德爾福精益生產(chǎn)Leanmanufacturing的培訓(xùn)

德爾福精益生產(chǎn)Leanmanufacturing的培訓(xùn)Lean/DMSOverviewLean(Exercise)精益（練習(xí)）Exercise:Bytable/groupcomeupwithyourdefinitionof揕ean練習(xí)：按課桌/小組給出您對(duì)“精益”的定義WhatisLean?什么是精益？Lean精益lean

adj.

精益：形容詞1a:lackingordeficientinflesh.b:containinglittleornofat a:無肉或少肉 b:少脂肪或無脂肪2:lackingrichness不富裕3:deficientinanessentialorimportantqualityoringredient 在必要性、重要性、質(zhì)量或成分方面稀缺4:charac-terizedbyeconomyofstyleorexpression文體或措辭簡(jiǎn)練syn. thin,skinny,lanky,scrawny,gaunt,bony,emaciated,svelte,lank同義詞：薄、極瘦、過分瘦長(zhǎng)、骨瘦如柴、瘦削的、似骨的、消瘦的、細(xì)長(zhǎng)的、 瘦長(zhǎng)的ant. fat,fleshy,overweight,flabby,obese,plump,chunky,corpulent,soft反義詞：肥胖的、多肉的、過重的、不結(jié)實(shí)的、過分肥胖的、豐滿的、粗 短的、肥大的、軟的Lean精益WhatisLean?-Womack什么是精益1.Definevaluepreciselyfromtheperspectiveoftheendcustomer 從最終用戶的角度準(zhǔn)確地定義價(jià)值2.Identifytheentirevaluestreamforeachproductorproductfamilyand eliminatewaste 確定每一種產(chǎn)品或產(chǎn)品系列的整個(gè)價(jià)值流，消除浪費(fèi)3.Maketheremainingvaluecreatingstepsflow 理順創(chuàng)造價(jià)值的步驟4.Designandprovidewhatthecustomerwantsonlywhenthecustomerwantsit 只在客戶需要時(shí)設(shè)計(jì)和提供他們所需的東西5.Pursueperfection 追求完美Lean精益AtDelphi,Leanis...Abusinessstrategy

formaximizing

profitbyenergizingpeople

torespondtocustomerdemandintheshortestpossibletime

byeliminatingwaste

ineverythingwedo.在德爾福公司，精益表示…一種經(jīng)營(yíng)戰(zhàn)略，它激勵(lì)人們?cè)谒龅娜魏问虑橹邢速M(fèi)，在盡可能短的時(shí)間內(nèi)對(duì)客戶需求作出反應(yīng)，從而使利潤(rùn)最大化。WhatisDMS?什么是德爾福制造系統(tǒng)ChangeinManufacturing制造業(yè)的演化HenryFord亨利·福特Assemblylinemassproduction裝配線大批量生產(chǎn)Produceinhighvolumewithlowvariety生產(chǎn)數(shù)量多、品種少Singleskill單一技術(shù)ToyotaProductionSystem(TPS)豐田公司制造系統(tǒng)Just-In-Time?Production(produceonlywhatisneeded)

“準(zhǔn)時(shí)生產(chǎn)制”（只生產(chǎn)所需要的）PullSystem拉動(dòng)系統(tǒng)Produceenoughvolumetomeetcustomers?needs生產(chǎn)足夠的數(shù)量以滿足客戶的需要Highvarietytomeetcustomerswants多品種以滿足客戶的要求

COMMONManufacturingSystemtoDelphiDivisionsVisionandOperatingPrinciplesSixInterdependentElementsThesixinterdependentelementsprovidethebasicframeworkofthemanufacturingsystem.Theyarethefocusofouractivities:Developingprofoundknowledge,planningandimplementation,andcontinuousimprovement.德爾福各分部共同的制造系統(tǒng)前景展望和運(yùn)行原則六個(gè)相互依存的要素六個(gè)相互依存的要素構(gòu)成了該制造系統(tǒng)的基本結(jié)構(gòu)。它們是我們活動(dòng)的中心：拓展豐富的知識(shí)、規(guī)劃和實(shí)施以及不斷改進(jìn)。WhatisDMS?什么是德爾福制造系統(tǒng)OperatingPrinciples運(yùn)行原則DefinetheFundamentalBasisoftheManufacturingSystem 確定制造系統(tǒng)的主要基礎(chǔ)EnsurethattheHealthandSafetyofallourpeopleisourpriority. 確保所有員工的健康和安全是我們的首要任務(wù)AggressivelyimproveCustomerresponsetime.

積極縮短對(duì)客戶的反應(yīng)時(shí)間ImplementQualityattheSource.

從源頭處保證質(zhì)量CreateaLearning,Supportive,andCooperativeCulture.

創(chuàng)造一個(gè)相互學(xué)習(xí)、相互支持和相互協(xié)作的企業(yè)文化CompetitivelymanufactureatanyvolumeandbeFlexibletoanyquest.

在任何制造批量下都具有競(jìng)爭(zhēng)力并能靈活地滿足客戶需求RelentlesslypursuetheEliminationofWaste.不懈努力，消除浪費(fèi)EstablishprocessmeasurementsthatcontributetoBusinessGoals.

建立有助于實(shí)現(xiàn)業(yè)務(wù)目標(biāo)的過程衡量指標(biāo)DrivetheTransformationProcessthroughKnowledgeableandInvolvedLeadership.

通過知識(shí)淵博和全身心投入的領(lǐng)導(dǎo)人員推動(dòng)變革進(jìn)程DefineandUnderstandRolesandResponsibilities.

確定并理解崗位和責(zé)任OptimizetheManufacturingSystemthroughbalancedImplementationoftheInterdependentElements.

通過均衡地實(shí)施六個(gè)相互依存的要素來優(yōu)化制造系統(tǒng)Characteristics特點(diǎn):InventoryStockpiles庫存積壓ExtraEquipment額外的設(shè)備ExtraStorageRacks額外的倉儲(chǔ)架ExtraManpower額外的人力AdditionalFloorSpace更多的工作場(chǎng)地Causes原因:IncapableProcesses過程能力低下LackofCommunication缺乏交流LongToolChanges工具更換周期長(zhǎng)LowUptimes計(jì)劃工時(shí)利用率低LackofStable/ConsistentSchedules缺乏穩(wěn)定/連貫的計(jì)劃安排WasteofOverproduction

過度生產(chǎn)的浪費(fèi)Characteristics特點(diǎn):ExtraTimeRequiredbyWorkforcetoInspect/Rework/Repair工人需要額外的時(shí)間來檢查/返工/修理MissedShipments/Deliveries錯(cuò)過了裝運(yùn)/交貨時(shí)間OrganizationBecomesReactive

(FireFighting,ExpeditingVs.PreventionOrientation)使組織變得被動(dòng)(疲于“救火”，而不是采取各種預(yù)防措施)Causes原因:IncapableProcesses過程能力低下OperatorControlError操作者控制失誤InsufficientTraining缺少足夠的培訓(xùn)WasteofCorrection

改正的浪費(fèi)Definition:Anymovementofmaterial

thatdoesnotdirectlysupporta

leansystem.WasteofMaterialMovement/Conveyance材料移動(dòng)/傳送的浪費(fèi)定義:任何不直接支持一個(gè)精益系統(tǒng)的材料移動(dòng)。Definition定義:

Anymovementofpeopleormachineswhichdoesnotcontributevaluetotheproductorservice.任何對(duì)生產(chǎn)和服務(wù)沒有帶來價(jià)值的人員或機(jī)器的運(yùn)動(dòng)。WasteofMotion動(dòng)作的浪費(fèi)Characteristics特點(diǎn):LookingforTools尋找工具ExcessiveReaching/Bending過度伸展/彎腰Machines/MaterialTooFarApart (WalkTime)機(jī)器/材料距離過遠(yuǎn)（步行的時(shí)間）ShuttleConveyorsBetweenEquipmenttoCarryParts零件在設(shè)備間傳送帶上的來回傳送Extra揃usy?MovementsWhileWaiting 等候期間的額外“忙亂”動(dòng)作Causes原因:Equipment,Office&PlantLayout設(shè)備、辦公室和工廠的布局不當(dāng)LackofWorkPlaceOrganization工作場(chǎng)地缺乏組織PoorPerson/MachineEffectiveness人員/機(jī)器效率不高PoorErgonomicDesign人機(jī)工程方面的設(shè)計(jì)不好InconsistentWorkMethods不一致的工作方法LargeBatchSizes加工批量過大WasteofMotion動(dòng)作的浪費(fèi)Characteristics特點(diǎn):PersonWaitingforMachine人員等候機(jī)器MachineWaitingforthePerson機(jī)器等候人員OnePersonWaitingforAnotherPerson一個(gè)人等候另一個(gè)人UnbalancedOperations(Work)不平衡的操作（工作）UnplannedEquipmentDowntime計(jì)劃外停機(jī)Causes原因:InconsistentWorkMethods不一致的工作方法LongMachineChangeOverTimes機(jī)器設(shè)置時(shí)間長(zhǎng)PoorMan/MachineEffectiveness人員/機(jī)器效率不高LackofProperMachines缺乏合適的機(jī)器LackofEquipmentResources缺乏設(shè)備資源WasteofWaiting等候的浪費(fèi)Definition:Anysupplyinexcess

ofprocessrequirementsnecessarytoproducegoods.WasteofInventory庫存的浪費(fèi)定義:任何超過生產(chǎn)產(chǎn)品過程所需要的供應(yīng)。

DEFINITION:Effortwhichaddsnovaluetoaproductorservice.Enhancementswhicharetransparenttothecustomers,orwork

whichcouldbecombinedwithanotherprocess.WasteofProcessing

加工過程的浪費(fèi)定義:對(duì)產(chǎn)品或服務(wù)附加的無效的

工作，或可以結(jié)合在另一過程的工作。

Characteristics特點(diǎn):ProcessBottlenecks工作過程出現(xiàn)瓶頸LackofBoundarySlesorClearCustomerSpecifications缺乏邊界樣品或明晰的客戶規(guī)格要求EndlessRefinement沒完沒了的修飾RedundantApprovals過多的批準(zhǔn)程序ExtraCopies/ExcessiveInformation額外的復(fù)印件/過多的信息Causes原因:EngineeringChangesWithoutProcessChanges工藝過程沒有隨著工程的更改而改變NewTechnologyUsedinOtherProcesses在其他工藝過程中使用了新技術(shù)DecisionMakingatInappropriateLevels在不適當(dāng)?shù)膶哟紊现贫ǖ臎Q策IneffectivePoliciesandProcedures無效的政策和程序LackofCustomerInputConcerningRequirements對(duì)客戶的有關(guān)要求缺乏了解WasteofProcessing

加工過程的浪費(fèi)Game:FindtheWasteLeanMetricsUptimeMaintenance(MERV)Scrap%Rework%CapacityUtilizationInternalProductivityManufacturingExpenseTotalProductionCycleTimeInventoryTurnsQualityandSafetyMetricsRRPPMRecordableAccidentRateLostWorkDayCaseRateKeyMetrics

21of309/22/2023OperatingPrinciples運(yùn)行原則EstablishprocessmeasurementsthatcontributetoBusinessGoals.

建立有助于實(shí)現(xiàn)業(yè)務(wù)目標(biāo)的過程衡量指標(biāo)EnsurethattheHealthandSafetyofallourpeopleisourpriority. 確保所有員工的健康和安全是我們的首要任務(wù)AggressivelyimproveCustomerresponsetime.

積極縮短對(duì)客戶的反應(yīng)時(shí)間ImplementQualityattheSource.

從源頭處保證質(zhì)量CreateaLearning,Supportive,andCooperativeCulture.

創(chuàng)造一個(gè)相互學(xué)習(xí)、相互支持和相互協(xié)作的企業(yè)文化CompetitivelymanufactureatanyvolumeandbeFlexibletoanyquest.

在任何制造批量下都具有競(jìng)爭(zhēng)力并能靈活地滿足客戶需求RelentlesslypursuetheEliminationofWaste.不懈努力，消除浪費(fèi)DefinetheFundamentalBasisoftheManufacturingSystem 確定制造系統(tǒng)的主要基礎(chǔ)DrivetheTransformationProcessthroughKnowledgeableandInvolvedLeadership.

通過知識(shí)淵博和全身心投入的領(lǐng)導(dǎo)人員推動(dòng)變革進(jìn)程DefineandUnderstandRolesandResponsibilities.

確定并理解崗位和責(zé)任OptimizetheManufacturingSystemthroughbalancedImplementationoftheInterdependentElements.

通過均衡地實(shí)施六個(gè)相互依存的要素來優(yōu)化制造系統(tǒng)InterdependentElements

相互依存的要素EmployeeEnvironment&Involvement員工環(huán)境于參與BusinessObjectivesScrapJan.Apr.Jul.Dec.UptimeGoalOnTimeDeliveryGoalGoalEmployeeInformationCenterJan.Apr.Jul.Dec.Jan.Apr.Jul.Dec.Ourimprovementteam抯effortshavehelpedusmeetourgoals.WorkplaceOrganization工作場(chǎng)地組織PULLCARDSTRASHTOWELSGLOVESTOOLSFlowManufacturing流動(dòng)制造CoatingMachiningWeldingPressingOurintegratedlineisbalancedtomeetcustomerdemand.Ourpeopleareflexible,andWIPisdownduetosinglepieceflow.Nowthatwedoquickchangeovers,wecanruneveryparteveryday.Quality