《精益生產(chǎn)實(shí)戰(zhàn)教材》經(jīng)典教材中英文版

1、12 Defect : X 1/10缺陷缺陷降低降低90% Inventory : X 庫(kù)庫(kù)存減半存減半 Productivity : X 2生生產(chǎn)產(chǎn)效率翻倍效率翻倍 Lead Time : X 生生產(chǎn)產(chǎn)周期減半周期減半 Scrap : X 1/10報(bào)廢報(bào)廢降低降低90% Space : X 面面積積減半減半Goal : Add Value & Eliminate Waste Relentlessly for Our Customers目目標(biāo)標(biāo): 減少浪減少浪費(fèi)費(fèi)&創(chuàng)創(chuàng)造價(jià)造價(jià)值值 全心全意全心全意為為客客戶戶服服務(wù)務(wù)ETE (End to End) Productivity Improvem

2、ent 端到端端到端( (從頭到尾從頭到尾) )產(chǎn)能提高產(chǎn)能提高ETE Zero Defect (Quality, TPM, OEE & etc.) 端到端端到端(從從頭頭到尾到尾)零缺陷（零缺陷（質(zhì)質(zhì)量，全面生量，全面生產(chǎn)維護(hù)產(chǎn)維護(hù)，全局，全局設(shè)備設(shè)備利用率等）利用率等）Inventory Reductions 降低降低庫(kù)存庫(kù)存Lead Time Reductions 縮短縮短生產(chǎn)前置期生產(chǎn)前置期Crew Size Optimization 優(yōu)化優(yōu)化人員數(shù)量人員數(shù)量Space Reduction 減少減少使用使用面積面積No Money 不投入更多金錢不投入更多金錢No Space 不占用更

3、多面積不占用更多面積No Manpower 不使用更多人力不使用更多人力3Standard Work & Standard Combination Sheet標(biāo)準(zhǔn)化標(biāo)準(zhǔn)化作業(yè)作業(yè) & 標(biāo)準(zhǔn)作業(yè)合并表標(biāo)準(zhǔn)作業(yè)合并表1) Standard work defined 標(biāo)準(zhǔn)作業(yè)定義 a) Takt time defined 節(jié)拍時(shí)間的定義節(jié)拍時(shí)間的定義 b) Work sequence defined 工序的定義工序的定義 c) Standard WIP defined 標(biāo)準(zhǔn)在線庫(kù)存定義標(biāo)準(zhǔn)在線庫(kù)存定義d) Cycle time defined 周期時(shí)間定義 e) No of operators de

4、fined 操作員數(shù)量的定義 f) Safety 安全性 g) Multi skill多技能 2) Standard work combination sheet defined 標(biāo)準(zhǔn)作業(yè)合并表定義a) Manual time手動(dòng)時(shí)間b) Auto time機(jī)器(自動(dòng))時(shí)間c) Walking time走動(dòng)時(shí)間d) Waiting time等待時(shí)間3) Is the Quality check legend defined on each process on std work sheet?標(biāo)準(zhǔn)作業(yè)合并表上，有定義每個(gè)流程中的品質(zhì)管控的關(guān)鍵點(diǎn)嗎？3 Key Elements3項(xiàng)項(xiàng)關(guān)關(guān)鍵鍵要素要

5、素43 Types of Standard Works3種標(biāo)準(zhǔn)作業(yè)種標(biāo)準(zhǔn)作業(yè)53 Types of Standard Works3種標(biāo)準(zhǔn)作業(yè)種標(biāo)準(zhǔn)作業(yè)Type 1 : Standard Work to support machine (90%) & man (10%) combination task.類型1：標(biāo)準(zhǔn)作業(yè)適用于90%的機(jī)器作業(yè)和10%的手動(dòng)作業(yè)的組合作業(yè)方式。Type 2 : Standard Work to support man (90%) & machine (10%) combination task. 類型2：標(biāo)準(zhǔn)作業(yè)適用于90%手動(dòng)作業(yè)和10%機(jī)器作業(yè)的組合作業(yè)方式。

6、Type 3 : Standard Work (also called as Work Standard) to support task carried out once signal is triggered.類型3：標(biāo)準(zhǔn)作業(yè)（也叫做作業(yè)標(biāo)準(zhǔn)）適用于當(dāng)信號(hào)產(chǎn)生時(shí)才去執(zhí)行相應(yīng)任務(wù)的作業(yè)方式。No Std Work means no Kaizen Std Work is the Mother of all Kaizen沒(méi)有標(biāo)準(zhǔn)作業(yè)就沒(méi)有改善標(biāo)準(zhǔn)作業(yè)是改善之母6How to start the Takt Time CalculationBased On Customer Demand 怎樣根據(jù)客

7、戶需求計(jì)算節(jié)拍時(shí)間 Step 1: Calculate Takt time Based on Customer Demand 第一步：根據(jù)客戶需求計(jì)算節(jié)拍時(shí)間 Example 例如:Customer Demand per Month 792K. Working hour per day is 22 hours, 20 days a month. 客戶每月需求量是792K。每天工作小時(shí)是22小時(shí)，一個(gè)月20天。Takt Time calculation shall display all the variable and units to make clarity to all. 計(jì)算節(jié)拍時(shí)間時(shí)

8、要顯示所有變量及單位，便于大家理解。計(jì)算節(jié)拍時(shí)間時(shí)要顯示所有變量及單位，便于大家理解。sec 2792,0001,584,000pcs 792,000s 3600 x days 20 x Hours 22 Demand Customer Time AvailableTime Takt客戶需求有效時(shí)間7How to start the Takt Time CalculationBased On Product and Process Design怎樣根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間Step 2: Calculate Process Takt time Based on Product and Pr

9、ocess Design 第二步：根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間Based on Step 1, Takt Time is 2 second to produce 1 pcs.根據(jù)步驟1，節(jié)拍時(shí)間是每 2 秒生產(chǎn) 1 件產(chǎn)品。8How to start the Takt Time CalculationBased On Product and Process Design怎樣根據(jù)產(chǎn)品和制程設(shè)計(jì)計(jì)算節(jié)拍時(shí)間Scenario 1: Product design is 6 pcs per one PCB panel. The Process Takt Time will be every 12 se

10、cond a panel. Besides, your process design is using a pallet to place 4 panels, then your Process Takt Time is 48 second a pallet. If 2 line running, process Takt time will be 96 sec.情節(jié)1：產(chǎn)品設(shè)計(jì)為每塊PCB板由 6 塊小板組成，節(jié)拍時(shí)間是每塊PCB板 12 秒; 制程設(shè)計(jì)治具同時(shí)放置 4 塊PCB板，則制程的節(jié)拍時(shí)間是 48 秒/治具。如果同時(shí)有 2 條生產(chǎn)線生產(chǎn)，制程的節(jié)拍時(shí)間則為 96 秒。Scenari

11、o 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec情節(jié)情節(jié)2 2：如果正反面產(chǎn)品同時(shí)在一條生產(chǎn)線生產(chǎn)，節(jié)拍時(shí)間則為一半，：如果正反面產(chǎn)品同時(shí)在一條生產(chǎn)線生產(chǎn)，節(jié)拍時(shí)間則為一半，4848秒。秒。As such the Process Takt Time Calculation as following: 制程節(jié)拍時(shí)間計(jì)算如下：= Takt Time X Product Up x Process Up X Number of Line = 2 se

12、c X 6 products per panel X 4 Panel per pallet X 2 Lines= 96 sec 9What is Standard WIP什么是標(biāo)準(zhǔn)WIPVarious types of WIP in our manufacturing process 生產(chǎn)過(guò)程中存在各種類型的WIP1.Standard WIP 標(biāo)準(zhǔn)WIP2.Process WIP制程WIP3.Process To Process WIP制程與制程間WIP4.Station To Station WIP工位與工位間WIP10What is Standard WIP什么是標(biāo)準(zhǔn)WIP WIP mea

13、ns INVENTORY. INVENTORY is Basically bad. WIP就是庫(kù)存。庫(kù)存從根本上說(shuō)是就是庫(kù)存。庫(kù)存從根本上說(shuō)是“不好不好”的。的。 Standard WIP is the Ideal or Should be conditions for WIP標(biāo)準(zhǔn)WIP是理想WIP或者是WIP的應(yīng)有狀態(tài)。 However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and

14、 bottle neck然而，在完全達(dá)到標(biāo)準(zhǔn)WIP數(shù)量前，你需要經(jīng)過(guò)不同的階段了解制程中的浪費(fèi)和瓶頸。Key Note from Sensei: 老師的重要提示：老師的重要提示： To understand the above WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解要理解WIP定義，你需要去到現(xiàn)場(chǎng)在工作中實(shí)

15、踐正確的定義，你需要去到現(xiàn)場(chǎng)在工作中實(shí)踐正確的WIP數(shù)量。數(shù)量。這是讓你理解這個(gè)定義的唯一方法。這是讓你理解這個(gè)定義的唯一方法。11What is Standard WIP什么是標(biāo)準(zhǔn)WIPThe purpose of Standard WIP is:標(biāo)準(zhǔn)WIP的目的：1.Separation between machine job and man job 區(qū)分機(jī)器作業(yè)和手動(dòng)作業(yè)2.Ensures quality requirements確保質(zhì)量要求3.Ensures smooth flow based on Takt time確?；诠?jié)拍時(shí)間的連續(xù)流Example 1: 例子1WIP in t

16、he reflow oven for curing with process time 6 min and Takt time 30 sec.在回流焊爐中固化的WIP，制程時(shí)間 6 min，節(jié)拍時(shí)間 30 sec.Standard WIP in the curing oven = Process Time / Takt Time 回流焊爐的標(biāo)準(zhǔn)WIP = 6 min / 30 sec = 12 Pcs12What is Standard WIP什么是標(biāo)準(zhǔn)WIPExample 2: 例子2WIP in the tester at backend assembly with process tim

17、e 60 sec and Takt Time 30 sec.后段組裝線測(cè)試機(jī)的WIP，制程時(shí)間 60 sec，節(jié)拍時(shí)間 30 sec.Standard WIP in the Test station = 60 sec/ 30 sec測(cè)試工位的標(biāo)準(zhǔn)WIP = 2 pcsIn other words, Standard WIP in order to fulfill the above 1), 2), 3) functions, It is the compulsory WIP in the machine / process before establish standard work for

18、the process. 換句話說(shuō)，標(biāo)準(zhǔn)WIP能夠確保上述1),2),3)達(dá)成，在建立標(biāo)準(zhǔn)作業(yè)前，標(biāo)準(zhǔn)WIP是機(jī)器和制程強(qiáng)制的WIP。13What is Standard WIP什么是標(biāo)準(zhǔn)WIPProcess WIP 制程WIPWIP within same process with low variation of cycle time同一個(gè)制程中的WIP，周期時(shí)間CT變化很小It is all that WIP in the same process, not categorized as Standard WIP or PTP WIP. 所有在同一個(gè)制程中的WIP，不是標(biāo)準(zhǔn)WIP或制程間

19、WIP.Example:- 例如例如Before Kaizen, Manual Insert (MI) Line Process WIP =9 pcs. After Kaizen MI Process WIP is 3. Standard WIP for each station is 1pc. 改善前，插件拉的制程WIP=9 pcs。改善后插件拉制程WIP=3pcs。每個(gè)工位的標(biāo)準(zhǔn)WIP為1pcs.T.T60 sec51455843PersonTimeABCDT.T60 sec60606012PersonTimeABCDvarianceAfterBeforeProcess WIP = 3,

20、Standard WIP = 1 Process WIP = 9, No standard WIP 14What is Standard WIP什么是標(biāo)準(zhǔn)WIPProcess To Process WIP (PTP WIP) 制程間WIPWIP between 2 different processes with big gap cycle time兩個(gè)周期時(shí)間相差很大的不同制程間的WIP.PTP WIP Is needed due to changeover in upstream line. 上游制程需要轉(zhuǎn)拉，則需設(shè)定制程間WIP. Not All line need PTP WIP.不是

21、所有產(chǎn)線都需要制程間WIP.If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期時(shí)間小于下游制程的周期時(shí)間Example 1:- SMT Cycle time (30 sec) Less then Manual Insertion (60 sec)例1：SMT周期時(shí)間(30 sec)小于MI插件周期時(shí)間 (60 sec)CT (Upstream process) Need PTP WIP 需要制程間WIP If Cycle time Upstream process is Equal or gr

22、eater then Down stream process, No PTP WIP required. 如果上游制程的周期時(shí)間大于或等于下游制程的周期時(shí)間，不需要制程間WIP.節(jié)拍時(shí)間前工序機(jī)器轉(zhuǎn)拉時(shí)間制程間Time Takt Machine Previous of Changeover WIP WIPProcess to Process15What is Standard WIP什么是標(biāo)準(zhǔn)WIPProcess To Process WIP制程間WIP節(jié)拍時(shí)間前工序機(jī)器轉(zhuǎn)拉時(shí)間程間制Time Takt Machine Previous of Changeover WIP WIPProcess

23、 to ProcessExample 2:- Process A cycle time 15 sec. It is faster then Process B cycle time 25sec. Process A is running 2 product models as capacity requirement. In order to Keep Process line running, process to process WIP is required between Process A and B. The calculation as below:-例2：制程A周期時(shí)間是15s

24、ec，比制程周期時(shí)間25sec快。制程A根據(jù)生產(chǎn)能力需求，需要生產(chǎn)2種產(chǎn)品。為了保證產(chǎn)線正常運(yùn)作，需要在制程A和制程B之間設(shè)定制程間WIP。計(jì)算如下：Takt Time = 30secChangeover Time = 5 min30secProcess AProcess Bpcs 10sec 3060sec x 5min WIPPTP16Takt Time 節(jié)拍時(shí)間節(jié)拍時(shí)間Cycle time Takt time ( 1 Station Process )C/T than takt for single process (2 same stations needed)C/TTakt (需要2

25、個(gè)相同工位)TAKT Time = 20s10203040Machine/Process A : St. #1Machine/Process A : St. #2Note注: CT TT : Additional Machine/Man needed 需要額外的機(jī)器/人員It can be used to calculate 節(jié)節(jié)拍拍時(shí)間時(shí)間可以可以計(jì)計(jì)算算 Total Operators needed員工需求數(shù)量 Total machines needed機(jī)器需求數(shù)量 Standard WIP needed & Etc標(biāo)準(zhǔn)WIP需求數(shù)量，等171)Is the Takt time visib

26、le (with counter and triggering point)? 節(jié)拍時(shí)間可以直觀地看出來(lái)嗎？有沒(méi)有借助工具(計(jì)數(shù)器和觸發(fā)機(jī)制) 。2) Is the Takt board defined (on the board)? 節(jié)拍時(shí)間確定了嗎？(把節(jié)拍時(shí)間寫在白板上) 3) Are the Standard WIP defined? 標(biāo)準(zhǔn)WIP有定義嗎? 4) Do you know how to separate manual (persons) from auto (the machines) work? 你知道如何區(qū)分手動(dòng)作業(yè)和自動(dòng)作業(yè)嗎? 5) Is the Work loa

27、d leveling defined for man，machine and C/O? 人工,機(jī)器以及換線使用工作負(fù)荷均衡表分析了嗎？ 6) Is the H/C calculated based on Takt time? 人力的多少是根據(jù)節(jié)拍時(shí)間計(jì)算出來(lái)的嗎? 7) Is the Std work (front page) SWCS (back page) posted in front of each operator? 每個(gè)工站前都有標(biāo)準(zhǔn)作業(yè)(前頁(yè))和標(biāo)準(zhǔn)作業(yè)合并表SWCS(背頁(yè))嗎? Operations操作操作 18Operations ( continue )操作操作(續(xù)頁(yè)續(xù)頁(yè))

28、8) Is the std work being followed by the operator? 操作員有沒(méi)有按照標(biāo)準(zhǔn)作業(yè)流程作業(yè)? 9) Is the std work defined for water strider? 有沒(méi)有定義物料員的標(biāo)準(zhǔn)作業(yè)? 10) Is the operator idle at the station? 在作業(yè)過(guò)程中,操作員是否有等待? 11) Does the operator search for components or tools? - Locate all tools and parts within easy access or reach (

29、Doctor & Nurse). 在作業(yè)中,操作員有沒(méi)有尋找物料或工具的動(dòng)作? 工具或物料應(yīng)該放置在易于獲取的位置,定點(diǎn)定位.(遵循醫(yī)生和護(hù)士概念：Doctor醫(yī)生,指直接作業(yè)的人員,nurse護(hù)士,指輔助作業(yè)人員,如物料員) 12) Do you have std work for inspection station? 檢查工站有沒(méi)有標(biāo)準(zhǔn)作業(yè)書? 13) Do you have shortest cycle time for inspection? 對(duì)于檢查工站,有沒(méi)有定義最短周期時(shí)間? 19Operations ( continue )操作操作(續(xù)頁(yè)續(xù)頁(yè))14) At the hand

30、load station, do you apply doctor and nurse concept? 在手工作業(yè)工站,有沒(méi)有運(yùn)用醫(yī)生和護(hù)士理念? 15) Do you meet the target of 3 sec per component during insertion at hand load? 在手插工站,有沒(méi)有達(dá)到每3 秒一顆零件的插件速度? 16) SIC less at hand load station (with template). 手插工站不需要SIC(用模板來(lái)顯示需要插件的位置)? 17)Hand load manual CT Takt time nurse n

31、ot required. Are there system in place to stop work when abnormal conditions arise? 當(dāng)手動(dòng)作業(yè)的周期時(shí)間小于節(jié)拍時(shí)間時(shí)，不需要”護(hù)士”(護(hù)士nurse:輔助作業(yè)人員) 當(dāng)異常情況出現(xiàn)時(shí)，有沒(méi)有系統(tǒng)來(lái)控制停止作業(yè)? 18 ) Does the supervisor respond in a quick/crude manner? 當(dāng)異常發(fā)生時(shí)，管理人員的反映是快速還是遲鈍? 19) Do you have 6S implemented on your line? 線上有實(shí)行6S嗎 ?(6S=5S+Safety)

32、20Operations ( continue )操作操作(續(xù)頁(yè)續(xù)頁(yè))20) Is the production qty for the day defined? 日產(chǎn)量有沒(méi)有定義? 21) Is the Multi skill charts visible and available? 有沒(méi)有顯示和使用多技能培訓(xùn)表？22) Do you allow banana peeling on the line? 允許在線拆卸物料包裝嗎? 23) Are you able to detect bottleneck station at a glance? 瓶頸工站能一眼看出來(lái)嗎? 24) The op

33、erator must not re-orient the part 操作員不允許重新調(diào)整零件方向,防止零件極性弄錯(cuò).(這里操作員指輔助作業(yè)人員,即nurse) 25) Change over : 快速換型a) Internal time 內(nèi)部時(shí)間d) Adjustment time調(diào)整校準(zhǔn)時(shí)間b) External time 外部時(shí)間e) Clean清潔c) Trial run試運(yùn)行21Operations ( continue )操作操作(續(xù)頁(yè)續(xù)頁(yè))26) ETE Operation criteria: 端到端運(yùn)行標(biāo)準(zhǔn)a)The line should run based on Takt

34、time 生產(chǎn)線必須按照客戶需求節(jié)拍合理安排生產(chǎn)b)The H/C should be loaded based on Takt time 生產(chǎn)線應(yīng)按客戶需求節(jié)拍時(shí)間合理安排人員c)Material should be loaded based on Takt time 按客戶需求節(jié)拍時(shí)間備置原材料d)The line should be configured to zero defects 配置生產(chǎn)線時(shí)需滿足零缺陷e)Supermarket should meet all the 15 criteria 超市必須符合15個(gè)設(shè)置準(zhǔn)則27) ETE consists of : 端到端包括: a)

35、 Productivity improvement (MLT,H/C, WIP, Space) 提高生產(chǎn)效率(生產(chǎn)前置期,科學(xué)的人員配置,適當(dāng)?shù)脑诰€庫(kù)存,有效的空間利用)b) Material replenishment (Water strider, Min- Max, Supermarket) 靈活精益的原材料供給方式(水蜘蛛補(bǔ)貨原則，設(shè)置最低最高庫(kù)存，超市)c) Quality improvement (Zero defects) 提高質(zhì)量(零缺陷)d) C/O (if the time more than 10 minutes) 換型時(shí)間(如果時(shí)間超過(guò)10分鐘)22Operations

36、 ( continue ) 操作操作(續(xù)頁(yè)續(xù)頁(yè))28) 4 functions of Conveyor, Say NO to Conveyor if below criterias not meet“傳送帶”的4個(gè)功能， 如果不符合以下條件則不能使用“傳送帶”Function as a Pace Setter ( Takt Manufacturing ) 節(jié)拍調(diào)節(jié)器（節(jié)拍生產(chǎn)）b)Function as a Value adding work station ( Value being added as it moves)增值工位（傳送帶移動(dòng)時(shí)產(chǎn)品可以增值，如在傳送帶上作業(yè)） c)Functi

37、on as a Jidoka ( Stop every abnormal ) 自働化（異常時(shí)停止作業(yè)）d)Function as a transportation mode ( 5% of the function ) 傳送作用（只占（只占5%的功能）的功能）23Layout 布局布局1) Insure the short walking distance. 確保產(chǎn)線行走距離短. 2) Do you have 3 TEI implemented on your line? 產(chǎn)線有沒(méi)有對(duì)物品實(shí)施三定原則? a) Fix place 定點(diǎn)b) Fix things 定位/定物 c) Fix qty

38、 定量3) Is the safety aisle easily accessed by the operator? 安全通道是否易于員工通過(guò)? 4) Are there trash bins inside the cell? 單元生產(chǎn)線內(nèi)有沒(méi)有垃圾箱? 5) Do you have cell concept implemented on your line? 有沒(méi)有在生產(chǎn)線上應(yīng)用單元生產(chǎn)的概念.24Layout ( continue ) 布局布局(續(xù)頁(yè)續(xù)頁(yè))6) The operator movement in a cell : is it counter clock wise(1) or

39、clockwise(0). Counter clock wise is recommended 操作員在單元內(nèi)的移動(dòng)是逆時(shí)針還是順時(shí)針(逆時(shí)針為佳) 7) The gap in a cell : is it wider(0) or narrower(1) (narrower recommended). 單元內(nèi)工站間的間距合適的嗎?寬(0) 還是窄(1) (推薦用窄).8) Is the station made of crefoam material and is it on the wheel for flexible movement? 工作臺(tái)是由復(fù)合管做成的嗎 ?是否有滑輪易于移動(dòng)呢?

40、9) The flow of a layout must be like a single stroke, no zigzag. 產(chǎn)線布局的流向必須是單行程的，而不是彎曲交錯(cuò)的。10) Do you use 7 ways when designing tools, jigs, fixtures, layout or process? 在設(shè)計(jì)工具,夾具,治具,工廠布局和流程時(shí)有沒(méi)有采用7種方法(7 ways)? 11) Do you use Pugh matrix to evaluate 7ways? 有沒(méi)有使用Pugh matrix來(lái)評(píng)估7種方法? .25Layout ( continue )

41、 布局布局(續(xù)頁(yè)續(xù)頁(yè))12) Hand load station should meet the below requirements :手動(dòng)作業(yè)工站應(yīng)該滿足以下要求: a) Part presentation 物料擺放方式 b) Zero defect 物料品質(zhì)零缺陷 c) Layout /Ergonomic, 插件的順序/根據(jù)人機(jī)工程學(xué)來(lái)安排d) Both hands of operator have to be used during insertion 插件時(shí)要雙手作業(yè) 13) Are the cables, wires and network using the overhead d

42、rop point for flexibility?電線,網(wǎng)線,信號(hào)線是否架設(shè)在線體上端并連接到產(chǎn)線，易于靈活使用? 14) Do you use the Spaghetti Chart to do the layout, process, movement? 在設(shè)計(jì)layout，流程,行走路線時(shí)有沒(méi)有使用到Spaghetti Chart(意大利面條圖)工具,清晰的畫出人流、物流及產(chǎn)品流路線? 15) Is the line visibility clear for the supervisor? (boarder post defined for clear visibility) 對(duì)于管理

43、者來(lái)說(shuō)，產(chǎn)線可視化嗎?(定義看板使其清晰可視化) 16) Do you use mock-up layout? 有沒(méi)有模擬layout實(shí)施后的情況嗎? 17) Tree and Branch connecting sub assembly & main assembly 主干和枝條 主裝配線和輔助裝配線的合理銜接26Layout ( continue ) 布局布局(續(xù)頁(yè)續(xù)頁(yè))18) Short Takt time 1minute, multiply takt time by (x) factor and duplicate the backend cell accordingly客戶節(jié)拍時(shí)間太

44、短小于 1 分鐘時(shí)，增大節(jié)拍時(shí)間 X 倍并建立相應(yīng)數(shù)量的相同的單元產(chǎn)線。19) Do your work stations are in same height ?工作臺(tái)都是同一個(gè)高度嗎？20) Do you carry out “rope test” to validate the continuous value flow ?有實(shí)施“繩子測(cè)試”驗(yàn)證連續(xù)價(jià)值流嗎？27Zero Defect 零缺陷零缺陷1)Can normal and abnormal be visually differentiated? 正常和異常現(xiàn)象易于區(qū)分嗎 ? 2) Are the escalation paths

45、 well defined if abnormality occurs? 針對(duì)異常的發(fā)生,有沒(méi)有制定出逐級(jí)上報(bào)的流程? 3) Are the defects allowed to escape to down stream? 有沒(méi)有不良流入下一工站? a) Do not pass defect ( Downstream Internal or To End Customer ) 不流出不良品不流出不良品 (內(nèi)部下游客戶或終端客戶) b) Do not make defect( In Own Process ) 不制造不良品不制造不良品（自己的工位）c) Do not accept defect

46、 ( From Upstream) 不接收不良品不接收不良品（從上游工序） d) Do not rework ( Not Build Product Via Rework ) 不允許返工不允許返工（不通過(guò)返工生產(chǎn)產(chǎn)品）4) Do you have a common area to view the defect (fish market)? 有沒(méi)有特定的地點(diǎn)來(lái)檢討不良?(fish market 魚市場(chǎng)) 28Zero Defect ( continue ) 零缺陷零缺陷(續(xù)頁(yè)續(xù)頁(yè))5) Do you apply 3 Gens? 有沒(méi)有做到三 現(xiàn)? a) Genba - Actual place

47、 現(xiàn)場(chǎng) b) Genbutsu - Actual product 現(xiàn)物 c) Genjitsu - Actual fact 現(xiàn)實(shí)6) Do you use 5 W ( who, what , where, when, why)+1H (how) where rule and regulation applied? 規(guī)章制度的制定有沒(méi)有運(yùn)用5W+1H的方法? 7) Do you have hand free inspection station? 視檢工站,有沒(méi)有不需要用手的? 8) Do you have template with navigation or pointer to guide

48、 inspection operators? 有沒(méi)有模板來(lái)輔助視檢作業(yè)？ 29Zero Defect ( continue ) 零缺陷零缺陷(續(xù)頁(yè)續(xù)頁(yè))9) Do you apply SDCA,PDCA? and for defects do you apply PDCA? (Problem,Display,Clear & acknowledge) SDCA ( Standardize, Do, Check & Action ) 工作中有沒(méi)有運(yùn)用 SDCA、PDCA方法？針對(duì)不良現(xiàn)象，有沒(méi)有運(yùn)用PDCA的方法？ 10) Do you have Kaizen Newspaper displaye

49、d? 改善活動(dòng)的海報(bào)有沒(méi)有展示出來(lái)? 11) Do you have 1hr, 2hr, 4hr, 8hr tracking system on the floor? (lead to zero defect) 產(chǎn)線有沒(méi)有跟蹤系統(tǒng)，隨時(shí)了解每1小時(shí)，每2小時(shí)，每4小時(shí)，每8小時(shí)的狀況？(向零缺陷靠近) 12) Identify POO & POD to solve the problem 當(dāng)問(wèn)題發(fā)生時(shí),鑒別出問(wèn)題的起源(POO)和問(wèn)題的發(fā)現(xiàn)點(diǎn)(POD)來(lái)解決問(wèn)題. POO=point of origin (where is the first point are the cause probl

50、em) POD=point of detection (where the point the problem been captured) 13) Learn how to make the defect to understand root cause 研究如何會(huì)產(chǎn)生不良, 從而了解根本原因。 30Zero Defect ( continue )零缺陷零缺陷(續(xù)頁(yè)續(xù)頁(yè))14) Do you have Auto Jidoka implemented in your line? 產(chǎn)線有沒(méi)有運(yùn)用自働化系統(tǒng)？ 15) Talk to the defect to understand the roo

51、t cause 深入研究不良或缺陷，找出根本原因 16) Duplicate the defect to understand the root cause 多次重復(fù)不良現(xiàn)象的發(fā)生，找到根本原因。 17) Do you have mean test ? - challenge the current state (Potential Problem Analysis) 有運(yùn)用均值檢驗(yàn)嗎? 對(duì)現(xiàn)狀進(jìn)行尋根究底(分析潛在的問(wèn)題)18) Do you use 5 Why analysis to understand the root cause? 有沒(méi)有運(yùn)用5個(gè)為什么來(lái)分析根本原因？ 19) Lan

52、dscape concept View from all angles (the mountain) ,Search for the truth (the forest), Look/Focus (the tree), See and fix it (the branch) 全局概念-全方位-遠(yuǎn)看(山)，尋找真相-近觀(森林)，細(xì)看(樹(shù))，深究并解決問(wèn)題(枝干)31One Piece Flow 單件流單件流 1) One piece flow 單件流2) Are the line visibility clear for the supervisor? Std.WIP? Takt counte

53、r? Line flow? 對(duì)于管理者來(lái)說(shuō)，產(chǎn)線狀況可視化嗎？有標(biāo)準(zhǔn)WIP?節(jié)拍計(jì)數(shù)器？產(chǎn)線是流動(dòng)的嗎？3) One piece flow which like as the eggs inside the chicken should be one by one flow ,but not in parallel. 單件流就像母雞肚里的雞蛋一樣是一個(gè)一個(gè)下蛋的，而不是一起下出來(lái)的。4) To shorten the information of defect feedback, one piece flow can reduce our lead time. 為縮短不良現(xiàn)象的信息反饋，單件流

54、可以幫助減少前置時(shí)間。5) When we set up new layout ,we must consider use the one piece flow. 當(dāng)建立新的生產(chǎn)線布局時(shí)，必須考慮使用單件流。6) The Ideally layout is one piece flow according our Takt time. 理想產(chǎn)線布局是按照節(jié)拍時(shí)間的單件流。7) The layout of “ Y” is better than the layout “ I I I ” series “Y”型布局比“I I I ”型布局好。8) As the quality feedback i

55、s fast and quick action taken. 品質(zhì)反饋速度快，能夠快速響應(yīng)采取行動(dòng)。32VSM 價(jià)值流圖價(jià)值流圖1)Do you have value stream done on your product?1. 產(chǎn)線有沒(méi)有做價(jià)值流分析？a) have you visualized improvements to the overall production flow, instead of spot improvements to single processes 有沒(méi)有把所有產(chǎn)線流程存在改善空間的地方明顯地標(biāo)識(shí)出來(lái)，而不是僅標(biāo)示某個(gè)地方。 b) have you creat

56、ed a complete material and information flow 有沒(méi)有規(guī)劃出完整的物料流和信息流 c) current state - how the process works today 現(xiàn)狀-產(chǎn)線現(xiàn)在是如何運(yùn)作的 d) future state - map shows improvements towards a long term ideal state 未來(lái)的情況-價(jià)值流圖表示出改善之后的理想狀況 e) 3D VSM for better visualization (for office kaizen) 3D價(jià)值流圖使流程更加直觀（針對(duì)辦公室改善） 33VS

57、M ( continue )價(jià)值流圖價(jià)值流圖(續(xù)頁(yè)續(xù)頁(yè))2) 7 types of flow must be clearly defined : 7大流程必須定義清楚 a) Material Raw物料-原材料 b) Material WIP 物料-在線庫(kù)存 c) Material - Finish Goods 物料-成品 d) Information - what info is required to move materials, what is the timing 信息-移動(dòng)/搬運(yùn)物料時(shí)需要什么信息，什么時(shí)間點(diǎn)e) People - std.work, Takt time 人流-標(biāo)準(zhǔn)

58、作業(yè)，節(jié)拍時(shí)間 f) Equipment - carts, conveyor, racks, andons, TPM 設(shè)備流-手推車，傳送帶，物料架，andons 異常停線系統(tǒng)，全面生產(chǎn)維護(hù)(TPM=Total Productive Maintenance) g) Engineering - quality, tooling, programs 工程-品質(zhì)，工具，程序 34Moonshine Shop 月光工作室月光工作室1) Do you have moonshine capability in your plant? 工廠有沒(méi)有月光工作室可以自己動(dòng)手制作治具或工具以及時(shí)滿足產(chǎn)能需求的能力.

59、? 35Golf Score 動(dòng)作評(píng)估表動(dòng)作評(píng)估表1)Are the operators having to bent down? 操作員在作業(yè)過(guò)程中需要彎腰嗎? 2) Are operators having to reach high? 操作員的手需要伸到很高的位置(獲取物料或工具)來(lái)完成作業(yè)嗎？ 3) Are operators having to twist/turn? 操作員在作業(yè)過(guò)程中需要轉(zhuǎn)身嗎? 4) Are operators leaving work area? 操作員在作業(yè)過(guò)程中離開(kāi)工作區(qū)嗎? 5) Are operators needing 3 arms?(hand be

60、ing used as fixtures) 操作員必須依靠三只手才能完成作業(yè)嗎?（第三只指的是治具） 6) Is the C/T set at 90% or less of the Takt time? 周期時(shí)間是設(shè)定在節(jié)拍時(shí)間的90%還是低于節(jié)拍時(shí)間？ C/T= cycle time， T/T=Takt time 7) Is there rework being done? 返工有沒(méi)有在做？36Machine 設(shè)備設(shè)備1)Are tools suspended above point-of-use? 工具有沒(méi)有懸掛在使用點(diǎn)(觸手可及之處)？ 2) Are proper gauges/fixt