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(yīng)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(lǐng)導者的角色.解釋為何異常的管理和對策對以下方面關(guān)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(jié)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(yīng)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(jié)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(gòu)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(guān)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(yīng):建立針對異常問題的快速響應(yīng)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(yīng):建立針對異常問題的快速響應(yīng)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(yīng):建立針對異常問題的快速響應(yīng)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(yīng)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(yīng)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(yīng)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(yīng):建立針對異常問題的快速響應(yīng)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(shè)定好異常的響應(yīng)系統(tǒng)每個人都經(jīng)過了異常響應(yīng)的培訓,都已明確異常發(fā)生時各自的職責所有問題相關(guān)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