康明斯目視管理法(1)

1、康明斯目視管理法Cummins Visible Controls 1Cummins 目視管理 Visible Controls 目的 Objectives闡述目視管理: 目標(biāo)，定義，和標(biāo)準(zhǔn) Describe Visible Controls: goal, definition, and criteria 了解如何運(yùn)用 Understand how to use them講解4種做法 Define the 4 categories展示與持續(xù)改進(jìn)的聯(lián)系 Show connection to Continuous Improvement Process2Cummins 目視管理 Visible Co

2、ntrols 與CPS*的聯(lián)系 CPS Connection隱藏問(wèn)題，不能使問(wèn)題受到重視并得到解決。我們必須能夠很快地標(biāo)識(shí)問(wèn)題，并立即做出反應(yīng)。問(wèn)題點(diǎn)必須可以一目了然。 CPS 員工手冊(cè) 1991，24頁(yè) *CPS-康明斯生產(chǎn)系統(tǒng)“Hidden problems will not get attention and will not be fixed. We must be able to identify problems quickly and respond to them immediately. Trouble spots must be obvious at a glance.”

3、CPS Employee Manual, 1991, pg. 243Cummins 目視管理 Visible Controls . 注意！ATTENTION！下面兩種方法對(duì)于信息運(yùn)用管理可能會(huì)有很大的區(qū)別： How information is organized is perhaps the most distinguishing feature between 信息共享 目視交流 Information Sharing Visible Communication4Cummins 目視管理 Visible Controls 目視管理目標(biāo) Visible Controls Goal1. CPS

4、 質(zhì)量目標(biāo)是： “使過(guò)程成效指標(biāo)和問(wèn)題均目視化” A CPS quality objective is to “make performance to processes and problems visible.”2. 持續(xù)改進(jìn)是我們的生存之道 Continuos Improvement is a way of life3. 建立發(fā)展一個(gè)部門區(qū)域間交互責(zé)任的體系 Developing a system of overlapping responsibilities between functional area 5Cummins 目視管理 Visible Controls 目視管理 VISI

5、BLE CONTROL DEFINITION 目視管理就是信息展示，全面直觀地、方便地 能看見(jiàn)，以便對(duì)其做出反應(yīng)，進(jìn)行調(diào)整控制。 A visible control is defined as a display of information devised to be in full view or readily seen in order to allow reaction or regulation to the source or cause of information.6Cummins 目視管理 Visible Controls 基本準(zhǔn)則 Essential Criteria 使

6、重要的信息以最快的速度方便地傳遞到?jīng)Q策和措施制定的地方 They are used to facilitate the transfer of important information as quickly as possible at the point where decision and action can be made.1、簡(jiǎn)潔陳述 Simplicity of presentation 2、可視測(cè)評(píng) Visibility of measurements情況目視通報(bào)到每位員工 situation are visible to everyone 目標(biāo)和責(zé)任目視通報(bào)到每位員工 goal

7、 and rules are visible to everyone 7Cummins 目視管理 Visible Controls 基本準(zhǔn)則 Essential Criteria3、每位員工進(jìn)行參與 Everyones involvement 4、基礎(chǔ)信息數(shù)據(jù)的真實(shí)收集 Undistorted collection of primary information 5、重要數(shù)據(jù)的直接測(cè)評(píng)（至關(guān)重要的幾個(gè)） The straightforward measurement of whats important (The Vital Few)6、對(duì)緊急情況有全面的了解掌握 Achieve an over

8、all feel of urgency 7、針對(duì)變異有完善計(jì)劃和受訓(xùn)練的反映 Planned and disciplined response to abnormalities8Cummins 目視管理 Visible Controls 行GO停STOP我該如何做？ What should I do?9Cummins 目視管理 Visible Controls 出口Exit 96目視信息-不好 Visible Information -Bad Example10Cummins 目視管理 Visible Controls 目視信息-好 Visible Information-Good Examp

9、le.出口Exit 9611Cummins 目視管理 Visible Controls 共同負(fù)責(zé) Shared Responsibility工廠質(zhì)量水平 Plant Level公司目標(biāo) Company Goals:*世界級(jí) World class*CPS*通告Inform visitors班組板塊區(qū)Teams Territory班組目標(biāo)Group Goal:*用戶/供應(yīng)商 customer/supplier*成本/質(zhì)量/發(fā)運(yùn) cost/quality/delivery*問(wèn)題 problem獨(dú)立工作站Individual Workstation工序說(shuō)明 Operation Specific:*工

10、藝文件 Process doc.*標(biāo)準(zhǔn)工作圖示 Std work charts*維護(hù) Maintenance*環(huán)境管理 Housekeeping12Cummins 目視管理 Visible Controls 工廠質(zhì)量水平 Plant Level 團(tuán)隊(duì)班組板塊區(qū)TeamsTerritory 用戶Customer 支持 Support 方法 Methods規(guī)范 Specification用戶 Customer工廠測(cè)評(píng) Plant measure過(guò)程測(cè)評(píng) Process measures供應(yīng)商 Supplier維護(hù) Maintenance 安全 Safety獨(dú)立工作站 Individual Work

11、station供應(yīng)商 Supplier 計(jì)劃 Plans安全Safety13Cummins 目視管理 Visible Controls 目視管理準(zhǔn)則The Rule of Visible Controls 班組必須審核和認(rèn)可目視管理 The team has to review and approve any visible control“提交目視管理文件進(jìn)行公開(kāi)評(píng)議使員工獲得認(rèn)知，提供員工發(fā)表建設(shè)性意見(jiàn)的機(jī)會(huì)”“submitting a visible control document to a process of public scrutiny -result in better ow

12、nership of the knowledge and opportunities for constructive criticism.”14Cummins 目視管理 Visible Controls 公開(kāi)式傳達(dá)信息Openness of Communication問(wèn)題狀況的明確展示使每位員工知道目前過(guò)程的狀態(tài)“Visible display of problem status lets everyone know the current status of the process.”度假, 一周后返回On vacation Return in 1week15Cummins 目視管理 Vi

13、sible Controls 生產(chǎn)計(jì)劃展示 例1 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #116Cummins 目視管理 Visible Controls 生產(chǎn)計(jì)劃展示例2 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #217Cummins 目視管理 Visible Controls 人力計(jì)劃舉例 Handout Solution for Situation 1 -Workfor

14、ce Planing A工廠 Plant A B工廠 Plant B18Cummins 目視管理 Visible Controls 四種展示 The Four Categories目視生產(chǎn)控制 Visible Production Control目視質(zhì)量控制 Visible quality control過(guò)程指示 Process indicators進(jìn)程顯示 Making Progress Visible改進(jìn) Improvement ： 節(jié)拍 cycle time實(shí)際 Actual: 3.5 min reduction19Cummins 目視管理 Visible Controls 生產(chǎn)管理 P

15、roduction Control(過(guò)程狀態(tài)一目了然 understanding the process at a glance.)看板或拉料卡顯示材料狀態(tài) Chanson or Pull Cards showing material status 工作標(biāo)準(zhǔn)化 Standardized work charts瓶頸工序標(biāo)識(shí)出 Bottleneck operations identified工序流程圖 Process flow charts預(yù)先確定場(chǎng)所 Predetermined locations整潔、工裝和設(shè)備定置擺放 clear, designated tool& equipment loc

16、ations20Cummins 目視管理 Visible Controls 生產(chǎn)管理 Production Control材料存儲(chǔ)標(biāo)識(shí)完善 well marked material storage 材料過(guò)量堆積 overflow areas警示燈顯示問(wèn)題或異常情況 Andon displays to indicate problems or abnormal situations生產(chǎn)量計(jì)數(shù) Production count status 發(fā)交狀況 Delivery status料箱（架）限制零件裝載量 Containers limiting the amount of parts21Cummi

17、ns 目視管理 Visible Controls 料架滿裝指示舉例Example of Production ControlInstructions for filling a container錯(cuò)誤 No 正確 Yes滿裝線Fill line22Cummins 目視管理 Visible Controls 警示燈板 Andon (a lighting panel)發(fā)生故障傳送信息的裝置 Which is an “information transfer device for trouble occurrence”.同時(shí)可指示停止或故障解除警示Also reference to as stop

18、alarms, uptime lights23Cummins 目視管理 Visible Controls 生產(chǎn)管理警示板 Production Control Board -Andon Board目標(biāo) 345Target實(shí)際 345Actual時(shí)間損失 8minLoss time最新消息：工作站 3材料短缺， 工作站 6有質(zhì)量問(wèn)題Status update:Station 3 has a material shortage, Station 6 has a quality problem 6789101234524Cummins 目視管理 Visible Controls 生產(chǎn)警示燈有如下表示

19、：Example of Production: Andon Lights-紅色 Red : 生產(chǎn)線停止Line Stop -黃色Yellow: 請(qǐng)求支持援助 Worker has called for help-綠色Green: 正常 Normal operation25Cummins 目視管理 Visible Controls 警示燈有如下表示：Example : Andon Lights-紅色Red: 設(shè)備故障 Machine trouble -白色White: 生產(chǎn)終止 end of production run-綠色Green: 材料短缺停產(chǎn) no work shortage of m

20、at.-蘭色Blue: 有問(wèn)題 defective unit-黃色Yellow: 要求調(diào)整 set-up required26Cummins 目視管理 Visible Controls 過(guò)程指示 Process Indicators (用于監(jiān)控工作進(jìn)程的設(shè)施 devices for monitoring work progress)設(shè)備機(jī)油消耗 Machine oil consumption班組培訓(xùn)矩陣表(技能水平/培訓(xùn)項(xiàng)目) Team training matrix (skill level/training)安全成效 Safety results 內(nèi)部環(huán)境管理維護(hù)成效 Housekeepi

21、ng results庫(kù)存周轉(zhuǎn) Inventory turns色彩編碼任務(wù) 時(shí)間安排卡片 Color coded job scheduling cards在制品 Line side storage 節(jié)拍 Tat time, cycle time調(diào)整時(shí)間 Set-up TimeSPC 圖 SPC charts27Cummins 目視管理 Visible Controls 過(guò)程標(biāo)示舉例: 發(fā)動(dòng)機(jī)掛旗Example of process indicators:Engine Flags 紅色 - 發(fā)動(dòng)機(jī)質(zhì)量問(wèn)題要拆檢 Red - Engine Quality Teardown黃色 - 缺“自制”件 Ye

22、llow - Shortage of “made in works” part蘭色 - 缺“外協(xié)”件 Blue -Shortage of “bought out finished “ part綠色 - 發(fā)動(dòng)機(jī)準(zhǔn)備做試驗(yàn) Green -Engine ready for test白色 - 等待檢查 White -Awaiting inspection 28Cummins 目視管理 Visible Controls 質(zhì)量管理 Quality Control (質(zhì)量狀況一目了然 understand quality status at a glance) 用戶質(zhì)量水平 Customer Quality

23、 Levels工序控制紀(jì)錄 Process Control RecordsSPC圖 SPC chartsCPC情況 CPC status (CPC triangles)量檢具檢定狀況 Gauge calibration status接受/不可接受標(biāo)樣 Boundary Samples referencing acceptable/non-acceptable quality供應(yīng)商質(zhì)量成效 Supplier results規(guī)定明確的不合格品區(qū) Clearly defined non-conforming area工藝文件 Process Documentation檢查計(jì)劃 Inspection

24、plans 29Cummins 目視管理 Visible Controls 工作場(chǎng)地一目了然A VISIBLE WORKPLACE產(chǎn)品陳列Product display用戶反饋Customer Feedback成效展示Results displayed30Cummins 目視管理 Visible Controls 工作場(chǎng)地一目了然A VISIBLE WORKPLACE1814131211101098716172619543211542031Cummins 目視管理 Visible Controls 32Cummins 目視管理 Visible Controls 33Cummins 目視管理 V

25、isible Controls 34Cummins 目視管理 Visible Controls 35Cummins 目視管理 Visible Controls 36Cummins 目視管理 Visible Controls 37Cummins 目視管理 Visible Controls 38Cummins 目視管理 Visible Controls 39Cummins 目視管理 Visible Controls 40Cummins 目視管理 Visible Controls 41Cummins 目視管理 Visible Controls 42Cummins 目視管理 Visible Contr

26、ols 工作場(chǎng)地一目了然 A VISIBLE WORKPLACE談?wù)撘曈X(jué)圖像信息卻不用圖片，似乎有些似是而非。這就是展示車間目視管理圖片的原因。 It would be somewhat paradox to speak of visual communication without relying on an image. This is the reason for presenting a visual workplace.上張圖示不是固定不變的逐條要遵循的實(shí)際例子，每個(gè)工廠有各自不同的實(shí)際操作運(yùn)行情況。沒(méi)有理由完全按照?qǐng)D示中每個(gè)項(xiàng)目去實(shí)施。其他內(nèi)容或展示可能更適合具體的情況。這里主要是

27、提供目視交流、管理的一種思路。The workplace depicted is not a practical example to be followed literally. Each firm has its own constraints and operating structure. There is no reason automatically to include everything appearing in this sketch. Conversely, other elements-or other forms of presentation-maybe more

28、suitable for certain situation. In this portrayal, the intent is to present significant visual communication themes.43Cummins 目視管理 Visible Controls 工作場(chǎng)地一目了然 A VISIBLE WORKPLACE班組板塊 The Teams Territory1.板塊標(biāo)識(shí) Identify territory2.標(biāo)識(shí)活動(dòng)、資源和產(chǎn)品 Identify activities, resource,& product.3.班組園地 Identify the te

29、am4.地面標(biāo)記 Marking floor5.標(biāo)識(shí)工裝和工位器具 Marking of tools and racks6.技術(shù)區(qū)域 Technical area7.交流和休息區(qū)域 Communication & rest area8.信息和指示 Info. & instruction 9.清掃工具 Neatness (broom)目視文件 Visual Doc.10.生產(chǎn)指導(dǎo)和技術(shù)程序Manufacture Instruction & tech. procedure44Cummins 目視管理 Visible Controls 工作場(chǎng)地一目了然 A VISIBLE WORKPLACE目視生產(chǎn)

30、管理 Visual production control11.計(jì)算機(jī)終端 Computer terminal12.生產(chǎn)計(jì)劃 Production schedule13.維修計(jì)劃 Maintenance schedule14.零標(biāo)識(shí) Identification of components目視質(zhì)量管理 Visual quality control15.設(shè)備監(jiān)控信號(hào) Machine monitor signals16.SPC17.記錄指標(biāo)展示 Display Indicators18.目標(biāo)、結(jié)果和差距Objectives, results, and differences進(jìn)展 Rendering

31、Progress Visible19.改進(jìn)活動(dòng) Improvement activities20.公司方針、計(jì)劃和任務(wù) Company policy, project & mission 45Cummins 目視管理 Visible Controls 實(shí)施改進(jìn) Making Improvements（目視板可使每個(gè)員工追蹤改進(jìn)工作的進(jìn)展）(Display so that anyone can follow improvement work as it progresses)用戶滿意 Customer satisfaction 用戶/供應(yīng)商合作協(xié)議Customer/supplier workin

32、g agreements項(xiàng)目和狀況 Projects and status改進(jìn)活動(dòng) Improvement activities之前/之后 Before/After培訓(xùn)計(jì)劃 Training matrices改進(jìn)板 Improvement boards問(wèn)題解決過(guò)程 Problem solving process status庫(kù)存降低騰空?qǐng)龅?Floor space freed up due to inventory reduction 預(yù)防性維護(hù)計(jì)劃 Preventative maintenance schedule46Cummins 目視管理 Visible Controls 合適的搬運(yùn)擺放

33、作業(yè)指導(dǎo)Instructions for Proper Stacking Procedure不在正確 No 正確Yes47Cummins 目視管理 Visible Controls 預(yù)防問(wèn)題重新設(shè)計(jì)Re-design for prevention of problem 目視管理的實(shí)施Levels of Visible Controls Implementation工藝文件 Process documentation環(huán)境維護(hù)管理 Housekeeping duties圖表-發(fā)交 ,員工培訓(xùn)計(jì)劃 Charts - parts shipped, - operator training matrice

34、s檢查計(jì)劃 Inspection plans不合格品報(bào)告 Reject reports色斑材料區(qū) Color striped material zonesSPC 圖 SPC charts控制限 Boundary samples發(fā)動(dòng)機(jī)試驗(yàn) Engine test活塞環(huán)顏色碼 piston ring color code特殊力矩復(fù)檢 specialized torque overchecks預(yù)防 PREVENTION發(fā)現(xiàn) DETECTION停線 燈machine down lights裝配紅燈 assembly red lights2預(yù)通道無(wú)線系統(tǒng) 2-way radio system最初展示運(yùn)行

35、狀態(tài)Initial display of operational status質(zhì)量信息和規(guī)范Quality information &specification工作環(huán)境探測(cè)異常Work environment for abnormality detection問(wèn)題可視或可見(jiàn)警示Visual or audible alerts to problem防錯(cuò) Failsafing自動(dòng)Automation48Cummins 目視管理 Visible Controls “標(biāo)準(zhǔn)是一個(gè)參照點(diǎn), 提供給班組追隨的目標(biāo), 同時(shí)也提供了出發(fā)的起點(diǎn).”“A standard is a point reference that simultaneously provides the group with a point to adhere to and a point of departure.” 通過(guò)信息展