精益生产基础0602

GBE-KPO-4-003-00SmallGroupActivities(SGA)DocumentRevision:00.Date:November12,2007.精益基础LEANTOEXCELLENCE2目录Overview&Scope概述与范围ABriefHistoryofLean精益历史简介TheFlextronicsLeanEnterprise(FLE)伟创力精益生产屋WasteElimination消除浪费ValueStreamMapping(VSM)价值流程图5S&VisualManagement5S及可视化管理SuperMarket超市LEANTOEXCELLENCE3概述&范围LeanManufacturingisagenericprocessmanagementphilosophyderivedmostlyfromtheToyotaProductionSystem(TPS)butalsofromothersources.Itisrenownedforitsfocusonreductionof‘SevenWastes’inordertoimproveoverallcustomervalue.精益生产是一门流程管理哲学，主要来自于丰田制造系统（TPS）。其焦点在如何减少“7大浪费”以增加客户价值。Toyota'sachievementmadeLeanahottopicinmanagementscienceinthefirstdecadeofthe21stcentury.丰田的成功使Lean成为21世纪前10年管理科学的热点。LeanManufacturingcanbedefinedas:Asystematicapproachtoidentifyingandeliminatingwaste(non-value-addedactivities)throughcontinuousimprovementbyflowingtheproductatthepullofthecustomerinpursuitofperfection.Lean可以如此定义：“从客户拉货到产品源头的整个流程不断改善，识别并消除浪费（无价值活动），使之日臻完善的一种系统方法”InfoSource:*LEANTOEXCELLENCE4执行者必须要知道的98%ofOrganisationsthatengagewithLean,Fail!!WHY???LeanisHARD!!!98%的企业推行过Lean,但失败了，为什么？因为太困难！Excerptsfromthebook“LeanMachines”LeanThinking精益思想It’sapeopleissue.That’swhyit’ssohard.Gettingpeopletochange–todothingsdifferentlythantheyhavedonethem–isreally,reallyhard.ArtByrne,CEOWiremold正是人的原因使它如此困难，让人去改变以前做事的方式—-确实很困难。IfacompanyisreallymaniacalaboutLeanittakestwotothreeyearstogofromkindergartentofirstgrade.That’showtoughitis.MarkDeLuzio,architectoftheDanaherBusinessSystem,Danaher如果一家公司已经真正开始推行Lean,那要花上2，3年的时间才能达到初级阶段。那是多么的困难！LEANTOEXCELLENCE精益历史简介LeanHistoryTimeline精益生产演变历史TheOriginsofLeanManufacturing精益生产的起源LEANTOEXCELLENCE6精益演变历史FatherofManagement科学管理学之父FatherofMotion-TimeStudy动作-时间研究之父FatherofAssemblyLineConcept组装线概念之父IndustryQualityTransformation工业质量转变BirthofTPS*/LeanConceptsTPS*/Lean概念诞生“TheMachineThatChangedTheWorld”改变世界的机器“LeanThinking”精益思想LEANTOEXCELLENCE7LeanManufacturinghasits’rootintheToyotaProductionSystem(TPS).SeveralindividualsatToyotawereinstrumentalindevelopingandsystematizingTPS.Amongthemostimportantwere:精益生产来自于丰田制造系统(TPS).几位丰田人对其进行了发展和系统化，其中贡献最大的：SakichiToyoda丰田佐吉(1867~1930)•Japan’s“KingofInventors.”日本“发明家之父”•HisconceptofJidoka(autonomation)isoneofthefoundationalprinciplesofTPS.他的概念jidoka(自动化)是TPS的几项基础原则之一•FirstappliedtoToyodaPowerLoomequippedwithanewweft-breakageautomaticstoppingdevice(developedin1896).最初应用在自动织布机上，只要有断线就自动停机(发明于1896年)•World‘sfirstautomaticloomwithanon-stopshuttle-changemotion,theType-GToyodaAutomaticLoom(developedin1924).发明了世界上第一台不停线换梭自动织布机，G型自动织机(发明于1924年)•FoundedToyotaMotorCo.in1937.1937年创立丰田汽车公司Formoreinfo::精益生产的起源LEANTOEXCELLENCE8KiichiroToyoda丰田喜一郎(1894~1952)•Sakichi’sson.丰田佐吉之子.•TheTPShasevolvedthroughmayyearsoftrialanderrortoimproveefficiencybasedontheJust–in–Time(JIT)conceptsdevelopedbyKiichiroToyoda,thefounder(andsecondpresident)ofToyotaMotorCorporation.TPS一直在准时制生产的基础上不断试验去提升效率，而准时制生产就是由丰田喜一郎发明的，丰田汽车的创始人。•InheritedSakichiToyodaphilosophy,setouttorealizehisbeliefthat“theidealconditionsformakingthingsarecreatedwhenmachine,facilitiesandpeopleworktogethertoaddvaluewithoutgeneratinganywaste“.继承了佐吉的丰田思想，他坚信”最理想的状态就是人，机，设备最佳配合增加价值，不产生任何浪费”•Conceivedmethodologiesandtechniquesforeliminatingwastebetweenoperations,betweenlines,betweenprocesses.TheresultwasthesocalledJITmethod.他一直思考在操作，线体和流程之间消除浪费最佳的方法，即“准时制生产“•Drawingonhisexperienceofintroducingaflowproductionmethodusingachainconveyorintotheassemblylineofatextileplant(completedin1927)withamonthlyproductioncapacityof300units.他将流水线生产的经验应用于纺织厂，链条式传送带使月产量达到300•IntroducedthismethodintothebodyproductionlineatToyotaMotorCo.,Ltd.‘sKoromoPlant(presentdayHonshaPlant),completedin1938.将这种方法引入到丰田汽车公司车身生产线,1938年完成•HestudiedFord’sproductionsystemandadaptedittothesmaller,morediverseJapanesemarket.他研究了福特生产系统并把它应用于更小，更多变的日本汽车市场Formoreinfo::精益生产的起源LEANTOEXCELLENCE9精益生产的起源EijiToyoda丰田英二(1913~)•ByensuringthoroughimplementationofJidokaandtheJust-in-Timemethod,EijiToyodaincreasedworkers‘productivityinaddingvalueandrealizedtheToyotaProductionSystem,whichenabledToyotatocompetehead-onwithcompaniesinEuropeandtheU.S.通过将Jidoka和JIT彻底应用,提高了工人的效率，TPS让丰田公司能够与欧美公司竞争。Formoreinfo:大野耐一(1912~1990)•WithstrongbackingfromEijiToyoda,TaiichiOhnohelpedestablishtheToyotaProductionSystem,andbuiltthefoundationfortheToyotaspiritof“makingthings”by,forexample,creatingthebasicframeworkfortheJust-in-Timemethod.得到丰田英二大力支持，他建立了TPS,并创建了“做事”的精神，创造了JIT的基础。•Knownasthe“ArchitectofTPS.”以“TPS大师”著称•SystematizedJidoka,JIT,standardizedworkandkaizenintowhatwenowknowasTPS.将Jidoka,JIT,标准作业和改善融入TPS系统•Fatherofthesupermarketsystemofinventorycontrol.超市库存管理之父Formoreinfo:://en.wikipedia.org/wiki/Taiichi_OhnoInfoSource:htt