Lean Manufacturing 4精益生產(chǎn)4英文

1、lean manufacturing training week 4Copyright Futuris Automotive Interiors All Rights Reserved2TPS 全程生產(chǎn)管理目視化管理穩(wěn)定標(biāo)準(zhǔn)化過程標(biāo)準(zhǔn)生產(chǎn) (Heijunka) 及時(shí)正確的零件, 數(shù)量, 時(shí)間生產(chǎn)節(jié)拍持續(xù)流程拉動(dòng)體系快速切換完備物流 Jidoka(現(xiàn)場(chǎng)質(zhì)量)問題可見性自動(dòng)停止暫停人與機(jī)器分離防錯(cuò)現(xiàn)場(chǎng)質(zhì)量控制解決根本原因 (5 Whys)高品質(zhì)高品質(zhì) 低成本低成本 短周期短周期 更安全更安全 高士氣高士氣簡(jiǎn)化生產(chǎn)流程排除浪費(fèi) lean manufacturing foundations 個(gè)人 &a

2、mp; 團(tuán)隊(duì)*選擇*快速?zèng)Q定*共同目標(biāo) *交叉培訓(xùn) 減少浪費(fèi)*Genchi Genbutsu*聚焦浪費(fèi)*5 為什么 *問題解決 持續(xù)改進(jìn)持續(xù)改進(jìn)Copyright Futuris Automotive Interiors All Rights Reserved3line balance adjusting the spread of work evenly between operators to the rate of customer demandremember:TAKT time available work time/customer demandcycle time actual

3、time to complete the tasksCopyright Futuris Automotive Interiors All Rights Reserved4line balancebenefits:improve throughput of assembly lineencourage one-piece flowincrease labour utilisationreduce costCopyright Futuris Automotive Interiors All Rights Reserved5line balanceYamazumi Japanese word lit

4、erally meaning to stack upstacked bar chart that shows the balance of cycle time workloads between a number of operators typically in an assembly line or work cellCopyright Futuris Automotive Interiors All Rights Reserved6line balanceeffects of imbalanceexcess inventoryidle equipmentidle peopleteam

5、dissensionindividual frustrationCopyright Futuris Automotive Interiors All Rights Reserved7line balanceLine Balance ExerciseCopyright Futuris Automotive Interiors All Rights Reserved8problem solvingwithin all organisations there are an endless supply of problemsthe inverse of a problem is an opportu

6、nity problems often classed as failures and thus hidden rather than addressed“every problem is an improvement opportunity”Copyright Futuris Automotive Interiors All Rights Reserved9problem solvingtraditional method of correcting problemscorrect problems off line in rework areas/baysadded layers of i

7、nspectionreluctance to identify problems & solutions not exploredproblems continue, added cost to correct laterapplication of 6 sigma and SPC to solve problemsCopyright Futuris Automotive Interiors All Rights Reserved10problem solvingnew approach stopping line to fix problems (Jidoka)principle “

8、get quality right the first time”stop to fix problems do not allow defects to pass through to next processurgency to fix problems challenges people to thinkAndon, Jidoka, Poke Yoke, Standard Work, Problem Solving, Trainingmotivation to identify and solve problemsCopyright Futuris Automotive Interior

9、s All Rights Reserved11problem solvingProblem Solving Process1.Define Problem2.Complete root cause analysis3.Consider solutions through consensus4. PDCA5. Reflect and learnCopyright Futuris Automotive Interiors All Rights Reserved12problem solving1.Define the problem go to where the problem is and o

10、bserve the situation without preconceptioncompare the actual situation to the standarduse Pareto Analysis to prioritise a number of different problemsset targets for improvement“Carefully aim before firing”Copyright Futuris Automotive Interiors All Rights Reserved13problem solvingPareto Chart (80/20

11、 Rule 80 percent of the problems stem from 20 percent of the causes)Copyright Futuris Automotive Interiors All Rights Reserved14problem solving2.Complete root cause analysisAnalysis not clouded no preconceived ideas of source of problemAnalysis continued until true “root” cause of problem are discov

12、eredMultiple causes for problems complete comprehensive analysisVarious problem solving tools availableCopyright Futuris Automotive Interiors All Rights Reserved15problem solving5 whys ask “why?” five timesexample:WHY is the press leaking? There is a crack in the oil filterWHY is the filter cracked?

13、 Because it gets too hot during useWHY does it get hot? Because cooling system not workingWHY doesnt the cooling system work? Too much dust on coilsWHY is there too much dust on coils? The air intake filter is missing!SOLUTION: Replace air intake filterCopyright Futuris Automotive Interiors All Righ

14、ts Reserved16problem solvingCause and effect (aka Fishbone diagram)Generate a comprehensive list of possible causesLead to greater understanding of the problem4Ms Man, Machine, Materials, Methods (additional Ms include M-environment and Measurement) easier identification and analysisCopyright Futuri

15、s Automotive Interiors All Rights Reserved17problem solvingCopyright Futuris Automotive Interiors All Rights Reserved18problem solvingHow to draw cause and effect diagramThis is a three step process.Step 1Write down the effect to be investigated and draw the backbone arrow to it. In the example show

16、n below the effect is Incorrect deliveries. Copyright Futuris Automotive Interiors All Rights Reserved19problem solvingStep 2Identify all the broad areas of enquiry in which the causes of the effect being investigated may lie. For incorrect deliveries the diagram may then become:Copyright Futuris Au

17、tomotive Interiors All Rights Reserved20problem solvingStep 3write in detailed possible causes in each of the broad areas of enquiry. Each cause identified should be fully explored for further more specific causes which, in turn, contribute to them. Copyright Futuris Automotive Interiors All Rights

18、Reserved21problem solvingBrainstorminga group creativity technique to generate a large number of ideas for the solution of a problembreak out of stale, established patterns of thinking to develop new ways of looking at thingsCopyright Futuris Automotive Interiors All Rights Reserved22problem solving

19、 3. Consider solutions through consensusStep 1.Broadly consider all possibilitiesStep 2. Narrow list by eliminating impractical solutionsStep 3. Evaluate based on simplicity, cost, quality and ability to implement quicklyStep 4. Develop consensus on the proposed solutionConsensus through cross-funct

20、ional team supervisor, operator, quality, manufacturing engineering, logistics, design engineering etc Copyright Futuris Automotive Interiors All Rights Reserved23problem solving4. PDCA - also known as Shewhart CycleAn iterative 4 step quality control strategyGet from “problem faced” to “problem sol

21、ved”Copyright Futuris Automotive Interiors All Rights Reserved24problem solvingP-PlanDevelop action plan to deliver required resultsD-DoImplement solutions rapidlyC-CheckVerify the resultA-ActMake necessary adjustments to solutions and action plan and determine future stepsCopyright Futuris Automotive Interiors All Rights Reserved25problem solving5. Reflect & learn from processBecome a learning org