Lean-古德里奇培訓資料9

SCIF--TimeObservation1Goodrich

ContinuousImprovement

持續(xù)改善SCIF--TimeObservation2TimeObservation作業(yè)觀察THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation3LearningObjectives學習目標Attheendofthislessonthestudentsshall:在本課程結(jié)束時，學生能夠:Knowthepurposeofdocumentingreality 明白記錄實際情況的目的Knowhowtoperformtimeobservation 知道如何執(zhí)行作業(yè)觀察Knowwhatlevelofdetailtorecord 知道記錄所需的詳細度THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation4Definition

定義TimeObservationisamethodofdocumentingreality.作業(yè)觀察是記錄實際情況的一種方法。Itmeanstogototheplacewhereaprocessoccursandrecordthedescriptionandtimeofeachworksteptoproduceoneunitofoutputbyasingleoperator

這意味著到流程發(fā)生現(xiàn)場，記錄操作員在生產(chǎn)單位產(chǎn)品時每個工作和步驟作業(yè)時間THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation5Typesofdocumentingreality實情記錄的類型TimeObservation作業(yè)觀察StandardWork標準作業(yè)PercentLoading工作載荷百分比ProcessMapping流程圖析5SEvaluation5S評估EH&SEvaluationEH&S評估THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation6Whydocumentreality?為何要記錄實情?Existingwrittendocumentsareeitherinaccurateorincomplete 現(xiàn)有的文檔不準確或不完整Tribalknowledgevariesfromemployeetoemployee員工對作業(yè)的知識參差不齊Computerreportscontainmisleadingoruselessinformation 電腦文檔內(nèi)容有誤導性或無用的信息Actualworkplaceconditionsarealwaysdifferentfromourperceptions 現(xiàn)場工作環(huán)境和我們的認知有出入THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation7Wedonotseethingsastheyare,WESEETHINGSASWEARE我們看不到事物的本質(zhì)，只看到我們認為的事實THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation8TimeObservation-mostdetailedtoolfordocumentingreality 作業(yè)觀察–最詳細的記錄實情工具Directobservationandrecordingtheinformationofatask/activitywhileitishappeningwillallowdocumentationofthefacts.Itwillnotbe:直接觀察，并記錄作業(yè)、活動的發(fā)生，可以讓我們記錄到實情。不是:Whatwethinkhappens 我們想像發(fā)生的Whatissupposedtohappen 我們認為應該發(fā)生的THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation9AllOtherDirectLaborFocusingonwhattheemployeeisdoingwillinturnexposethebalanceofthetotalcost專注員工的作業(yè)方式,將會曝露總成本的余額THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation10

Equipmentisasunkcost

設備是已支付的成本Depreciates

會貶值Wearsout

會磨損Becomesobsolete

會過時Peopleareanongoingresource人力資源是一種得持續(xù)支付的資源Appreciatesovertime

隨著時間的推移不斷加增Gainskill可獲得技能Gainknowledge可獲得知識Whyfocusonpeopleinsteadofequipment?為什么要注重人力資源，而不是設備呢?Observingtheemployeewillleadtobiggeropportunities觀察員工會導致更多機會THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation11MultipleObservationForm多次作業(yè)觀察表THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation12SingleObservationForm單次作業(yè)觀察表THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation13TimeObservationFormGuidelines 作業(yè)觀察表使用指南Onesetoftimeobservationformsperemployee每位員工（觀察對象）使用一份時間觀察表Twoobserversperemployee 兩名觀察員觀察一位員工Oneoperatesthetimepiece一人操作秒表Onerecordstheinformation一人記錄信息Focusontheemployee,notpartflowormachine/equipmentcycletime 注意員工（工作方式），而非物流或機器、設備的周期時間Completelyfilloutheaderinformationatthetopofeachsheet把表格頂部的標題信息填寫完整THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation14Priortoperformingtimeobservations在作業(yè)觀察開始前Informtheemployeeandappropriatesupervisionwhatyouwillbedoing 通知員工及其相應的管理員你要進行作業(yè)觀察Introduceyourselftotheoperator對操作員自我介紹Explaintheevent/activityandlocationofthemeetingplace解釋項目、活動和會面的地點Communicatethatyouareobservingtoidentifywasteandsimplifythetask 傳達您的觀察是用來標識浪費和簡化工作Instructtheoperatortoperformthejobasusual;asifyouwerenotthere指示操作員如常工作；正如你要不在現(xiàn)場一樣THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation15Usingthe“TimeObservationForm用“作業(yè)觀察表”First,observetheemployee;don’tbeconcernedabouttimeorelements首先，觀察員工；不要過分注意時間或單元工序Isthereapatternofconsistency?工作方式是否有重復性?Ifnorepetitiveness,instructtheemployeetofollowaspecificroutineasastartingpoint 如果沒有重復性，指示員工開始例行工序Now,wecanobserveandrecordtheelementsofthecycleinthetaskdescriptioncolumn 現(xiàn)在，我們可以開始觀察，并記錄單元工序說明欄和單元周期THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation16TimeObservationForm--ComponentTasks作業(yè)觀察表--組件工序

Describewhattheemployeedoes;useeverydaywords,notindustrialengineering-ese 描述員工的如何工作；使用日常用語，非工業(yè)工程用語Donotmixvalueaddedandnon-valueaddeditemsintoonesingleelement;describethemasseparateelements勿將增值和非增值項放進同一個單元；把它們分開成單獨的單元來描述Elementsshouldbebite-sized;“thesmallestobservabletask”單元要?。弧白钚〉目捎^察工序”O(jiān)bserveonly;donotinterview只觀察；不訪談Donothelpifthereisaproblemunlesssafetyorqualitywillbesignificantlyimpacted 出現(xiàn)問題，不能幫忙，除非對安全或質(zhì)量有嚴重的影響THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation17TimeObservationisthemostcriticaltoolindocumentingreality 作業(yè)觀察-記錄實情最有效的工具Thesmallertheelementobserved,thegreatertheopportunitytodiscoverwaste 觀察的單元越小，找出浪費的機率越大Howaggressivedowewanttobe? 我們要多積極?Howmuchwastedowewanttofind? 我們要找到多少浪費?Whatarethedetails?有什么細節(jié)?THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation18What’sthecorrectsizeelementtoobserve?觀察工序單元要多小?Thisisdirectlyrelatedtoourcurrentproblemsolvingcapacity&leanknowledge這是直接與我們現(xiàn)有解決問題的能力與精益知識Striveforelementsof30secondsorless,however爭取30秒或更少的單元，但是Acycletimeof60secondswouldneedelementsizesinthesingledigitstoexposethewaste

周期時間為60秒則需以單數(shù)字的單元來顯露浪費ElementSize,ElementSize,ElementSize!單元大小，單元大小，單元大小THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation19What’sthecorrectsizeelementtoobserve?(cont’d)觀察工序單元要多小?（續(xù)）Useyourjudgementtodeterminetheoptimumelementsize 用你的判斷來確定單元的最佳大小ElementSize,ElementSize,ElementSize!單元大小，單元大小，單元大小Usetheseguidelinesandyourdocumentationofrealityandrelatedimprovementeffortwillbemuchmoresuccessful使用這些準則，你的實情記錄文檔和有關改進的努力會更成功THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation20Consequencesofrecording“toosmall”elements記錄“太小”單元的后果You’llmisssomethingbyalwayswriting 你總是寫而錯過了些什么Youwon’tbeabletoreadwhatyouwrote 你無法了解你所寫的Yourfrustrationlevelwillreachcapacity 你的挫折的水平達到容量ElementSize,ElementSize,

ElementSize!單元大小，單元大小，單元大小THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation21Drawbacksofhaving“toolarge”elements

單元“太大”的壞處HighprobabilitythatVAandNVAarecombined

很可能在同個單元里有增值和非增值的工序Can’tseethedetailofwhathappened

無法說明發(fā)生的細節(jié)You’llmissopportunitiestoremovewaste

會錯失消除浪費的機會ElementSize,ElementSize,

ElementSize!單元大小，單元大小，單元大小THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation22UsingtheStopwatch使用秒表Keepthewatchrunningfortheentireobservation秒表在整個觀察過程中保持走動Recordthecumulativeelapsedtimeinthetophalfofthedividedboxwhentheoperatorcompletesoneelementandtransitionstoanother 當操作員完成一個單元，過渡到下一個單元時，把累積時間填寫在方格上半部Aftercompletionoftheobservation,individualelementtimescanbedetermined(bysubtraction)andrecordedinthebottomhalfofthebox 當觀察完畢后，相減得單元時間，并記錄在方格下半部THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation23AdvantagesofKeepingtheWatchRunningfortheEntireObservation

在觀察過程保持秒表走動的好處Reducesmissedtimes,eitherwhenlookingatcyclesorspecificelements

減少因為觀察某個單元而錯失的時間Eliminatestendencytoeditpotentiallyvaluableitems--Thesemaybeabnormalthingsthatwetendtodismiss,forexample,machinegoingdown,brokentools,badsupplierparts,etc.

避免重要項目被修改的可能性--這些項目可能是我們常忽視的異?，F(xiàn)象，例如，機器停產(chǎn)，工具破損，外供零件缺陷等。THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation24TwoPersonObservingTeamTechnique二人小組的觀察技巧Therecorder-observerobservesthetasksandwritesthemintheTaskDescriptionblockofStep.Attheendofeachtask,therecorder-observercalls“time” 記錄兼觀察員觀察員工工作，并把單元工序?qū)懺诓襟E工序說明欄（TaskDescription）內(nèi)。在每項單元結(jié)束時，記錄兼觀察員喊”時間”Thestopwatchoperatorstatesthetimefromthestopwatch.Forexample,“42”or“1:13”meaning42secondsorone-minuteand13secondshaveelapsedfromstartingtheobservation. 秒表操作員即時讀出秒表時間例如，“42”或“1:13”。意思是從觀察開始已過了42秒或1分13秒。Therecorder-observerthenwritestheelapsedtimeinthetopblockoftheStep 記錄兼觀察員把秒表操作員讀出的秒表時間，（則已過時間）填寫在這步驟方格的頂部方塊內(nèi)THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation25TimeObservationForm:PointsObserved

作業(yè)觀察表：觀察到的重點Maybethemostimportantcolumnontheform

可能是這個表里最重要的一欄Usedto:

用來:Captureopportunities

記錄可改善的機會Highlightareasforadditionalinvestigation顯出需要額外調(diào)查的地方Commentonvariationintime

闡明時間長短變化的原因Identifysafetyorqualityconcerns

提出工作現(xiàn)場安全或質(zhì)量隱憂Explainobviousimprovement

解釋明顯的改進方法Boththepersonrecordingtheinformationandthepersonoperatingthewatchshouldmakeobservationsoftheoperatorsothemaximumamountofinformationcanberecorded.

記錄兼觀察員和秒表操作員都要觀察操作員，并記錄觀察到的重點，以便獲取更多的改善的機THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation26MultipleObservationsarerecommended建議多次觀察員工作業(yè)Willexposeanyvariationintheprocess 顯出各次作業(yè)中的時間變異VariationwillunderminequalityandmaketheCT=TTequationdifficulttoestablish 時間的變異可能會降低質(zhì)量，并使等式CT=TT難以建立Variationprovidesfertilegroundforimprovement時間變異化為改進提供有利基礎We’reobligatedtounderstandthesevariances我們有義務找出時間變異的原因THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation27Ifatimeismissed,simplymarktheboxwiththeletter“m”andkeepgoing.Don’tpanic,anddon’tstopthewatch!Alsonotethatamissedtimewillresultintwoblankelementtimeboxes.如果錯失一個單元時間，就在方格內(nèi)記個“m”，然后繼續(xù)。不要驚慌，也不要停止秒表!務必繼續(xù)觀察！并且注意錯失的時間會照成兩個空白單元時間格TimeObservationFormExample作業(yè)觀察例Notethatthetimesarecumulative--keepthestopwatchrunning!注意：記錄的時間是累積的–確保秒表走動!Makesuretokeepappropriatelydetailednotesduringtimeobservations確保在時間觀察中記錄祥細的細節(jié)Runningtime(watchtime)isinthetopoftheblock累積時間（秒表時間）寫在白色方格。NOTE:ThisTOusedastopwatchthatreadsoutindecimalsecondsonly.注：此TO使用展示小數(shù)秒的秒表THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation28Ifatimeismissed,simplymarktheboxwiththeletter“m”andkeepgoing.Don’tpanic,anddon’tstopthewatch!Alsonotethatamissedtimewillresultintwoblankelementtimeboxes.如果錯失一個單元時間，就在方格內(nèi)記個“m”，然后繼續(xù)。不要驚慌，也不要停止秒表!務必繼續(xù)觀察！并且注意錯失的時間會照成兩個空白單元時間格Makesuretokeepappropriatelydetailednotesduringtimeobservations(usuallyonlyonechancetoobserve,won’tbeabletowatchitagain)

確保在時間觀察中記錄祥細的細節(jié)（通常只有一次機會，可能不能再觀察了）Notethatthetimesarecumulativenoneedtorecordhour(exceptwhenitchanges)切記：記錄的時間是累積的–不必記錄小時（除非有改變）Runningtime(watchtime)isinthetopoftheblock

累積時間（秒表時間）寫在白色方格。NOTE:ThisTOusedastopwatchthatreadsoutinseconds,minutes,andhours.注：此TO使用展示秒，分和時的秒表THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation29TimeObservationForm-DataAnalysis作業(yè)觀察表–分析數(shù)據(jù)Calculateindividualelementtimes計算單元時間Determinetheoverallcycletime計算周期時間IdentifyVA,NVAandanyabnormalelements 分辨增值，非增值和任何異常單元Determineifexcessvariationispresent 確定是否有過多的時間變異Identifyproblems/issues/opportunities(afterrealityiscompletelydocumented) 在完成實情記錄后，找出問題/爭議/機會（IPO）。THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation30Calculateindividualelementtimes 單元時間計算法ElementtimescanbecalculatedattheendoftheTOthroughsubtraction.Theyarerecorded(inseconds)inthebottomhalfofthebox.Becausewerecordthetimeattheendofeachelement,the“0”starttimeisrecordedinthetopoffirstbox.在作業(yè)觀察后，用互減計算單元時間。把單元時間（以秒）記錄在方格下半部。因為我們是在單元完成時記錄時間，“0”的開始時間假設記錄在第一行。

Example:260-247=13例：260-247=13THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation31Example:18m40s-15m10s=3m30sor210s例：18分40秒-15分10秒=3分30秒或210秒ElementtimesarecalculatedattheendoftheTOthroughsubtractionandarerecorded(inseconds)inthebottomhalfofthebox.Becausewerecordthetimeattheendofeachelement,the“0”starttimeisassumedtoberecordedabovethefirstline.25-0=25在作業(yè)觀察后，用互減計算單元時間。把單元時間（以秒）記錄在方格下半部。因為我們是在單元完成時記錄時間，“0”的開始時間假設記錄在第一行。25-0=25THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation32MultipleObservationForm-ElementTaskTimeDetermination 多次作業(yè)觀察表–如何確定單元工序時間Howdowerecognizevariationfromthetimeobservationform?如何從作業(yè)觀察表中找出時間長短變化?Ifthesinglelowesttimeisalwayschosen,whatcouldhappen?總是選擇最短的單元時間，會出現(xiàn)什么狀況?Ifanaverageiscalculated,whatwouldthiscause?用平均值，會出現(xiàn)什么狀況?Ifthesinglelongesttimewaschosen,whatwouldthismean?總是選擇最長的單元時間，

意味著什么THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation33MultipleObservationForm-ElementTaskTimeDetermination

多次作業(yè)觀察表–如何確定單元工序時間Usethelowestrepeatabletimefortheelement

使用最小可重復單元時間Aslongasworkisdoneinasafemannerandrequiredqualitylevelsaremaintained

只要工作能安全完成，并且質(zhì)量得以保證Understandwhythevariationisoccurringandimplementcountermeasurestoeliminate/reducethevariation

了解時間長短變化產(chǎn)生的原因，并執(zhí)行消除/減少變化的對策Don’tignorethisvariationortherecordedcycletimewillnotbeachieved

不要渺視單元工序時間的變一，不然所記錄的周期時間將會無法達到THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation34ElementTaskTimeDetermination確定單元工序時間Foreachelement,pickthelowestrepeatablerecordedtimeandenteritintheTaskTimeblock選出最小可重復單元時間，把它填到工序時間方格內(nèi)。AddupalltasktimestogetoverallcycletimeandenterithereontheTOform把所有工序時間相加得出總周期時間，把它填到TO表內(nèi)THISDOCUMENTSUBJECTTOTHECONTROLSANDRESTRICTIONSONTHEFIRSTPAGESCIF--TimeObservation35VAandNVAElementDetermination VA和NVA單元的確定IdentifyVAandNVAelementsontheTOform 在TO表內(nèi)標識VA和NVA單元Usecolorcode(green/red)toidentifywhiche