标准化作业简介

Page1KeytoStandardization标准化作业简介Page2Demandvs.Schedulevs.OutputRightparts,righttime,rightquantityInstalledCapabilityVs.OutputResourceutilization(ManpowerandEquipment)LogicalKaizenApproach1.SystemEvaluation2.Op.SystemChange1.Pre-conditions-Supermarkets-SMED:Shortchangeovertime2.Simplification(Process/Product)-Kitbreak-Kitprocessimplementation3.Connections-Order-Production.(Orderkitting,ordercutting)-PullSystem.(Components,Kit’s,cutleads)-DeliveryRoutes.(Wires,components)4.StandardizedWork-StaticSOS(W.C.T…)-MovingLineSOS-Qualityimprovement5.Improveresourcesutilization-Motionkaizen-SigmaET,CT-OA....Qual.Vol.Cost3.PerformanceImprovementPage3SOSKaizenProcedureWait等待Walk走动Work工作ValueAdded增值NonValueAdded不增值TT需求节拍时间Increase增加Decrease减少Increase增加Decrease减少BringAnotherwork加入新工作Value-added(VA)work:Anyprocessthataddsvaluetoproduct,whatthecustomeriswillingtopayforNon-valueadded(NVA)work:Anyprocessthatdoesnotaddvaluetotheproduct,whatthecustomersisnotwillingtopayforPage4•确定目标Identifythegoal•观察和测量ObserveandMeasure•寻找改善机会FindKaizenOpportunity•实施改进活动Improvetheactivity•实施标准化Implementstandardwork•改善绩效KaizenResultafterimprovementSOS改善步骤KaizenstepsofSOSPage5SOS改善步骤KaizenstepsofSOS•确定目标IdentifythegoalPage6确定目标IdentifythegoalAlwayslateforabout2minutesX先生总迟到2分钟Gettingupat5:00a.m.5点起床Needstoleavethehouseat5:145:14要离开TaktTime(T.T.)=840“14minX60sec目标Goal当前表现CurrentStatusPage7•观察和测量ObserveandMeasureSOS改善步骤KaizenstepsofSOSPage8Splittheprocessinto12elements:划分12个要素1.Getup起床2.Cleanteeth刷牙3.Shave刮脸4.Takeashower洗澡5.Dryhair吹干头发6.Getdressed穿衣服7.Makecoffee做咖啡8.Takecoffee拿咖啡9.Maketoast做面包10.Taketoast拿面包11.Getthecarkeys拿钥匙12.Putonshoesandcoat穿鞋和外套Processname:Getupanddressed过程名称:起床并穿衣服确定要素IdentifytheelementPage9WhatisaJobElement?什么是工作要素AjobelementcontainsONLYworkingtime.(CyclicJob)一个工作要素仅包含工作时间(循环的工作)Assemblytime装配时间Pickupparts拿取物料Pickupassisttools拿取辅助工具Itdoesn’tcontainanywalkingtimeandnon-valueaddedworkelementssuchas:不包含走动时间和非增值工作要素adjustmentjobs调整rework返工repair返修qualitychecks质检Page10Usethelowestrepeatabletime用最低可重复时间DeterminetheStartingpointandFinishingpoint确定起点终点Fillintheworkelementsandcapturethewalking1step=0.5sec填入工作要素并确定走动700”860”测量要素和走动MeasureworkelementsandcapturethewalkingPage11840”标准化作业表StandardizedOperationSheet•要素发生在什么点上Whereistheelement?•要素与要素间的连接Connectivitybetweenelements•工位布局LayoutPage12Cycletimeis980”OvercycleWaitingtime7070820CT=820+160160TT840”工作合并表StandardizedWorkCombinationTablePage133.Measureallelementtimes测量所有要素时间5.CreatetheSOSsheet做标准操作表6.CreatetheWorkcombinationtable做工作合并作表1.……2.….3.……....Sequencetograsptheprocessinformation:2.Identifytheelementsoftheprocess确定工作要素4.Establishallelementssheets做工作要素表ManMachine1.……2.….3.……....1.Graspingthefacts抓住事实StaticSOSPage14SOS改善步骤KaizenStepofSOS•寻找改善机会FindKaizenOpportunityPage15123456125436OLDSOSNEWSOS-Compactlayout-LesswalkingT/mmove-mentM/Cmove-mentMat.move-mentOLDWCTNEWWCTIneveryprocesstheworkingsequenceisconstructedofthreemajormovements–每个工序的工作次序由三个主要的运动构成1.Teammembermovement人员的移动2.Equipmentmovement设备的移动-processing加工-conveyortransfer输送带传动-ejectoretc.打出机等3.Materialmovement(processsequence)物料的移动Toachieveidealcondition,thesethreemovementsmustbeorganized要达到理想的状态,必须对这三种移动进行整合WhatcanweseefromtheSOSandWCT?从SOS和WCT上能看到什么?Page16Analysis:HowdoweusetheStandardisedWorkcharts?分析:我们如何使用标准化工作表Page17时间测量表TimeMeasurementSheetPage18时间测量表告诉我们什么WhatdoweknowonlinebalanceWall目标Page19工作要素表告诉我们什么WhatcanweknowonJobelementsheet观察Observe•操作顺序Operationstep•物料摆放位置MaterialArrangement•移动MovementPage20SOS表告诉我们什么WhatcanweknowonSOS观察Observe•操作顺序OperationStep•物料位置MaterialArrangement•走动Walking•Cell布局CellDesignPage21WorkAreaMap告诉我们什么WhatcanweknowonWorkAreaMap观察Observe•操作顺序OperationStep•走动Walking•物料位置MaterialArrangementPage22WCT告诉我们什么WhatcanweknowonSWC检查Check•Wholethecycle•要素时间Elementtime•走动WalkingPage23SOS改善步骤SOSimprovementStep•实施改善活动ImprovetheactivityPage24840”Processtime工序时间Cycletime工作循环时间Machiningtime机器时间TT980”MisterXneedstoachieve840”X先生要达到840秒Target目标Actual实际Manualtime手动时间ATT=CTPage25123567849121110Ideais……想法是1.Relocatethekeys重定钥匙的放置位置2.Changethelayout改变家里的布局3.Changethesequence调整顺序4.Usedoubleelectricaloutlet装双插座的电源5.Combinethemachiningtimewiththemanualwork将人的工作和机器的时间合并WhatshouldIdo??12345A.T.T.Howcanweimprovethemorningprocedure?如何改善过程?Reducewalking,减少走动Reducewaiting减少等待Page26•Correction•Overproduction•MaterialMovement/conveyance•Motion•Waiting•Inventory•Processing7TypesofWastes7种类型的浪费•改正•过度生产•物料的移动和运输•动作•等候•库存•加工过程的浪费Page27Definition:•ProducingMoreThanNeeded•ProducingFasterThanNeededWasteofOverproduction过度生产的浪费定义:•生产超过了需求•生产快过了需求Page28Characteristics特点:•InventoryStockpiles库存积压•ExtraEquipment额外的设备•ExtraStorageRacks额外的仓储架•ExtraManpower额外的人力•AdditionalFloorSpace更多的工作场地Causes原因:•IncapableProcesses过程能力低下•LackofCommunication缺乏交流•LongToolChanges工具更换周期长•LowUptimes计划工时利用率低•LackofStable/ConsistentSchedules缺乏稳定/连贯的计划安排WasteofOverproduction过度生产的浪费Page29Definition:ReworkofaProductorServicetoMeetCustomerRequirementsWasteofCorrection改正的浪费定义:为满足客户的要求，对产品或服务进行的返工。Page30Characteristics特点:•ExtraTimeRequiredbyWorkforcet