如何做好異常管理課件

異常管理

AbnormalityManagement管理體系培訓

ManagementSystemTraining課程目的

Objectives–AbnormalityManagement認識異常并解釋快速反應的重要性解釋標準化作為目視化控制和異常管理的前提的重要作用.描述異常管理中領導者的角色.解釋為何異常的管理和對策對以下方面關系重大:問責維持持續(xù)改善本課程學習后,學員將能夠:

Aftersuccessfullycompletingthismodule,participantswillbeableto:2IdentifyabnormalitiesandexplaintheimportanceofrapidresponseExplaintheimportanceofstandardworkasaprerequisitetovisualcontrolsandabnormalitymanagementDescribetheleader’sroleinabnormalitymanagementExplainwhyabnormalitymanagementandcountermeasuresareessentialintermsof:AccountabilitySustainmentContinuousImprovement日程何為異常?目視化管理的本質(zhì)實施步驟異常管理問題對策的策略管理者的角色小結3AgendaWhatisanabnormality?EssenceofVisualControlsImplementationStepsAbnormalitymanagementCountermeasureStrategiesLeader’sroleSummary異常管理

AbnormalityManagement異常:與標準相偏離的部分異常的管理:針對異常的識別和快速響應的能力4Abnormality:ADeviationfromtheexpectedstandardsAbnormalityManagement:Theabilitytoidentifyandrapidlyrespondtoanabnormality為何要停線解決問題?邏輯偏離標準(糾正的浪費)原則提高質(zhì)量一次合格率策略停線解決問題

(決不接受缺陷流到下序)方法

在停線處解決問題并

改進支持體系提高解決問題的緊迫度鼓勵發(fā)現(xiàn)問題業(yè)績衡量指標質(zhì)量一次合格率生產(chǎn)產(chǎn)出,l每日停線次數(shù)評審結果

PerformanceMeasureFirst-timequality,productionoutput,linestop

timeauditresultsdaily精益工具安東(Andon)，自動化，標準化，問題解決，培訓

LeanToolsAndon,jidoka,standardisation,problemsolving,training控制方法目視化控制,標準化作業(yè),質(zhì)量審核

ControlmethodVisualcontrols,standardwork,qualityaudits效果減少系統(tǒng)浪費構建利于改進的相互協(xié)作的工作環(huán)境

ResultSystemwastereducedCostreducedCooperativeenvironmentForimprovement5PhilosophyDeviationfromStandard(WasteofCorrection)PrincipleGetqualityRightFirstTimeStrategyStoptofixproblems(Neverknowingly

passonadefect)MethodFixstoppositionand

supportstructureReasonIncreaseurgencyand

correctproblemsEffectMotivatetoidentifyproblems為何異常管理至關重要?

WhyAbnormalityManagementisImportant?秒小時班次每日每周每月有清晰的KPI指標衡量我當前狀況(檢查什么)

ClearcriticalKPI’stojudgemycondition(Whattocheck)為了確保健康狀況持續(xù)改善檢查的頻次如何?(如何檢查)

Howoftenshouldyoucheckmydatatoensuremyconditioncontinuestoimprove?(Howtocheck)生產(chǎn)線停止很類似于心跳停止

Whentheprocessstopsitislikehavingacardiacarrest6SecondsHoursShiftDailyWeeklyMonthly實施步驟

StepstoImplementation標準:確立標準–能夠檢測出異常檢測:實施目視化控制以識別正常和異常檢測:建立安東系統(tǒng)響應:建立針對異常問題的快速響應系統(tǒng)解決措施:實施解決措施維持:評審系統(tǒng)的有效性7Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:EstablisharapidresponsesystemtoaddressabnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem實施步驟

StepstoImplementation8標準:確立標準–能夠檢測出異常檢測:實施目視化控制以識別正常和異常檢測:建立安東系統(tǒng)響應:建立針對異常問題的快速響應系統(tǒng)解決措施:實施解決措施維持:評審系統(tǒng)的有效性Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:EstablisharapidresponsesystemtoaddressabnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem標準的范例

ExamplesofStandards產(chǎn)品質(zhì)量特性過程參數(shù)操作工標準化作業(yè)9ProductQualitySpecificationProcessParametersOperatorStandardWork步驟一:確立標準

StepOne:EstablishtheStandard103種產(chǎn)品

3份標準化作業(yè)表

RMFGACB必須要確定節(jié)拍時間和標準作業(yè)順序

TaktTimeandstandardworkmustbedefined1236543ProductModels3StandardOperationSheets步驟一:確立標準–流程行業(yè)

StepOne:EstablishtheStandard–ProcessIndustry11每100磅2.5分鐘作業(yè)每500磅5.0分鐘作業(yè)每1000磅2.0分鐘作業(yè)可用時間=60分鐘

實際作業(yè)時間=39.5分鐘2.5mintaskevery100lbs5.0mintaskevery500lbs2.0mintaskevery1000lbsAvailableTime=60min ActualTaskTime=39.5min實施步驟

StepstoImplementation12標準:確立標準–能夠檢測出異常檢測:實施目視化控制以識別正常和異常檢測:建立安東系統(tǒng)響應:建立針對異常問題的快速響應系統(tǒng)解決措施:實施解決措施維持:評審系統(tǒng)的有效性Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:EstablisharapidresponsesystemtoaddressabnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem步驟二:實施目視化控制

StepTwo:ImplementVisualControls一旦定義了何謂正常,需要將流程目視化使流程一目了然目視化s使得我們能觀察到異常為持續(xù)改進提供快速響應13Oncenormalisdefined,thentheprocessmustbemadevisualVisualataglanceVisualControlsallowustoobservetheabnormalitiesProvidesimmediateinputforimprovement確立了標準–建立目視化

EstablishtheStandard–ThenMakeitVisual14目視控制&持續(xù)改進文化

VisualControls&ContinuousImprovementCulture試想保齡球的球瓶如果被遮擋起來，保齡球如何投擲?誰應該知道得分?如果你每天/每周/每月才得知得分會怎樣?如何知道我們獲勝?我們怎樣激勵自己去改進?15目視化管理創(chuàng)建了團隊的氛圍–使每人都知道比分

Visualcontrolscreateateamatmosphere–

everyoneknowsthescore

Whatwouldbowlingbelikeiftherewasacurtainblockingyourviewofthepins?Whowouldknowthescore?Whatifyouwereonlytoldyourscoreonceperday/week/month?Howwouldweknowifwewerewinning?Howmotivatedwouldwebetoplayorimprove?338271ActTar目視化控制–未達成節(jié)拍時間

VisualControl–NotAchievingTakt16每小時產(chǎn)量管理表

AdministrativeHourByHourChart17對于需求的響應ResponsetoDemand流程行業(yè)小時產(chǎn)量管理表

ProcessIndustryHourbyHourPerformance18異常管理和目視控制

AbnormalityManagementandVisualControls

19如沒有目視化,未達到標準的問題不會被發(fā)現(xiàn)

Withoutvisualcontrols,aviolationfrom

standardwouldnotbeknown實施步驟

StepstoImplementation20標準:確立標準–能夠檢測出異常檢測:實施目視化控制以識別正常和異常檢測:建立安東系統(tǒng)響應:建立針對異常問題的快速響應系統(tǒng)解決措施:實施解決措施維持:評審系統(tǒng)的有效性Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:Establisharapidresponsesystemtoaddress

abnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem步驟三:建立安東系統(tǒng)

StepThree:EstablishanAndonSystem21是一種安裝在流水線上能夠檢測問題的信號燈裝置，通常運用聲光的方式。

Andon:Adeviseforsignalingthereisaproblemintheproductionflow.Usuallybothvisualandaudible.1Help!234步驟三:安東系統(tǒng)

StepThree:AndonSystem安東必須要在異常發(fā)生時立即發(fā)揮作用最好是自動地報警報警必須要一目了然(和發(fā)出報警聲音)必須明確設定好異常的響應系統(tǒng)每個人都經(jīng)過了異常響應的培訓,都已明確異常發(fā)生時各自的職責所有問題相關信息被追蹤和記錄針對數(shù)據(jù)的趨勢進行分析,持續(xù)改進針對問題制定了改進對策并追蹤其效果22AndonmustbeimmediateinassociationwiththeabnormalityPreferably,shouldbeautomaticMustbevisible(and/oraud