上海通用精益生產(chǎn)

1、精益生產(chǎn)的歷史Lean Manufacturing History 1955豐田制造系統(tǒng)TOYOTA PRODUCTION SYSTEM 1979 質(zhì)量體系 QUALITY SYSTEM 1983 NUMMI, SYCHRONONS MANUFACTURING 1990 LEAN MANUFACTURING, ESENACH 1995 DELPHI MANUFACTURING SYSTEM 1996 GM-GMS 1998 COMPETITIVE MANUFACTURING適應性經(jīng)濟性尊尊重重人人才才，發(fā)發(fā)揮揮人人的的作作用用不不斷斷暴暴露露問問題題，不不斷斷改改善善Edited by 意識改

2、革*5S追求7個極限目標Edited by Edited by GMS簡介簡介GMS Brief Introduction GMS簡介簡介GMS Brief Introduction 通用汽車全球制造系統(tǒng)的原則和要素構成了一個完整的系統(tǒng),只有把它作為一個完整的整體實施才能有效。各原則之間相輔相成，沒有一個原則或要素能獨立存在。因此我們用一個類似太陽系的圖標來表示GMGMS。只有當五個原則共同實施，GMGMS才是一個完整的系統(tǒng)。The principles and elements of GM-GMS comprise a comp-lete system, and to be effectiv

3、e must be taken toget-her as a whole. Each principle supports and reinforces the others. No one principle or element can stand alone. For this reas-on, the solar system icon is used to symbolize GM-GMS. GM-GMS is a complete system when all five principles are implemented. GMS簡介簡介GMS Brief Introducti

4、on GMS簡介簡介GMS Brief Introduction 8個要素8 Elements1. 宗旨、價值觀和文化理念 Vision, Values, & Cultural Priorities 2. 使命 Mission3. 健康和安全第一 Health & Safety Priority4. 合格的員工 Qualified People5. 人員支持系統(tǒng)/小組原則 People Support System/Team Concept6. 員工參與 People Involvement7. 開放式交流 Open Communication Process8. 車間現(xiàn)場管理 Shop Fl

5、oor Management目的：目的：引導員工的個人行為和公司決策，創(chuàng)造一個關注過程和結果的氛圍。Purpose: To guide individual behavior and organizational decisions, creating a process and results focused culture. 核心要求核心要求 Core Requirements:u 領導層維護和糾偏 Leadership champions the Corporate Vision, Core Values, and Cultural Priorities u 明確清晰The Vision

6、, Values, and Cultural Priorities are clearly u 公司的政策（包括一、二、三級文件）與其一致Policies, practices, procedures, and systems are consistent with the Vision, Values, and Cultural Prioritiesu 領導層以身作則Leadership leads by example u 評估和改進，確保公司宗旨、價值觀和文化理念的一致性Evaluate and improve to ensure consistency with the Vision,

7、 Values, and Cultural Priorities1.宗旨、價值觀和文化理念Vision, Core Values and Cutrual Priorities 2. 使命MISSION定義：定義：傳達給具體車間或職能部門的一個目標或者期望 值的陳述Definition: A local statement that conveys a mental image of the goal or desired state for a specific plant or function. 目的：目的：激勵員工工作并使全體員工知道、理解并趨近理解并趨近公 司的奮斗目標Purpose:

8、 To motivate/inspire people to act and help the entire workforce visualize, understand, and relate to the organizations competitive goals and objectives. 核心要求：核心要求：Core requirements:l是公司領導層制定和牽頭，全公司共同參與的Developed and championed by leadership and shared with the entire organization. l支持公司的宗旨、價值觀和文化理念

9、，并與其保持一致Aligned with and supports the Corporate Vision, Values, and Cultural Priorities. l全公司上下理解和全力支持Understood and committed to by all levels of the organization l審查策略、行動和體系以保證提供支持Strategies, activities, and systems are reviewed to ensure they support peoples efforts to reach the mission. l需支持公司的業(yè)

10、務目標Supports the business goals and objectives. l有定期評審使命陳述的流程A process is in place to periodically evaluate the Mission Statement. 定義：定義： 實施一系列的行為、措施、政策和方法以幫助 員工實現(xiàn)一個健康無傷害的工作環(huán)境。Definition: Implementation of behaviors, actions, policies, and practices that help our employees realize a healthy, injury f

11、ree environment.目的：目的： 以安全是最重要的、所有的事故都是可預防的安全是最重要的、所有的事故都是可預防的 理念理念為指導，采取切實的措施保證員工良好的 健康狀況和健康無害的環(huán)境Purpose: To ensure we protect the well being of our people through actions consistent with the belief that safety is our overriding priority and all accidents are preventable. 3. 健康和安全優(yōu)先Health and Safet

12、y Priority 核心要求：核心要求：Core Requirements: l 領導層對所有健康和安全核心要素的實施和監(jiān)控負責 Leadership is responsible for implementation and monitoring of these Health and Safety core requirementsl 工廠安全回顧板 Plant Safety Review Boardl 定期安全巡檢 Safety Observation Toursl 安全作業(yè)（危險的工作，有健康和安全作業(yè)指導書）Safe Operating Practices (Health and

13、Safety standardized work instructions are documented and implemented for jobs where risks to employees warrant)l 事故調(diào)查（“5個為什么”問題解決流程)Incident Investigation (“5 Why” problem solving process )l 嚴格遵守安全規(guī)章Abide by the safety rules strictly4.合格的員工Qualified People 目的：目的： 確保員工的能力與競爭性的生產(chǎn)制造角色 和職責相匹配Purpose: To

14、 ensure the best possible fit of peoples abilities with the expectations of the competitive manufacturing roles and responsibilities. 核心要求核心要求Core Requirements ：l 制定行為規(guī)范，體現(xiàn)公司核心價值觀，書面形式交流 Competencies (Required Behaviors) are defined for each level of the organization l 選擇 Selectionl 培訓 Trainingl 激勵

15、Inspiritl 發(fā)展 Development 5.員工支持系統(tǒng)/班組原則People Support System / Team Concept 定義：定義： 賦予各班組主人翁和基本工作單位的功能使小組成 員共同承擔職責相互支持，通過不斷改進達到共同 的目標Definition: Small groups of employees that are empowered to function as the owners and basic work unit who share common tasks, support each other, and achieve common goa

16、ls through continuous improvement.目的：目的： 通過團隊合作使員工參與整個工作過程，不斷改進 自身表現(xiàn)，產(chǎn)品質(zhì)量和工作環(huán)境，最終樹立員工自 豪感和工作成就感并促進員工個人的發(fā)展Purpose: To involve employees in the work process to continuously improve performance, product quality, and working conditions through teamwork. To develop employee pride, job satisfaction, and p

17、ersonal growth.核心要求核心要求 Core Requirements：l 制定各級和職能塊的職責Roles and responsibilities for each level and function of the organization are defined. l 履行,交流T/M, T/L, G/L職責Team members, team leaders, and group leaders fulfill responsibilities of their position. l 班組原則 Team criteria.l 業(yè)務系統(tǒng)和實踐操作支持小組原則的實施Busi

18、ness systems and practices support implementation of the team concept.l 班組長的選擇 Team leader selection.l 班組長支持小組和班組目標的標準化任務Team Leaders are not assigned standardized work but are assigned standardized tasks that support the team and objectives.l 支持部門對于班組的支持（HR,財務，工程部，質(zhì)量部等）Support organizations (e.g. H

19、R, Finance, Engineering, Quality, etc.) understand and execute their responsibility to the teams.6.人員參與People Involvement定義：定義：一整套鼓勵員工以積極的態(tài)度參與公司不斷改進活 動的系統(tǒng)、程序、實踐和方案Definition: Systems, procedures, practices, and programs that involve all employees as active participants in continuous improvement acti

20、vities.目的：目的：營造和保持一種培育“自豪感”的氛圍。 Purpose: Create and maintain an environment which fosters a spirit of pride”.核心要求：核心要求： 實施計劃幫助員工作出有依據(jù)的決策和改進 Programs and activities are implemented to help people make informed decisions and improvements. 實施活動（合理化建議，Go fast(加速），持續(xù)改進等）Implement activities (e.g. suggest

21、ion program, GoFast Activities, CIP Programs, etc.) 建立小團隊參與持續(xù)改進Small groups are established and participate in improvement activities. 給予員工/團隊認可Recognition is provided to employees/teams. 個人、小組和公司績效應與福利待遇系統(tǒng)掛鉤 Individual, team, and company performance is factored in to the compensation system. 7.開放式交

22、流流程Open Communication Process定義：定義： 為營造一種所有層次都能暢所欲言和有效 交流的氛圍的手段和方法。Definition: Behaviors and practices that create an environment that fosters a free and open flow of communication at all levels.目的：目的： 交流信息使各級員工作出有依據(jù)的決策和 改進部門的表現(xiàn)。Purpose: To exchange information that helps people at all levels make i

23、nformed decisions and improve organizational performance. 核心要求核心要求Core Requirements：會議交流 Conduct regularly scheduled meetings to communicate交流媒介（Notes，暗燈板，其它可行的交流工具） Use communication media effectively (e.g. Notes, Andon boards, or any communication tools available). 營造公開交流的辦公環(huán)境（開放式辦公室，玻璃分隔，支持部門靠近制造

24、生產(chǎn)部門，小組會議區(qū)域，關注操作人員信息的及時獲?。〦nsure the physical environment fosters open communication (e.g. open offices, glass partitions, support departments in close proximity to the manufacturing organization, group meeting areas, concern about). 領導層以身作則（平易近人，能主動聽取意見和深入車間）The leadership style demonstrates behavi

25、ors exhibiting open communication (e.g. accessibility, active listening skills, floor presence).信息快速傳遞的結構程序A structured process is in place to quickly disseminate information (e.g. promotion announcement, cancellation of overtime). 8.車間現(xiàn)場管理Shop Floor Management定義：定義： 管理和支持小組的行動要在工作現(xiàn)場進行，便于 理解，支持和管理操作

26、Definition: The behavior of management and support groups to go to where the work is performed, to understand, support, and manage the operations.目的：目的： 確保所有的決策均在工作現(xiàn)場利用相關、實際、 正確的第一手材料作出Purpose: To ensure that decisions are made at the work site by utilizing relevant, factual, accurate, and first-han

27、d information.核心要求：核心要求：定期的管理評審（SPQRC)和流程評審(5S,標準化工作）Regular Management reviews include SPQRC (Safety, People, Quality, Responsiveness, Cost) and process evaluations (e.g. Workplace Organization/5S, Standardized Work). 每個員工都了解SPQRC的狀態(tài)SPQRC status indicators are visible so every employee can see and

28、understand current conditions. 管理支持人員幫助班組成員通過直接觀察相關工藝/工作區(qū)域來解決問題 Management and Support Personnel assist Team Members to solve problems by directly observing the process/work area where concerns exist 問題的通報流程 （問題升級）Problem escalation processes are developed車間辦公室到達所有生產(chǎn)區(qū)域，Team Room設置在線旁Shop offices mus

29、t be accessible to all production areas and team leader workstations are located line side. 會議/休息區(qū)域能容納所有員工且在一線主管（工段長/值班長）的控制/責任范圍內(nèi)Meeting/break areas are to be sized to accommodate all members within the first line supervisors span of control/responsibility (group leader/area leader) where appropria

30、te.定義和消除浪費（七種浪費）Waste is actively identified and eliminated. 目視化管理 Visual Management： -偏離標準的情況對每個人可見 make deviations from standards visible to everyone -用顯而易見的方式顯示操作狀態(tài) display the operating status in an easy to see format -提供指示和/或信息給員工 provide instruction and/or information to employees標準化標準化 標準化是不斷

31、改進的基石9.工作場地有序布置 Workplace Organization 10. 節(jié)拍定額時間管理 Management By Takt Time 11. 標準化作業(yè) Standardized Work 12. 目視化管理 Visual Management 9.工作場地有序布置Workplace Organization 核心要求核心要求 Core Requirements：l5S標準l員工的參與 People involvementl去除多余物品Excess or non-essential things are eliminated. l評估和改進 Audit and adressS

32、ort分類Sift篩選Sweep清掃Sustain保持Self-discipline自律物在其位，位有其物物在其位，位有其物目的：目的：通過工作場地的布置和保持，使“不符合標準”的情況顯而易見。Purpose: To put order to and maintain the workplace by making out of standard conditions readily visible.定義：定義：用于調(diào)節(jié)和均衡滿足銷售需求的生產(chǎn)產(chǎn)量的測量體 系。Definition: A measurement system that regulates and levels the prod

33、uction output to meet sales demand TT=生產(chǎn)時間（秒）/客戶需求（件）目的：目的：均衡生產(chǎn)計劃且生產(chǎn)所需的產(chǎn)量。Purpose: To level the production schedule and produce what is needed when it is needed. 作用：杜絕七種浪費之：“過量生產(chǎn)，等待過量生產(chǎn)，等待”zl:結合開動率，分析一下TT,ATT,CT,JPH之間的關系。10.節(jié)拍定額時間管理Management By TAKT Time 核心要求核心要求 Core Requirements：lATT近似滿足需求，TT與AT

34、l在某一段時間內(nèi)（至少一個月）保持節(jié)拍定額時間和實際節(jié)拍定額時間固定。Takt time and actual takt time remains fixed for a period of time one month minimum. l 應對變化的流程（具體的流程）Procedures must be established to manage takt time and actual take time changes (detailed process).l 相關文件的修改 Relevant documents modificationl 輔助設施 Assistant facilit

35、y11.標準化作業(yè)SOS定義：定義：由功能組織同意，制定，遵守和保持的可用于重復 性工序的功能性文件。Definition: The documentation of work functions performed in a repeatable sequence, which are agreed to, developed, followed, and maintained by the functional organization.目的：目的：為持續(xù)改進建立可重復，可預測的基礎并使操作者 參與最初和不斷的改進過程以便獲得最高水平的安 全，質(zhì)量和生產(chǎn)率。Purpose: To esta

36、blish a repeatable, predictable baseline for continuous improvement and to involve the operator in both the initial and ongoing improvements to achieve the highest levels of safety, quality, and productivity.核心要求核心要求 Core Requirements:l 記錄并且標準化所有重復性工作All repeatable work must be documented and standa

37、rdizedl 需記錄的要素 The following criteria are documented l 所有班次的同意（保證不同班次、不同的人做的一樣）All elements and detail of standardized work must be agreed to across all shifts. l 清晰可見 Visually displayedl 評審和改進 Audit and adressl 生產(chǎn)和支持人員共同參與Manufacturing and support personnel involvementzl:可以在標準化作業(yè)單中體現(xiàn)出改版的歷史。12.目視化管理

38、Visual Management目的：目的：使工作場地的標準和實際狀況一目了然Definition: A process in which standards and actual conditions become quickly visual in the workplace.特點 Specialty：1.作為一種管理手段Work as an measure of management 2.管理差異性Manage the discrepancy 3.是即時的Instantaneous核心要求核心要求 Core Requirements：l目視管理使用和范圍 the extent and

39、use of visual management l在標注化作業(yè)中，關鍵或規(guī)范的程序應有特別的目視標示Critical or regulated processes receive special visual identifications on the standardized work. l更新并維護目視管理表格和工具Visual management forms and tools are current and maintained l用于相同應用的目視化方法必須標準化The methods to visualize common applications must be stand

40、ardized l當前和標準的（指標或目標）的狀態(tài)必須清晰可辨 Both the current and standard (target or goal) conditions must be clearly identifiable.l簡單明了 Easily understood l難以立即改正，應記錄、張示并交流其相應對策Countermeasures for observed out-of-standard conditions that cannot be easily rectified must be documented, displayed, and communicated

41、. （與問題解決的鏈接）應用：工位地址牌，標簽，線標識，暗燈板Application: station address brand, label, line indication, Andon board 5 5個要素個要素5 Elements1. 產(chǎn)品質(zhì)量標準 Product Quality Standards 2. 制造工藝認證 Manufacturing Process Validation 3. 工序內(nèi)控制及驗證 In-Process Control & Verification4. 質(zhì)量反饋/前饋 Quality Feedback/Feedforward 5. 質(zhì)量系統(tǒng)管理 Qual

42、ity System Management13.產(chǎn)品質(zhì)量標準Product Quality Standards定義：定義：產(chǎn)品特性可測的要求，這些要求如能滿足， 將確保我們的產(chǎn)品達到內(nèi)/外部客戶的要求Definition: Measurable requirements for product characteristics, which when satisfied, ensure our products meet internal/external customer requirements.目的：目的：提供產(chǎn)品評估的標準 Purpose: To provide criteria for

43、 product evaluation.核心要求核心要求 Core Requirements:制定,批準,修改的流程(PTQ-1-00-0021.012004 .12.30)A documented process is in place to develop, approve, and revise the product quality standards. (PTQ-1-00-0021.012004 .12.30)質(zhì)量標準 quality standards 滿足用戶,工程,法規(guī)的要求Product quality standards must satisfy customer 用于反饋

44、給工程部的正式的流程A formal process exists to feed back工具tools：KPC, SOS, Visual Aids，邊界樣品，工序檢查記錄 表，質(zhì)量檢驗規(guī)范，冷試規(guī)范，熱試規(guī)范14.制造工藝認證Manufacturing Process Validation 定義：定義：在開始全面生產(chǎn)前進行工藝準備和認證的方法在開始全面生產(chǎn)前進行工藝準備和認證的方法Definition: The method by which processes are prepared and validated before starting full volume productio

45、n.目的：目的：確保每道制造工序在完成生產(chǎn)計劃的同時達到既定 的產(chǎn)品質(zhì)量標準Purpose: To ensure that each manufacturing process is capable of meeting defined product quality standards, while achieving schedule. 核心要求核心要求 Core Requirements: 符合GPDP工具 Tools： Process Flow Diagram（Review) Process Control Plan（Review) PFMEA（RPN） PTR Bucket Buil

46、d PPAP，Pilot，F(xiàn)irst piece15.在線控制及驗證In-Process Control & Verification 定義：定義：通過預防，檢測和遏制非正常狀況在工位上造入質(zhì)量的系統(tǒng)Definition: The system of building quality in station through prevention,detection,and containment of abnormalities.目的：目的：減少工序的波動以確保在工位上的所有產(chǎn)品都符合質(zhì)量要求，并且盡可能快地在制造后的下道工序得到確認以減少缺陷相關的浪費Purpose: To minimize

47、process variation to ensure that all products are OK in station and are confirmed as soon as possible following manufacture and to reduce waste associated with defects. 核心要求: 預防 Prevention 檢測 Detection 遏制 Containmentn下述情況 前饋前饋 缺陷外溢 備用工具/設備 問題解決（經(jīng)驗借鑒） 產(chǎn)品/工藝變更下述情況 反饋反饋 缺陷確定 問題解決 為問題解決提供流程 記錄跟蹤工具：暗燈，問題

48、解決跟蹤系統(tǒng),CARE前饋：對于可能發(fā)生的質(zhì)量問題進行事先的控制反饋：對于已發(fā)生的質(zhì)量問題進行控制16.質(zhì)量反饋/前饋Quality Feedback/Feedforward 目的：目的：確保質(zhì)量信息達到需要這些信息的人員手中 Purpose: To ensure that information on quality reaches those who need it. 核心要求核心要求 Core Requirements:文件形式確定:v每道工序的客戶和供應商v客戶和供應商所需的時間表,內(nèi)容等v工序內(nèi)測量(FTQ等)17.質(zhì)量系統(tǒng)管理Quality System Management 目的

49、：目的：定義和規(guī)范質(zhì)量活動的既定操作 Purpose: To define and regulate the intended operation of the quality activities.包括：QS-9000體系，質(zhì)量閥流程，GPDP（GQS）Including: QS-9000 system, Quality valve process, GPDP(GQS)核心要求核心要求 Core Requirements: :質(zhì)保向工廠領導匯報Head of quality department reports to Manager/Director of the plant. 質(zhì)保有足夠的

50、資源Assure resource allocation for quality activities is sufficient 與質(zhì)量體系相符compliant with the appropriate quality system standard(s)與質(zhì)量相關職能的合適的組織結構An appropriate organizational structure is in place for quality related functions BPD來管理和跟蹤The BPD process is used to manage measurements and track progres

51、s to goals.17.質(zhì)量系統(tǒng)管理Quality System Management 產(chǎn)品質(zhì)量標準u清晰易懂 clearly communicated to the user u融于標準化作業(yè)中 incorporated in standardized worku統(tǒng)一的 commonu不能比前道工序應用的標準更苛刻not tighter than those applied in upstream processesu在工藝的每一階段都有定義和應用defined & applied at each stage of the processu對于已經(jīng)建立的標準是可測量,可比較measura

52、ble and/or comparable with established criteriaGPDP 結合防錯到工藝/產(chǎn)品設計中 在工藝開發(fā)過程（至少:關鍵工藝）中使用FEMA方法 確定和實施工序控制來符合工程要求（KPC工藝控制計劃） 有人、機、料、法和環(huán)的變更時，對工藝進行認證 (PTS-0101.012000-4-24工藝驗證程序) 在生產(chǎn)情況下實施制造認證 (PPAP) 使用前認證工具、設備、料箱、檢具和方法 (PTS-0101.012000-4-24工藝驗證程序) 在系統(tǒng)完成之前實施TPM計劃 預防Preventionu 標準化作業(yè)(生產(chǎn),維修,檢查)SOS( Manufactur

53、e, Maintenance, Inspection)u TPMu 遵循零件質(zhì)量控制計劃Follow parts quality control planu 符合標準的部件才能運到生產(chǎn)線旁(來料檢查)Only qualified parts can be delivered to the line (material check)u 關鍵設備的檢查 Key equipment checkingu 驗證工序改變后的有效性Effectiveness validation for process changingu 在標準化過程中對相似過程進行借鑒。Use similar process for r

54、eference during standardizationu 防錯計劃，防錯清單，防錯驗證error-proofing plan, error-proofing list, error-proofing validation檢測Defectionu 把所需的質(zhì)檢納入標準化作業(yè)中（裝配）Required quality checks are included in standardized work (assembly).u 質(zhì)檢項目有標準Quality check items are based on defined criteria u 根據(jù)質(zhì)量計劃配備足夠的資源Sufficient r

55、esources are allocated in accordance with the quality plan u 更新系統(tǒng) Quality check systems are updated u 制定重要工序的檢測頻次Inspection frequencies of critical operations are established u 檢查站 Inspection stationu 把檢查方法（觸摸，聽，看）納入標準化作業(yè)（裝配）Point, touch, listen, and count inspection methods are incorporated in stan

56、dardized work. u 用聲光信號 Audio/visual signals are implemented 遏制CONTAINMENTu采用暗燈 An Andon system is implemented u本工位控制缺陷A process is stopped when discrepancies that impact downstream activities must be controlled in station. u問題解決流程確定有效的長期措施A problem solving process is initiated to identify permanent

57、corrective action that is verified as being effective.縮短制造周期縮短制造周期 整體制造周期(從得到訂單到收到貨款） 產(chǎn)品發(fā)展周期（從概念到投產(chǎn)） 過程制造周期（從原材料到最終裝配）9個要素9 Elements18.簡易的工藝流程 Simple Process Flow 19.少量包裝 Small Lot Packaging 20.固定周期定貨系統(tǒng)/定購零部件Fixed Period Ordering System/Order Parts 21.受控的外部運輸 Controlled External Transportation 22.有計

58、劃的交運/收貨 Scheduled Shipping/Receiving 23.臨時物料儲存-CMA（中心物料區(qū)域）Temporary Material Storage (CMA Central Material Area) v拉動式系統(tǒng) Pull Systems 24.均衡已定購車輛的生產(chǎn)計劃 Level Vehicle Order Schedules 25.供應鏈管理 Supply Chain Management 18.簡易的工藝流程 Simple Process Flow定義定義: : 以獲得一個簡易的物料與信息流為目的的流程Definition:Definition: A proce

59、ss that incorporates a constant drive to attain a simple sequential process flow of material and information.目的目的: :設計和實行流程，來維護“先進先出”，可追溯，可視，縮短制造周期，檢查降低成本時的問題，降低庫存和按流程工作。(簡易的物料和信息流） Purpose:Purpose: To design and implement processes that maintain FIFO, allow traceability, are visual, reduce lead tim

60、e, easily detects problems while optimizing cost, and reduces inventory and work in process. 核心要求核心要求 Core RequirementsCore Requirements：所有操作中體現(xiàn)“先進先出先進先出”FIFOFIFO present in all operations. 工序和緩沖區(qū)（車輛，零件）是受控，優(yōu)化和目視的Work-in-process and buffers (vehicles, parts) are controlled, optimized, and visualized