偉創(chuàng)力制造系統(tǒng)介紹演示文稿課件

偉創(chuàng)力制造系統(tǒng)介紹演示文稿偉創(chuàng)力制造系統(tǒng)介紹演示文稿ABriefIntroductiontoFMS

FMS簡介

TPS,DFT,&Lean豐田生產(chǎn)系統(tǒng),需求流程技術(shù),&精益生產(chǎn)IntegratingLean&DFTFMSFMS是精益生產(chǎn)&需求流程技術(shù)的集成2ABriefIntroductiontoFMS

FMTPS*:PresentDayStructure豐田生產(chǎn)系統(tǒng)的結(jié)構(gòu)Quality,Cost,Delivery品質(zhì),成本,交期ShortenProductionFlowbyEliminatingWaste通過消除浪費縮短生產(chǎn)流程JustInTime準(zhǔn)時生產(chǎn)RightPartattheRightTimeintheRightAmount只在正確的時間生產(chǎn)正確的產(chǎn)品和數(shù)量ContinuousFlow連續(xù)流PullSystems拉動系統(tǒng)LevelProduction分級生產(chǎn)Built-InQuality(Jidoka)過程品質(zhì)控制(自動化)ErrorProofing–PokaYoke防錯法VisualControls目視控制OperationalStability操作穩(wěn)定性StandardizedWork標(biāo)準(zhǔn)化作業(yè)RobustProducts&Processes強(qiáng)大的產(chǎn)品&工藝TotalProductiveMaintenance全員生產(chǎn)性維護(hù)保養(yǎng)SupplierInvolvement供應(yīng)商參與Kaizen改善5S/VisualManagement5S/可視化管理HighlyMotivatedandCreativePeople高主動性和創(chuàng)造性的人員*ToyotaProductionSystem3TPS*:PresentDayStructure豐田生DFT*inFlexToday偉創(chuàng)力目前實施的需求流程技術(shù)*DemandFlowTechnology需求流程技術(shù)4DFT*inFlexToday偉創(chuàng)力目前實施的需求流/Value價值CorrectlySpecifyValueofProduct/ServicewithCustomerinmind從正確識別產(chǎn)品/服務(wù)的價值,始終考慮客戶的需求/ValueStream價值流IdentifytheValueStreamandremovealltheWastes識別價值流,消除浪費/Flow流程MaketheProductandValueFlowSmoothly理順產(chǎn)品關(guān)系和價值流/Pull拉動ProduceonlytothePullofCustomerDemand以客戶需求拉動生產(chǎn)/Perfection完成WastesEliminationasanOngoingProcesstowardsPerfection浪費消除,流程趨于完善TheUniversalLeanPrinciples普遍的精益原則5/Value價值/ValueStream價值流/Flow流

TheOriginofFMS:FlexManufacturingSystem偉創(chuàng)力制造系統(tǒng)的起源ToyotaProductionSystem豐田生產(chǎn)系統(tǒng)DFT需求流程技術(shù)LEAN精益生產(chǎn)FlexManufacturingSystem偉創(chuàng)力制造系統(tǒng)BanishWastesCreateValueFlexE2EValueStream6TheOriginofFMS:FlexManuFlexManufacturingSystem(FMS)偉創(chuàng)力制造系統(tǒng)LeadTimeImprovement+BanishWastesDriveValueCreation縮短生產(chǎn)周期+消除浪費以驅(qū)動價值創(chuàng)造7FlexManufacturingSystem(FMSLeanisamanufacturingphilosophythatrecognizesWASTEastheprimarydriverofcycletime,andemploystechniquestocontinuallydriveoutthewasteinprocesses.精益生產(chǎn)是這樣一種制造業(yè)哲學(xué),它認(rèn)為生產(chǎn)周期,員工的操作方法是造成浪費的主要原因,并致力于消除這些浪費PRODUCTSHIPMENT出貨TotalLeadTime生產(chǎn)周期BusinessasUsual正常工作Waste浪費CUSTOMERORDER客戶訂單LeanManufacturing精益制造PRODUCTSHIPMENT出貨CUSTOMERORDER客戶訂單LeadTime(Shorter)生產(chǎn)周期(更短)Waste浪費WhyLeadTimeiscrucialtobecomeLean?為什么生產(chǎn)周期在精益生產(chǎn)中如此的至關(guān)重要LeanisamanufacturingphilosCycleTimeandWaste生產(chǎn)周期和浪費TypesofWaste*1

七種浪費Transportation運輸Inventory庫存Motion動作Waiting等待Overproduction過量生產(chǎn)Over-processing不必要的過程Defects缺陷*1Prompter:Whois“TIMWOOD”?敦促者:誰是”TIMWOOD”WasteeliminationisthemosteffectivemethodtowardsCycleTimereduction消除浪費是縮短周期的最有效的方法Waste浪費Waste浪費MUDA*=WasteMUDA=浪費*Japanese9CycleTimeandWaste生產(chǎn)周期和浪費Typ1.Overproduction過量生產(chǎn)Makingmore-earlier-fasterthanthenextprocessorcustomerneedsit相對于下一工序或客戶過早過快生產(chǎn)-Justincaselogic以防萬一的邏輯-Unbalancedworkload工作量不平衡-Improperscheduling不適當(dāng)?shù)挠媱?.Defects缺陷NotdoingworkRighttheFirstTime沒有做到第一次就把工作做對-NotusingPoka-yoke*1沒采取防錯法-LackofStandardization,inconsistentworkmethods缺乏標(biāo)準(zhǔn)化,不一致的工作方法-Ineffectivecommunication無效的溝通Littleinvestmentintraining缺乏培訓(xùn)3.Inventory庫存Anysupplyinexcessofone-pieceflow一個流之外的任何供給品-Oftentheresultof“Overproduction”常常是”過量生產(chǎn)”的結(jié)果-Unbalancedworkload工作量不平衡-Improperscheduling不適當(dāng)?shù)挠媱?Unreliablesuppliers不可靠的供應(yīng)商7TypesofWaste七種浪費*1-alsocalledmistakeorerror-proofing101.Overproduction過量生產(chǎn)7Typeso7TypesofWaste七種浪費4.Over-processing不必要的過程Processingbeyondthecustomer’s(internalorexternal)requirements過程超過客戶(內(nèi)部或外部)的要求-Poorknowledgeofspecsorcustomerrequirements缺乏對客戶規(guī)格或要求的知識-Inconsistentworkmethods(non-standardization)不一致的工作方法(非標(biāo)準(zhǔn)化)-Ineffectivecommunication無效的溝通Examples:舉例:Manuallycleaningproductbecauseofdirt用手清除產(chǎn)品上的塵土100%visualinspectionatend-of-line線末100%目視檢驗5.Transportation運輸Inefficientmovementofpeople,materialsandinformationintheorganization人員,物料和信息的低效率的移動-Poorlayout差的工廠布局-Inefficient“flow”低效的流動Carryinglargeinventories大量庫存Exposesproducttopotentialdamage/lossduringtransportation產(chǎn)品在運輸過程中遭受潛在的損害/損失Examples:Anywheresequentialoperationsarebroken任何連續(xù)作業(yè)中斷的地方-Materialstoredtoofarfromworkstation物料存儲離工作站太遠(yuǎn)Toomanyconveyors,forklifts,pallettrucks,etc.過多的傳送帶,鏟車,叉車117TypesofWaste七種浪費4.Over-pr7TypesofWaste七種浪費6.Waiting等待Waitingfor…man,machine,materials,information,etc.等待…人,設(shè)備,物料,信息等-Unbalancedworkload工作量不平衡-Unplanneddowntime無計劃的停機(jī)時間Poorworkplacediscipline工作場所無紀(jì)律Examples:舉例:

Lookingfortoolstorepairmachines尋找工具維修設(shè)備Firstpiecewaitingfortheentirebatchtofinish第一件等待整批完成Peopleidlebecauseofnomaterialstoworkon因為缺料造成的人員空閑Waitingforinstructionstoproceed等待繼續(xù)的指示7.Motion動作Unnecessarymovementofpeople,partsormachineswithintheprocess生產(chǎn)過程中,不必要的人員,工件或機(jī)器的移動Poorlayout不好的工廠布局InefficientWorkplaceOrganization工作場所缺乏組織LackofStandardization,inconsistentworkmethods缺乏標(biāo)準(zhǔn)化,不一致的工作方法Increaseoperatorfatigueleadingtootherwastese.g.defects增加作業(yè)員疲勞造成浪費,如缺陷Ergonomicissuescausinghealthe.g.repetitivemotioninjuries,etc.工效問題對健康的影響,如重復(fù)的動作性傷害127TypesofWaste七種浪費6.Waiting

Understandthedifferenttypesofwaste理解不同的浪費種類Identifythem識別浪費Carryoutyourprocessaccordingtoprocedure按照程序?qū)嵤┠愕姆椒≒roperhandlingofPCBandmaterials恰當(dāng)?shù)奶幚砦锪螰ollowthetakttime,worktocycletimeoftheprocess跟隨節(jié)拍時間工作以形成過程的周期時間Reporttosupervisorifyouspotanyofthe“waste”,like…“Iamwaiting”當(dāng)你發(fā)現(xiàn)任何浪費應(yīng)該報告給你的主管

HowcanIcontributetoeliminatewaste?怎樣才能消除浪費13UnderstandthedifferenttypeFlexManufacturingSystem(FMS)偉創(chuàng)力制造系統(tǒng)(FMS)FMSCharacteristicsFMS的特點FMSToolsandTechniquesFMS的工具和技術(shù)14FlexManufacturingSystem(FMSWhatFMSis什么是FMSAnintegratedsystemofprinciples,operatingpractices,andelementsthatdrivetherelentlesspursuitofbusinessexcellencethroughwasteidentification,eliminationandprevention.Peoplemakesithappen.FMS是一個集成了眾多生產(chǎn)原理,生產(chǎn)實踐的綜合系統(tǒng),它通過浪費的識別,消除和預(yù)防以求對卓越事業(yè)的不懈追求.其中人是最關(guān)鍵的因素.

Outcome:ValueCreationfortheCompanyandCustomer結(jié)果:為公司和客戶創(chuàng)造價值Outcome:AJourneyTowardsPerfection結(jié)果:是追求完善的旅程LEANFMS15WhatFMSis什么是FMSAnintegrate

CharacteristicsFMSwantstoachieve…典型的FMS想要達(dá)到…

People:人員:-Multifunctionalteamsindesignandproduction具備復(fù)合功能的設(shè)計和生產(chǎn)團(tuán)隊Peoplehavewidevarietyofskills(flexibility)人員具備多種技能(柔性)-Teamsperformwholetasks通過團(tuán)隊執(zhí)行任務(wù)

Tools:工具:

Low/minimalsetuptimes最少的設(shè)立時間Availability&Maintainability有用性和可維護(hù)性

Productionprocess:生產(chǎn)過程-Demandpullinsteadofschedulepush需求拉動代替計劃推動-MinimalInventories最小庫存Fast,FlexibleFlow16CharacteristicsFMSwantsto

CharacteristicsFMSwantstoachieve…

Quality:品質(zhì) -Informationcollectedduringproduction生產(chǎn)過程中的信息收集 -Problemsaresolvedduringproduction生產(chǎn)過程中解決問題Volumeflexibility:產(chǎn)量的機(jī)動性 -Switchingbetweenproductsiseasy易于更換產(chǎn)品進(jìn)行生產(chǎn) -Productionloadsareleveled生產(chǎn)負(fù)荷分等級Organization:組織 -Optimizethechain:assemblerandsupplierworkcloselytogether優(yōu)化供應(yīng)鏈:組裝員工和供應(yīng)商密切協(xié)作ProductionCustomerDemandFast,FlexibleFlow17CharacteristicsFMSwantstoFMSTools

&

Techniques

FMS工具和技術(shù)18FMSTools

&

Techniques

FMS工具FMSToolsandTechinquesFMS工具和技術(shù)Amongothers,theseareFMStoolsandtechniquesthatwillhelpustoeliminatewastesandincreaseFlextronicsSuccess:以下這些FMS工具和技術(shù)將幫助我們消除浪費和增加FLEX的成功:1. ValueStreamMapping價值流程圖 -Toidentifyvaluestreamandwaste

用于識別價值流和浪費19FMSToolsandTechinquesFMS工具ContinuousFlow連續(xù)流-Toreduceoverall7sourcesofwaste用于減少7種浪費AMaterialInventoryBInventoryCFinishProductInventoryInventoryABCMaterialFinishProductCellularManufacturing細(xì)胞制造-Toreduceoverall7sourcesofwaste

用于減少7種浪費ReceivingSawMillLathePaintGrinderStoragePlatingAssemblyStorageKaizen改善–It’satechniqueforcontinuousimprovement

持續(xù)改善的技術(shù)20ContinuousFlow連續(xù)流AMaterialIn1SeiriSort整理2SeitonStraigthen整頓3SeisoSweep清掃4SeiketsuStandardize清潔5ShitsukeSustain自律FromThis…從這里….ToThis…到這里EliminateWasteMaintaintheDiscipline5S-Basicstepforthewasteelimination消除浪費的基本步驟-Toimprovesafetyandproductivity提高安全性和生產(chǎn)力211SeiriSort整理2SeitonStraigthePullsystem拉動系統(tǒng)–Tomakevalueflowsatpullofthecustomer根據(jù)客戶的需求建立價值流XXXXXFlowofworkFlowofinformationUpstreamDownstreamSingleMinuteExchangeDie(SMED)快速換模–Aprocessforequipmentchangeoverandset-uptimereductioninunder10minutes.設(shè)備換模和設(shè)立的時間縮短至十分鐘的方法FastenhereAttachandremoveplatehereExamplesofsetupwasteseliminationassociatedwithfinding,replacingandmotion22Pullsystem拉動系統(tǒng)XXXXXFlowofwCommonMistakeproofingDevicesGuidePinsBlinkinglightsandalarmsLimitswitchesProximityswitchesCountersChecklistsSensorsLightTransmitterReceiverObjectCHECKLISTPokaYoke防錯–It’satechniquetopreventhumanmistakes

防止人類錯誤的技術(shù) Example:Forgetfulness,misunderstanding,wrongidentificationetc.例:健忘的,誤解,錯誤辨認(rèn)TotalProductiveMaintenance

全員生產(chǎn)性維護(hù)保養(yǎng)-Toincreaseuptimeofthemachine增加設(shè)備運轉(zhuǎn)時間 -Operatorinvolvementinrepairingthemachines作業(yè)員直接參與設(shè)備維修

-Reducethemaintenancecost減少維護(hù)費用23CommonMistakeproofingDeviceThe6KanbanPractices關(guān)于看板的六個實踐

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