefineStandards定義標(biāo)準(zhǔn)DevelopChampions開發(fā)冠軍TrainEntireOrganization培訓(xùn)組織DevelopActionPlans開發(fā)行動(dòng)計(jì)劃DevelopAShowcase開發(fā)范例包SeizeOpportunities抓住機(jī)會LeanLessons精益經(jīng)驗(yàn)Beware!注意Peoplearecomfortablewithextrainventory,WIP,manpowerandexcesscapacitybecauseitcovers-upsins.人們對特別庫庫存、WIP、人力及過量能能力感到舒適因?yàn)樗谏w了了過失Peoplewilladamantlydefendexcessesandwhattheycreated。人們總總是保保護(hù)超超量和和他們們所生生產(chǎn)的的東西西Resistancetochangeisinevitable.抵抗變變化是是必然然的Leantakespeopleoutoftheircomfortzonebecauseitexposesthings.LEAN把人從從其舒舒適區(qū)區(qū)帶出出來，，因?yàn)闉樗┍┞妒率虑?問題題Beprepared(plan)forredeploymentofdisplacedpeople.準(zhǔn)備替替代員員工的的再顧顧用計(jì)計(jì)劃Peopleissueswillarise.會引起起人力力問題題Somefolksviewtheword““Lean””as““Mean””.一些人人看““LEAN””不舒服服Ifwewerecapableandwillingtomakeproductivitygains…wewouldhavedoneitalready(I.E.talentdepth?Training?Politics?)正如我我們有有能力力并愿愿意通通過提提高生生產(chǎn)效效率的的話、、我們們就已已經(jīng)去去做到到了（I。E資深、培訓(xùn)訓(xùn)、問題））LinkingheadcountreductiondirectlywithLeanSystemsimplementationcouldspellproblems.把降低人頭頭直接和精精益系統(tǒng)聯(lián)聯(lián)系可能會會引發(fā)問題題LeanLESSONSLEARNEDBeware注意!DirectLaborProductivity直接人工生生產(chǎn)力HighLowDirectLaborManpower直接人工IndirectLaborManpower間接人工Sequencing排序Kitting成套Repacking在包裝FrequentDeliveries頻繁運(yùn)輸KaizenActivities持續(xù)改善BeforeandafterInternalLeanImplementation內(nèi)部精益實(shí)實(shí)施前后AfterInternalLeanImplementationBeforeInternalLeanImplementation內(nèi)部精益實(shí)實(shí)施前BeforeandafterExternalLeanImplementation外部LEAN實(shí)現(xiàn)前后DirectLaborProductivity直接人工生生產(chǎn)力HighLowDirectLaborManpower直接人力IndirectLaborManpower間接人工IndirectLaborProductivity間接人工生生產(chǎn)力StandardizeWorkloads標(biāo)準(zhǔn)化工作負(fù)荷StandardDeliveryRoutes標(biāo)準(zhǔn)化運(yùn)輸路線OrganizedStorage存儲有組織OutsourceStorage外部存儲SuppliersSequence供應(yīng)商排序SuppliersKit供應(yīng)商配套DownsizedPackaging減少包裝AfterExternalLeanImplementationBeforeExternalLeanImplementation外部精益實(shí)實(shí)施前OperatorInsideOutNot…OutsideIn!內(nèi)到外..不是外到內(nèi)內(nèi)

SupportForTheOperator支持員工Involvement參與Responsiveness快速反應(yīng)ProvideWhat’sNeededWhen需要時(shí)提供Needed(NotBefore)（而不是之前）PartPresentation傳送零件

OperatorOptimization優(yōu)化人員BalancedOperations平衡操作LevelMix平衡產(chǎn)品系列65%>ValueAddedContent增值65%

OperationEffectiveness有效操作JobDesign工作設(shè)計(jì)CompressWorkArea縮小工作區(qū)OperatorAssistDevices員工幫助設(shè)備

MinimizeWaste減少浪費(fèi)Motion移動(dòng)Processing加工Waiting等待StartHere開始點(diǎn)MaterialHandling材料處理Maintenance維護(hù)Inspection檢斂SupportPersonnel支持人員ThenHereSuppliers供應(yīng)商LogisticsProviders物流供應(yīng)者TransportationCompanies運(yùn)輸公司ThenHereEventProjectBlitzBlitzConnectingTheDotsProject

PullSystems拉動(dòng)系統(tǒng)WindowReceiving收料（定位）WindowShipping發(fā)貨（定位）PointOfUseDelivery靠近使用點(diǎn)MilkRuns平凡使用緩沖區(qū)Kitting&Sequencing成套及排序DollyExchange推車轉(zhuǎn)換ElectronicKanban電子看板KanbanCards看板卡片StandardDeliveryRoutes標(biāo)準(zhǔn)運(yùn)輸線路BufferingStrategy緩沖區(qū)戰(zhàn)略SmallLotProduction小批量生產(chǎn)SmallLotContainers小批量集裝箱StandardizedWork標(biāo)準(zhǔn)化工作LeveledMix均衡產(chǎn)品系列Five‘S’5SAudio&VisualControls目視化管理AndonSystemAndon系統(tǒng)ErrorProofing防錯(cuò)FixedPositionStops固定位置的停頓Decoupling坼分（工序）SelfDirectWorkGroups自我結(jié)果工作組TPMQuickChangeover快速換模PocketsofSuccessMarginalProgressShortTermApproachTotallyIntegratedSystemApproach全集成系統(tǒng)的方法

TheTrap!TheTrap!陷阱LeanProblemSolvingErrorProofingAndonQuickSet-UpJITTeamConceptQualityCirclesTPMVisualControlsThroughputTQMStandardizedWork5’sWasteKaizenVSMappingWhatnext?Let’stry...ClickClickWheelofFortuneLessonsLearnedCherrypickingdoesnotwo