精益生产工具

TenantsofSinglePieceFlow•DoNotMakeDefects•DoNotPassAlongDefects•DoNotAcceptDefectsZeroDefects=0DefectsNot3.4ppmQuality,Quality,Quality…DefectsaretheWorstKindofWaste7TypesofWaste•DefectiveParts•OverProduction•Inventory•Motion•Transportation•Waiting•ManualTouchesBatchSinglePieceFlowFrom:TheToyotaProductionSystemBuildingQualityintotheProcessSinglePieceFlowThenextprocessisthecustomer…neversenddefects!SampleInspectcatchesDefecttooLate•WhenyouFinallyFindaDefect•Howmanymoredoyouhave?•Wherearetheyintheprocess?•WhatistherootCause?SinglePieceFlowcatchesDefectsimmediately•WhenyoufindaDefect•Youonlyhaveone•Youknowwhereitoccurred•YouCanfind/ResolvetheRootCauseimmediatelyCheck,Do,VerifyCheck-Thepreviousoperatorswork.Do-Yourwork.Verify-Thatyoudidyourworkcorrectly.ProcessInspectTransportTransportationisintegratedintotheproductionprocessviaautomatione.g.,movinglineProcessInspectProcessInspectTransportProcessInspectTransportationisintegratedintotheproductionprocessviahumanconveyancee.g.,Chaku-ChakuBuildingQualityintotheProcess2waystoperformSPFThenextprocessisthecustomer…neversenddefects!Check,Do,VerifyGetsyouintoPartsPerMillionquality-Whenyouverifyyourwork,youcatch1flawin100parts.Thenextpersonchecksyourworkandcancatch1/100sothat’s1/10,000.ThenthatpersonVerifiestheirworkandcancatch1/100.That’s1/1,000,000errorsthatcangetthrough.Check,Do,VerifyEveryCustomerinaProcesshas:-arighttoexpectperfectmaterial-anobligationtoinspectthematerialbeforeuse.-anobligationtoinformthepreviousstepintheprocessofanyproblem.-anobligationtostoptheprocessuntilanyproblemhasbeenresolved.SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess.ThisisachievedbyestablishingataktTime,developingstdwork,andswip.ThepremiseisthatanOperatorcanonlyworkononepieceatatime,andperformsaQuickqualitycheckontheCTQsoftheprocessbeforemovingTheparttothefollowingprocess.Ifadefectisdetected,JidokaIsenacted…thelineisstopped,andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurence1.Takttime2.StdworkFlow:work(process)thatisdoneinconjunctionwithorsimultaneoustotransportationOnePieceFlowTheproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis/hersupplierandcustomerinthechain.Asonepersonfinishestheirelement,sodoall.Workisthenmoveddownthelinesynchronously.Everypersonisempoweredtostoptheproductionprocessifarejectisspotted.OrganizationAreaSupervisorNew/RevPageofDateProductionLinePartNumberPartNameOperatorStandardWorkSheetTo:TurnsDPU'sScopeofOperationsFrom:QualityCheckSafetyPrecautionStandardWork-in-Process#LotsofStandardWork-in-ProcessTakt/RateTimeTotalManual&TravelTimeMan/TravelTimeOperatorEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeTubingCFMCellFernBissonnetteCell6AllPartsAllTubes11Mech.CleanRawmaterialWeld100/DayFPIX-RayEDM2ndQtr.‘01EndFinishOutsideCell27-avglot=6FlexFinishedGoodsACTIONWORKOUTgGEMSGlobalProductionSystemThenextprocessisthecustomer…neversenddefects!Check,Do,VerifyOnePieceFlowYourcustomeristhenextstepintheprocess.Givetoyourcustomer,exactlywhattheyneed(1item),exactlywhentheyneedit,doneperfecteverytime.Tenantsof1pcsFlow•DoNotMakeDefects•DoNotPassAlongDefects•DoNotAcceptDefectQuality,Quality,Quality…DefectsaretheWorstKindofWasteSystemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals,intheexactstandardizedamountneeded.PullProductionMethodology&SequenceDefinitionRefMaterialPresentationtrainingforexplanationonSupermarketdefinitionanduseEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeMech.CleanFlexEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeMech.CleanFlexParts13456EndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeMech.CleanFlexEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeMech.CleanFlex789102AssemblyLineCellorChaku-ChakulineSupplierMaterialInformationSupermarketEmptycontainerFullcontainerLegend1Sequence/TimingPullProductionMethodology&SequenceJITJidokaeGPSforGPCHeijunkaLevelLoadingSequencing•Findingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacity•Adjustingaproductionscheduletomeetunexpectedchangesincustomerdemand•OrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitemstakenfrommemoryJoggerLeveledproductionmeansloweringthepeaksamongthedailyproductionvolumesasmuchaspossibleandmakingtheproductionflowsmoothandunflucuating.Ingeneral,themorefluctuationsyouintheproductionflow,themoremudayouenduphaving.Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand.Iftheproductionlineproducesonlyasingleproduct,youmaybeabletoreducemudasimplybyadjustingtheproductionscheduleandstaffinglevel.Butifyouwanttoproduceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline,youhavetodotheaveragingnotjustinvolumebutinkindsaswell.Thiswayofaveragingbothvolumeandinkindsiscalledproductionlevelingorheijunkai