精益生產(chǎn)管理手冊(cè)（中英文版）.ppt

1、1,Lean Hand Book 精益生產(chǎn)手冊(cè),2,Defect : X 1/10 缺陷降低90% Inventory : X 庫存減半 Productivity : X 2 生產(chǎn)效率翻倍 Lead Time : X 生產(chǎn)周期減半 Scrap : X 1/10 報(bào)廢降低90% Space : X 面積減半,Goal : Add Value 制程設(shè)計(jì)治具同時(shí)放置 4 塊PCB板，則制程的節(jié)拍時(shí)間是 48 秒/治具。如果同時(shí)有 2 條生產(chǎn)線生產(chǎn)，制程的節(jié)拍時(shí)間則為 96 秒。,Scenario 2: If Top and Bottom product running on same line at

2、 the same time, Takt time shall be half = 48sec 情節(jié)2：如果正反面產(chǎn)品同時(shí)在一條生產(chǎn)線生產(chǎn)，節(jié)拍時(shí)間則為一半，48秒。,As such the Process Takt Time Calculation as following: 制程節(jié)拍時(shí)間計(jì)算如下： = Takt Time X Product Up x Process Up X Number of Line = 2 sec X 6 products per panel X 4 Panel per pallet X 2 Lines = 96 sec,9,What is Standard WIP

3、什么是標(biāo)準(zhǔn)WIP,Various types of WIP in our manufacturing process 生產(chǎn)過程中存在各種類型的WIP Standard WIP 標(biāo)準(zhǔn)WIP Process WIP制程WIP Process To Process WIP制程與制程間WIP Station To Station WIP工位與工位間WIP,10,What is Standard WIP什么是標(biāo)準(zhǔn)WIP,WIP means INVENTORY. INVENTORY is Basically bad. WIP就是庫存。庫存從根本上說是“不好”的。 Standard WIP is the I

4、deal or Should be conditions for WIP 標(biāo)準(zhǔn)WIP是理想WIP或者是WIP的應(yīng)有狀態(tài)。 However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and bottle neck 然而，在完全達(dá)到標(biāo)準(zhǔn)WIP數(shù)量前，你需要經(jīng)過不同的階段了解制程中的浪費(fèi)和瓶頸。 Key Note from Sensei: 老師的重要提示： To understand the

5、above WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解WIP定義，你需要去到現(xiàn)場(chǎng)在工作中實(shí)踐正確的WIP數(shù)量。這是讓你理解這個(gè)定義的唯一方法。,11,What is Standard WIP什么是標(biāo)準(zhǔn)WIP,The purpose of Standard WIP is:標(biāo)準(zhǔn)WIP的目的： Separation

6、between machine job and man job 區(qū)分機(jī)器作業(yè)和手動(dòng)作業(yè) Ensures quality requirements確保質(zhì)量要求 Ensures smooth flow based on Takt time確?；诠?jié)拍時(shí)間的連續(xù)流 Example 1: 例子1 WIP in the reflow oven for curing with process time 6 min and Takt time 30 sec. 在回流焊爐中固化的WIP，制程時(shí)間 6 min，節(jié)拍時(shí)間 30 sec. Standard WIP in the curing oven = Proc

7、ess Time / Takt Time 回流焊爐的標(biāo)準(zhǔn)WIP = 6 min / 30 sec = 12 Pcs,12,What is Standard WIP什么是標(biāo)準(zhǔn)WIP,Example 2: 例子2 WIP in the tester at backend assembly with process time 60 sec and Takt Time 30 sec. 后段組裝線測(cè)試機(jī)的WIP，制程時(shí)間 60 sec，節(jié)拍時(shí)間 30 sec. Standard WIP in the Test station = 60 sec/ 30 sec 測(cè)試工位的標(biāo)準(zhǔn)WIP = 2 pcs In

8、other words, Standard WIP in order to fulfill the above 1), 2), 3) functions, It is the compulsory WIP in the machine / process before establish standard work for the process. 換句話說，標(biāo)準(zhǔn)WIP能夠確保上述1),2),3)達(dá)成，在建立標(biāo)準(zhǔn)作業(yè)前，標(biāo)準(zhǔn)WIP是機(jī)器和制程強(qiáng)制的WIP。,13,What is Standard WIP什么是標(biāo)準(zhǔn)WIP,Process WIP 制程WIP WIP within same pro

9、cess with low variation of cycle time 同一個(gè)制程中的WIP，周期時(shí)間CT變化很小 It is all that WIP in the same process, not categorized as Standard WIP or PTP WIP. 所有在同一個(gè)制程中的WIP，不是標(biāo)準(zhǔn)WIP或制程間WIP. Example:- 例如 Before Kaizen, Manual Insert (MI) Line Process WIP =9 pcs. After Kaizen MI Process WIP is 3. Standard WIP for eac

10、h station is 1pc. 改善前，插件拉的制程WIP=9 pcs。改善后插件拉制程WIP=3pcs。每個(gè)工位的標(biāo)準(zhǔn)WIP為1pcs.,variance,After,Before,Process WIP = 3, Standard WIP = 1,Process WIP = 9, No standard WIP,14,What is Standard WIP什么是標(biāo)準(zhǔn)WIP,Process To Process WIP (PTP WIP) 制程間WIP WIP between 2 different processes with big gap cycle time兩個(gè)周期時(shí)間相差很大

11、的不同制程間的WIP. PTP WIP Is needed due to changeover in upstream line. 上游制程需要轉(zhuǎn)拉，則需設(shè)定制程間WIP.,Not All line need PTP WIP.不是所有產(chǎn)線都需要制程間WIP. If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期時(shí)間小于下游制程的周期時(shí)間 Example 1:- SMT Cycle time (30 sec) Less then Manual Insertion (60 sec) 例1：SMT周期

12、時(shí)間(30 sec)小于MI插件周期時(shí)間 (60 sec) CT (Upstream process) Need PTP WIP 需要制程間WIP If Cycle time Upstream process is Equal or greater then Down stream process, No PTP WIP required. 如果上游制程的周期時(shí)間大于或等于下游制程的周期時(shí)間，不需要制程間WIP.,15,What is Standard WIP什么是標(biāo)準(zhǔn)WIPProcess To Process WIP制程間WIP,Example 2:- Process A cycle tim

13、e 15 sec. It is faster then Process B cycle time 25sec. Process A is running 2 product models as capacity requirement. In order to Keep Process line running, process to process WIP is required between Process A and B. The calculation as below:- 例2：制程A周期時(shí)間是15sec，比制程周期時(shí)間25sec快。制程A根據(jù)生產(chǎn)能力需求，需要生產(chǎn)2種產(chǎn)品。為了保

14、證產(chǎn)線正常運(yùn)作，需要在制程A和制程B之間設(shè)定制程間WIP。計(jì)算如下：,Takt Time = 30sec Changeover Time = 5 min,30sec,Process A,Process B,16,Takt Time 節(jié)拍時(shí)間,Cycle time Takt time ( 1 Station Process ) C/TTakt Time (1個(gè)工位）,Cycle time than takt for single process (2 same stations needed) C/TTakt (需要2個(gè)相同工位),TAKT Time = 20s,Note注: CT TT : A

15、dditional Machine/Man needed 需要額外的機(jī)器/人員,It can be used to calculate 節(jié)拍時(shí)間可以計(jì)算 Total Operators needed員工需求數(shù)量 Total machines needed機(jī)器需求數(shù)量 Standard WIP needed & Etc標(biāo)準(zhǔn)WIP需求數(shù)量，等,17,Is the Takt time visible (with counter and triggering point)? 節(jié)拍時(shí)間可以直觀地看出來嗎？有沒有借助工具(計(jì)數(shù)器和觸發(fā)機(jī)制) 。 2) Is the Takt board defined (

16、on the board)? 節(jié)拍時(shí)間確定了嗎？(把節(jié)拍時(shí)間寫在白板上) 3) Are the Standard WIP defined? 標(biāo)準(zhǔn)WIP有定義嗎? 4) Do you know how to separate manual (persons) from auto (the machines) work? 你知道如何區(qū)分手動(dòng)作業(yè)和自動(dòng)作業(yè)嗎? 5) Is the Work load leveling defined for man，machine and C/O? 人工,機(jī)器以及換線使用工作負(fù)荷均衡表分析了嗎？ 6) Is the H/C calculated based on T

17、akt time? 人力的多少是根據(jù)節(jié)拍時(shí)間計(jì)算出來的嗎? 7) Is the Std work (front page) SWCS (back page) posted in front of each operator? 每個(gè)工站前都有標(biāo)準(zhǔn)作業(yè)(前頁)和標(biāo)準(zhǔn)作業(yè)合并表SWCS(背頁)嗎?,Operations操作,18,Operations ( continue )操作(續(xù)頁),8) Is the std work being followed by the operator? 操作員有沒有按照標(biāo)準(zhǔn)作業(yè)流程作業(yè)? 9) Is the std work defined for water s

18、trider? 有沒有定義物料員的標(biāo)準(zhǔn)作業(yè)? 10) Is the operator idle at the station? 在作業(yè)過程中,操作員是否有等待? 11) Does the operator search for components or tools? - Locate all tools and parts within easy access or reach (Doctor & Nurse). 在作業(yè)中,操作員有沒有尋找物料或工具的動(dòng)作? 工具或物料應(yīng)該放置在易于獲取的位置,定點(diǎn)定位.(遵循醫(yī)生和護(hù)士概念：Doctor醫(yī)生,指直接作業(yè)的人員,nurse護(hù)士,指輔助作業(yè)人員

19、,如物料員) 12) Do you have std work for inspection station? 檢查工站有沒有標(biāo)準(zhǔn)作業(yè)書? 13) Do you have shortest cycle time for inspection? 對(duì)于檢查工站,有沒有定義最短周期時(shí)間?,19,Operations ( continue )操作(續(xù)頁),14) At the hand load station, do you apply doctor and nurse concept? 在手工作業(yè)工站,有沒有運(yùn)用醫(yī)生和護(hù)士理念? 15) Do you meet the target of 3 se

20、c per component during insertion at hand load? 在手插工站,有沒有達(dá)到每3 秒一顆零件的插件速度? 16) SIC less at hand load station (with template). 手插工站不需要SIC(用模板來顯示需要插件的位置)? Hand load manual CT Takt time nurse not required. Are there system in place to stop work when abnormal conditions arise? 當(dāng)手動(dòng)作業(yè)的周期時(shí)間小于節(jié)拍時(shí)間時(shí)，不需要”護(hù)士”(護(hù)士

21、nurse:輔助作業(yè)人員) 當(dāng)異常情況出現(xiàn)時(shí)，有沒有系統(tǒng)來控制停止作業(yè)? 18 ) Does the supervisor respond in a quick/crude manner? 當(dāng)異常發(fā)生時(shí)，管理人員的反映是快速還是遲鈍? 19) Do you have 6S implemented on your line? 線上有實(shí)行6S嗎 ?(6S=5S+Safety),20,Operations ( continue )操作(續(xù)頁),20) Is the production qty for the day defined? 日產(chǎn)量有沒有定義? 21) Is the Multi skill

22、 charts visible and available? 有沒有顯示和使用多技能培訓(xùn)表？ 22) Do you allow banana peeling on the line? 允許在線拆卸物料包裝嗎? 23) Are you able to detect bottleneck station at a glance? 瓶頸工站能一眼看出來嗎? 24) The operator must not re-orient the part 操作員不允許重新調(diào)整零件方向,防止零件極性弄錯(cuò).(這里操作員指輔助作業(yè)人員,即nurse) 25) Change over : 快速換型 a) Intern

23、al time 內(nèi)部時(shí)間d) Adjustment time調(diào)整校準(zhǔn)時(shí)間 b) External time 外部時(shí)間e) Clean清潔 c) Trial run試運(yùn)行,21,Operations ( continue )操作(續(xù)頁),26) ETE Operation criteria: 端到端運(yùn)行標(biāo)準(zhǔn) The line should run based on Takt time 生產(chǎn)線必須按照客戶需求節(jié)拍合理安排生產(chǎn) The H/C should be loaded based on Takt time 生產(chǎn)線應(yīng)按客戶需求節(jié)拍時(shí)間合理安排人員 Material should be load

24、ed based on Takt time 按客戶需求節(jié)拍時(shí)間備置原材料 The line should be configured to zero defects 配置生產(chǎn)線時(shí)需滿足零缺陷 Supermarket should meet all the 15 criteria 超市必須符合15個(gè)設(shè)置準(zhǔn)則 27) ETE consists of : 端到端包括: a) Productivity improvement (MLT,H/C, WIP, Space) 提高生產(chǎn)效率(生產(chǎn)前置期,科學(xué)的人員配置,適當(dāng)?shù)脑诰€庫存,有效的空間利用) b) Material replenishment (Wa

25、ter strider, Min- Max, Supermarket) 靈活精益的原材料供給方式(水蜘蛛補(bǔ)貨原則，設(shè)置最低最高庫存，超市) c) Quality improvement (Zero defects) 提高質(zhì)量(零缺陷) d) C/O (if the time more than 10 minutes) 換型時(shí)間(如果時(shí)間超過10分鐘),22,Operations ( continue ) 操作(續(xù)頁),28) 4 functions of Conveyor, Say NO to Conveyor if below criterias not meet “傳送帶”的4個(gè)功能， 如

26、果不符合以下條件則不能使用“傳送帶” Function as a Pace Setter ( Takt Manufacturing ) 節(jié)拍調(diào)節(jié)器（節(jié)拍生產(chǎn)） Function as a Value adding work station ( Value being added as it moves) 增值工位（傳送帶移動(dòng)時(shí)產(chǎn)品可以增值，如在傳送帶上作業(yè)） Function as a Jidoka ( Stop every abnormal ) 自働化（異常時(shí)停止作業(yè)） Function as a transportation mode ( 5% of the function ) 傳送作用

27、（只占5%的功能）,23,Layout 布局,1) Insure the short walking distance. 確保產(chǎn)線行走距離短. 2) Do you have 3 TEI implemented on your line? 產(chǎn)線有沒有對(duì)物品實(shí)施三定原則? a) Fix place 定點(diǎn) b) Fix things 定位/定物 c) Fix qty 定量 3) Is the safety aisle easily accessed by the operator? 安全通道是否易于員工通過? 4) Are there trash bins inside the cell? 單元生產(chǎn)

28、線內(nèi)有沒有垃圾箱? 5) Do you have cell concept implemented on your line? 有沒有在生產(chǎn)線上應(yīng)用單元生產(chǎn)的概念 .,24,Layout ( continue ) 布局(續(xù)頁),6) The operator movement in a cell : is it counter clock wise(1) or clockwise(0). Counter clock wise is recommended 操作員在單元內(nèi)的移動(dòng)是逆時(shí)針還是順時(shí)針(逆時(shí)針為佳) 7) The gap in a cell : is it wider(0) or na

29、rrower(1) (narrower recommended). 單元內(nèi)工站間的間距合適的嗎?寬(0) 還是窄(1) (推薦用窄). 8) Is the station made of crefoam material and is it on the wheel for flexible movement? 工作臺(tái)是由復(fù)合管做成的嗎 ?是否有滑輪易于移動(dòng)呢? 9) The flow of a layout must be like a single stroke, no zigzag. 產(chǎn)線布局的流向必須是單行程的，而不是彎曲交錯(cuò)的。 10) Do you use 7 ways when

30、designing tools, jigs, fixtures, layout or process? 在設(shè)計(jì)工具,夾具,治具,工廠布局和流程時(shí)有沒有采用7種方法(7 ways)? 11) Do you use Pugh matrix to evaluate 7ways? 有沒有使用Pugh matrix來評(píng)估7種方法? .,25,Layout ( continue ) 布局(續(xù)頁),12) Hand load station should meet the below requirements :手動(dòng)作業(yè)工站應(yīng)該滿足以下要求: a) Part presentation 物料擺放方式 b) Z

31、ero defect 物料品質(zhì)零缺陷 c) Layout /Ergonomic, 插件的順序/根據(jù)人機(jī)工程學(xué)來安排 d) Both hands of operator have to be used during insertion 插件時(shí)要雙手作業(yè) 13) Are the cables, wires and network using the overhead drop point for flexibility? 電線,網(wǎng)線,信號(hào)線是否架設(shè)在線體上端并連接到產(chǎn)線，易于靈活使用? 14) Do you use the Spaghetti Chart to do the layout, pro

32、cess, movement? 在設(shè)計(jì)layout，流程,行走路線時(shí)有沒有使用到Spaghetti Chart(意大利面條圖)工具,清晰的畫出人流、物流及產(chǎn)品流路線? 15) Is the line visibility clear for the supervisor? (boarder post defined for clear visibility) 對(duì)于管理者來說，產(chǎn)線可視化嗎?(定義看板使其清晰可視化) 16) Do you use mock-up layout? 有沒有模擬layout實(shí)施后的情況嗎? 17) Tree and Branch connecting sub asse

33、mbly & main assembly 主干和枝條 主裝配線和輔助裝配線的合理銜接,26,Layout ( continue ) 布局(續(xù)頁),18) Short Takt time 1minute, multiply takt time by (x) factor and duplicate the backend cell accordingly 客戶節(jié)拍時(shí)間太短小于 1 分鐘時(shí)，增大節(jié)拍時(shí)間 X 倍并建立相應(yīng)數(shù)量的相同的單元產(chǎn)線。 19) Do your work stations are in same height ? 工作臺(tái)都是同一個(gè)高度嗎？ 20) Do you carry o

34、ut “rope test” to validate the continuous value flow ? 有實(shí)施“繩子測(cè)試”驗(yàn)證連續(xù)價(jià)值流嗎？,27,Zero Defect 零缺陷,Can normal and abnormal be visually differentiated? 正常和異?，F(xiàn)象易于區(qū)分嗎 ? 2) Are the escalation paths well defined if abnormality occurs? 針對(duì)異常的發(fā)生,有沒有制定出逐級(jí)上報(bào)的流程? 3) Are the defects allowed to escape to down stream?

35、有沒有不良流入下一工站? a) Do not pass defect ( Downstream Internal or To End Customer ) 不流出不良品 (內(nèi)部下游客戶或終端客戶) b) Do not make defect( In Own Process ) 不制造不良品（自己的工位） c) Do not accept defect ( From Upstream) 不接收不良品（從上游工序） d) Do not rework ( Not Build Product Via Rework ) 不允許返工（不通過返工生產(chǎn)產(chǎn)品） 4) Do you have a common a

36、rea to view the defect (fish market)? 有沒有特定的地點(diǎn)來檢討不良?(fish market 魚市場(chǎng)),28,Zero Defect ( continue ) 零缺陷(續(xù)頁),5) Do you apply 3 Gens? 有沒有做到三 現(xiàn)? a) Genba - Actual place 現(xiàn)場(chǎng) b) Genbutsu - Actual product 現(xiàn)物 c) Genjitsu - Actual fact 現(xiàn)實(shí) 6) Do you use 5 W ( who, what , where, when, why)+1H (how) where rule an

37、d regulation applied? 規(guī)章制度的制定有沒有運(yùn)用5W+1H的方法? 7) Do you have hand free inspection station? 視檢工站,有沒有不需要用手的? 8) Do you have template with navigation or pointer to guide inspection operators? 有沒有模板來輔助視檢作業(yè)？,29,Zero Defect ( continue ) 零缺陷(續(xù)頁),9) Do you apply SDCA,PDCA? and for defects do you apply PDCA? (

38、Problem,Display,Clear & acknowledge) SDCA ( Standardize, Do, Check & Action ) 工作中有沒有運(yùn)用 SDCA、PDCA方法？針對(duì)不良現(xiàn)象，有沒有運(yùn)用PDCA的方法？ 10) Do you have Kaizen Newspaper displayed? 改善活動(dòng)的海報(bào)有沒有展示出來? 11) Do you have 1hr, 2hr, 4hr, 8hr tracking system on the floor? (lead to zero defect) 產(chǎn)線有沒有跟蹤系統(tǒng)，隨時(shí)了解每1小時(shí)，每2小時(shí)，每4小時(shí)，每8小時(shí)

39、的狀況？(向零缺陷靠近) 12) Identify POO & POD to solve the problem 當(dāng)問題發(fā)生時(shí),鑒別出問題的起源(POO)和問題的發(fā)現(xiàn)點(diǎn)(POD)來解決問題. POO=point of origin (where is the first point are the cause problem) POD=point of detection (where the point the problem been captured) 13) Learn how to make the defect to understand root cause 研究如何會(huì)產(chǎn)生不良,

40、 從而了解根本原因。,30,Zero Defect ( continue )零缺陷(續(xù)頁),14) Do you have Auto Jidoka implemented in your line? 產(chǎn)線有沒有運(yùn)用自働化系統(tǒng)？ 15) Talk to the defect to understand the root cause 深入研究不良或缺陷，找出根本原因 16) Duplicate the defect to understand the root cause 多次重復(fù)不良現(xiàn)象的發(fā)生，找到根本原因。 17) Do you have mean test ? - challenge the

41、 current state (Potential Problem Analysis) 有運(yùn)用均值檢驗(yàn)嗎? 對(duì)現(xiàn)狀進(jìn)行尋根究底(分析潛在的問題) 18) Do you use 5 Why analysis to understand the root cause? 有沒有運(yùn)用5個(gè)為什么來分析根本原因？ 19) Landscape concept View from all angles (the mountain) ,Search for the truth (the forest), Look/Focus (the tree), See and fix it (the branch) 全局概

42、念-全方位-遠(yuǎn)看(山)，尋找真相-近觀(森林)，細(xì)看(樹)，深究并解決問題(枝干),31,One Piece Flow 單件流,1) One piece flow 單件流 2) Are the line visibility clear for the supervisor? Std.WIP? Takt counter? Line flow? 對(duì)于管理者來說，產(chǎn)線狀況可視化嗎？有標(biāo)準(zhǔn)WIP?節(jié)拍計(jì)數(shù)器？產(chǎn)線是流動(dòng)的嗎？ 3) One piece flow which like as the eggs inside the chicken should be one by one flow ,b

43、ut not in parallel. 單件流就像母雞肚里的雞蛋一樣是一個(gè)一個(gè)下蛋的，而不是一起下出來的。 4) To shorten the information of defect feedback, one piece flow can reduce our lead time. 為縮短不良現(xiàn)象的信息反饋，單件流可以幫助減少前置時(shí)間。 5) When we set up new layout ,we must consider use the one piece flow. 當(dāng)建立新的生產(chǎn)線布局時(shí)，必須考慮使用單件流。 6) The Ideally layout is one piec

44、e flow according our Takt time. 理想產(chǎn)線布局是按照節(jié)拍時(shí)間的單件流。 7) The layout of “ Y” is better than the layout “ I I I ” series “Y”型布局比“I I I ”型布局好。 8) As the quality feedback is fast and quick action taken. 品質(zhì)反饋速度快，能夠快速響應(yīng)采取行動(dòng)。,32,VSM 價(jià)值流圖,Do you have value stream done on your product? 1. 產(chǎn)線有沒有做價(jià)值流分析？ a) have y

45、ou visualized improvements to the overall production flow, instead of spot improvements to single processes 有沒有把所有產(chǎn)線流程存在改善空間的地方明顯地標(biāo)識(shí)出來，而不是僅標(biāo)示某個(gè)地方。 b) have you created a complete material and information flow 有沒有規(guī)劃出完整的物料流和信息流 c) current state - how the process works today 現(xiàn)狀-產(chǎn)線現(xiàn)在是如何運(yùn)作的 d) future stat

46、e - map shows improvements towards a long term ideal state 未來的情況-價(jià)值流圖表示出改善之后的理想狀況 e) 3D VSM for better visualization (for office kaizen) 3D價(jià)值流圖使流程更加直觀（針對(duì)辦公室改善）,33,VSM ( continue )價(jià)值流圖(續(xù)頁),2) 7 types of flow must be clearly defined : 7大流程必須定義清楚 a) Material Raw物料-原材料 b) Material WIP 物料-在線庫存 c) Materia

47、l - Finish Goods 物料-成品 d) Information - what info is required to move materials, what is the timing 信息-移動(dòng)/搬運(yùn)物料時(shí)需要什么信息，什么時(shí)間點(diǎn) e) People - std.work, Takt time 人流-標(biāo)準(zhǔn)作業(yè)，節(jié)拍時(shí)間 f) Equipment - carts, conveyor, racks, andons, TPM 設(shè)備流-手推車，傳送帶，物料架，andons 異常停線系統(tǒng)，全面生產(chǎn)維護(hù)(TPM=Total Productive Maintenance) g) Engine

48、ering - quality, tooling, programs 工程-品質(zhì)，工具，程序,34,Moonshine Shop 月光工作室,1) Do you have moonshine capability in your plant? 工廠有沒有月光工作室可以自己動(dòng)手制作治具或工具以及時(shí)滿足產(chǎn)能需求的能力.?,35,Golf Score 動(dòng)作評(píng)估表,Are the operators having to bent down? 操作員在作業(yè)過程中需要彎腰嗎? 2) Are operators having to reach high? 操作員的手需要伸到很高的位置(獲取物料或工具)來完成

49、作業(yè)嗎？ 3) Are operators having to twist/turn? 操作員在作業(yè)過程中需要轉(zhuǎn)身嗎? 4) Are operators leaving work area? 操作員在作業(yè)過程中離開工作區(qū)嗎? 5) Are operators needing 3 arms?(hand being used as fixtures) 操作員必須依靠三只手才能完成作業(yè)嗎?（第三只指的是治具） 6) Is the C/T set at 90% or less of the Takt time? 周期時(shí)間是設(shè)定在節(jié)拍時(shí)間的90%還是低于節(jié)拍時(shí)間？ C/T= cycle time， T/

50、T=Takt time 7) Is there rework being done? 返工有沒有在做？,36,Machine 設(shè)備,Are tools suspended above point-of-use? 工具有沒有懸掛在使用點(diǎn)(觸手可及之處)？ 2) Are proper gauges/fixtures used? 所用到的治具是否合適？ 3) Are distances between stations held at minimum? 工站間距離是否是最短的？ 4) Are there 2 or more stations for each operators work? 操作員是

51、否有操作2個(gè)或更多工站？ 5) Is there an aisle way and cart for the water strider? 物料員是否有專用通道和專用推車？ 6) Is there information being sent to the water strider in real time? 發(fā)送給物料員的信息是否實(shí)時(shí)？ 7) Is there an andon lamp installed? 有沒有安裝異常警示燈？( Andon lamp,異常警示燈),37,Machine ( continue ) 設(shè)備(續(xù)頁),8) Is a production control bo

52、ard in place? 產(chǎn)線有沒有看板，易于及時(shí)且清楚地了解產(chǎn)線的狀況? 9) Can you separate internal setup from external setup and externalize internal setup? 你能區(qū)分內(nèi)部信息和外部信息，并使內(nèi)部信息具體化嗎？ 比如：換線時(shí)的內(nèi)部時(shí)間與外部時(shí)間 比如：某些機(jī)器的參數(shù)我們自己可以設(shè)定，有些需要求助于供應(yīng)商 10) Be sure that material flows in one direction. 確保物流同方向，不迂回. 11) Is your machine 6 Sigma Process Ca

53、pability gauge R & R done? 是否有對(duì)機(jī)器做6制程能力分析，重復(fù)性與再現(xiàn)性分析？ 注：Gauge Repetition & Reappearance 量具重復(fù)性與再現(xiàn)性分析。R&R是推進(jìn)6 SIGMA及 QS 9000中常用的評(píng)價(jià)測(cè)定系統(tǒng)再現(xiàn)性及再生性的工具，被廣泛應(yīng)用于尺寸測(cè)定的工具上。 12) Is the Layout for machine and tools by process? 機(jī)臺(tái)和工具的擺放布局是根據(jù)流程來安排的嗎?,38,Machine ( continue ) 設(shè)備(續(xù)頁),13) Are all the stations on wheels? 所

54、有的工站是可移動(dòng)的嗎？ 14) Is the station load based on Takt time? 各工站的負(fù)荷是按節(jié)拍時(shí)間設(shè)計(jì)的嗎？ 15) Are the power cables suspended above the station for easy plug and play? 電源插頭是否是位于工站易于插拔的地方？ 16) Do you have work standard done for tester? 測(cè)試工位有沒有做作業(yè)標(biāo)準(zhǔn)指導(dǎo)書？ 17) Are there systems in place to stop work when abnormal conditi

55、ons arise? Does the supervisor respond in a quick/crude manner? 當(dāng)異常發(fā)生時(shí)，有沒有系統(tǒng)會(huì)報(bào)警并自動(dòng)停止產(chǎn)線作業(yè)？管理人員對(duì)于異常的反映是迅速還是遲鈍/拖延? 18) If a machine is identified as Bottleneck(no flow) create a flow by working on reducing the machine cycle time, manage the machine with eagle eyes or put up SM to create the flow. 如果某個(gè)機(jī)

56、器是瓶頸工位，我們應(yīng)當(dāng)對(duì)該工位特別關(guān)注，研究并降低它的周期時(shí)間或者設(shè)立超市，建立出一個(gè)新的流.,39,Machine ( continue )設(shè)備(續(xù)頁),19) How many of your machines are built in with human intelligence (autonomation)? 有多少機(jī)器是當(dāng)不良或異常出現(xiàn)時(shí)是會(huì)自動(dòng)報(bào)警的? 20) Do you define work standard by andon for tester? 有沒有通過“安燈”系統(tǒng)指導(dǎo)測(cè)試作業(yè)員達(dá)到標(biāo)準(zhǔn)作業(yè)？ (Andon,日語,自動(dòng)停線系統(tǒng)) 21) Do all the fee

57、ders have medical chit attached? 所有的FEEDERS都有表示狀態(tài)的標(biāo)簽嗎? 22) Do you have ECC(Equipment critical checklist) list defined? 有沒有ECC（設(shè)備關(guān)鍵檢查清單）？ 23) Does TPM cover the whole line? No point TPM. It should be AREA TPM. 所有的產(chǎn)線都有做全面生產(chǎn)維護(hù)(TPM)嗎？不是某個(gè)點(diǎn)的維護(hù)，而是整體的維護(hù)。 24) Do you train your operator to act as sensor to m

58、achine problem? 有沒有把操作員培訓(xùn)成對(duì)機(jī)器的異常非常敏感？,40,Machine ( continue )設(shè)備(續(xù)頁),25) Is your feeder color coded based on size? FEEDER有沒有根據(jù)其大小做顏色標(biāo)示？ 26) Do you build the fixture based on :有沒有根據(jù)以下要求來制作治具: a) Reference points 治具的相關(guān)參數(shù) b) X and Y axis X&Y軸坐標(biāo) c) jig - hands free 不需要手來輔助作業(yè),41,Total Productivity Mainten

59、ance ( Skill Matrix )全面生產(chǎn)維護(hù)（技能表）,Zero Knowledge 無相關(guān)知識(shí),Apprenticeship under training 培訓(xùn)中,Full Knowledge 熟練,Full knowledge, able to lead 熟練，能領(lǐng)導(dǎo)他人一起作業(yè),Full knowledge, able to lead, able to train 熟練，能引導(dǎo)他人，并且有能力培訓(xùn)人員,Skill Matrix Good visual management tool to evaluate current organization strength and plan TPM development strategy. 技能矩陣良好的可視化管理工具，用于評(píng)估當(dāng)前機(jī)制是否具有優(yōu)勢(shì)，計(jì)劃TPM發(fā)展戰(zhàn)略。 Example : Break down m