Lean简介3.

LeanLeadershipDevelopmentProgramAllrightsreserved1Part3-Lean第三部分-精益Lean和AWAW的Lean计划LeanLeadershipDevelopmentProgramAllrightsreserved2发现–参观工厂Backinlate2006…..FromvisitsofStoneywood,Chartham,Dettingen,Wizernes,Arches,Crevecoeur,Besse,Ivybridge,Dartford,Palalda.我们拥有一个以技术为重点的工厂,参与改善员工人数有限,客户不参与其中.安全第一这一思想做的非常到位专业技能知识扎实,工作主动性强,产品与工艺非常重视.大多数据有记录&主要指示器如OEE,损纸率,污泥量FewtransformationprojectsinitiatedmainlyinP&P.极少转型项目由P&P.开始.Industrialtoolmostlyinadequationwiththemarketserved大多工具与市场提供的一致.Strengths车间基本管理--5次会议,每日事宜,问题解决小组没有利用起来.车间情况与产品质量要求不一致.可视指示器非常有限仅仅只显示月绩效大部分工厂无改进计划WeaknessesversusInd.Stds.工艺程序控制有效?标准化贯彻到位?纸机内部和分切车间WIP的数量?是否有2/3星期库存量?客户抱怨数量..300/每月OEE设备的总体效率低?损纸率高?Observations&SurpriseLeanLeadershipDevelopmentProgramAllrightsreserved3发现–时间文化我们仍旧把目光集中于大批量生产,而非时间上.如果有足够的机动性和资金允许,那么我们有很多东西需要学习/工作.(TotalWIP(40M€)+FG(110M€)verymuchlinkedtothat).工艺效率1%通常~0.1%=(增值时间/完全生产时间)=工艺技术时间/总时间)我们公司有2-4星期的的在制品或者成品库存:1,涂布纸行业,1-2星期的在制品（WIP）库存2,描图纸行业,分切前有1个月的在制品（WIP）库存3,Deco:成品有5-10星期的成品（FG）库存量Observations观察20年前电子卡的增值时间是10分钟,然而需要5天的完全生产时间.30年前汽车锻造工艺的增值时间是30分钟,然而需要30天的完全生产时间目前他们的工艺效率目标是5-20%.我们公司的工艺中增值时间在客户看来甚至少于60分钟.Observations观察LeanLeadershipDevelopmentProgramAllrightsreserved4Leaninitiativesummary.Step1MOSintroductionorManagingExecutionThese3toolsarekeyfoundationsofourManagementOperatingSystem(MOS)作为AW集团精益项目的初始部分，我们将部署三大标准化精益工具：VPM（VisualPerformanceManagement）是车间里显示（目标+跟进）部门或小组团队绩效，区域职责的关键工具PSF（ProblemSolvingFocus），是一个吸引各部门员工参与的横向团队，专为解决终端客户抱怨和消除当前隐患……并且也能提升绩效/持续改善质量。MIP（MacroImprovementPlan）要点：寻找改善KPI的机会并且计划和采取联合行动。跟踪有效行动的执行情况一直到得到最终的结果。LeanLeadershipDevelopmentProgramAllrightsreserved5VisualManagementPerformanceontheshopfloor.车间绩效可视管理KPI8StepsTeamCornerActionPlanDelegationofresponsibilitiesTargetsAreaTeamTransparencyVisualPerformanceManagementVPMLogicTreePI&CICyclesleaninitiativesummary精益精要VPMintroduction介绍VPMLeanLeadershipDevelopmentProgramAllrightsreserved6聚焦问题解决,好的Kaizen是通过具有强烈关注度的持续改善团队来进行.OTIF,OEE,Sales,Claims,FGInv.…KPI8StepsTeamCornerActionPlanProblemSolvingFocusPSFToolsTransversalteamRootcauseanalysisLogicTreePI&CICyclesleaninitiativesummary.PSFintroductionLeanLeadershipDevelopmentProgramAllrightsreserved7leaninitiativesummary.MIPintroduction宏观改进计划:识别最佳改善点（$value）,并执行管理.(Thearmyatwork!)MILLKPITREEvalueunitKPI:KbaseH-1MBtargetHMTMillBaseContributorsBaseTargetResultsTargetcoveredM1M2M3M4M5M6Mi%1C1BTKPIKMB2DeptX3DeptY4CnTOTALMBMTRTRT/MiTForecastedActionPlanSuiviPland’action:XsiterminéeN°DésignationO/NResponsableDélaiLancéeAvancéeTerminéeAbandonnéeKPI8StepsTeamCornerActionPlanMeasureKPIPlantheactionsLinkactionstocostTrackresultsMacroImprovementPlanMIPLogicTreePI&CICyclesLeanLeadershipDevelopmentProgramAllrightsreserved8leaninitiativesummary.MOSintroductionHourQuarterVisual5’meetingVisualMgt&PerformanceDayWeekMonthIP5SProductionmeetingQ1StandardsdefinedQ2StandarddeploymentTraining/ActionsH2DeploymentCtd.1stResultsLeanLeadershipDevelopmentProgramAllrightsreserved9HourQuarterStandardProblemSolvingMethodology解决问题标准方法DayWeekMonthQ1StandardsdefinedQ2StandarddeploymentTraining/ActionsH2DeploymentCtd.1stResultsForallTechno.OperatorCrossFunctionalTeamFocusonmostdifficultsubjects.+Visualboard.leaninitiativesummary.MOSintroductionLeanLeadershipDevelopmentProgramAllrightsreserved10HourQuarterVisual5’meetingStandardMacroImprovementPlanDayWeekMonthIP5SProductionmeetingQ1StandardsdefinedQ2StandarddeploymentTraining/ActionsH2DeploymentCtd.1stResultsGlobalObjectivesdeployment.€KPIimprovementtargets.KPIParetoscontributorsContributorsTargetedactions.leaninitiativesummary.MOSintroductionLeanLeadershipDevelopmentProgramAllrightsreserved11HourQuarterVisual5’meetingForallTechno.OperatorCrossFunctionalTeamFocusonmostdifficultsubjects.+Visualboard.GlobalObjectivesdeployment.€KPIimprovementtargets.KPIParetoscontributorsContributorsTargetedactions.VisualMgt&PerformanceStandardProblemSolvingMethodologyStandardMacroImprovementPlanDayWeekMonthIP5SProductionmeetingQ1StandardsdefinedQ2StandarddeploymentTraining/ActionsH2DeploymentCtd.1stResultsleaninitiativesummary.MOSintroductionLeanLeadershipDevelopmentProgramAllrightsreserved12leaninitiativesummary.MOSintroductionMOSKPI8StepsTeamCornerActionPlanDelegationofresponsibilitiesTargetsAreaTeamTransparencyMeasureKPIPlantheactionsLinkactionstocostTrackresultsMacroImprovementPlanMIPVisualPerformanceManagementVPMProblemSolvingFocusPSFToolsTransversalteamRootcauseanalysisEfficiencythroughStandardsContinuousImprovementWasteeliminationLogicTreePI&CICyclesIP5SLeanLeadershipDevelopmentProgramAllrightsreserved13Whywechosethese3tools?我们为什么选择这三个工具?LeanLeadershipDevelopmentProgramAllrightsreserved14我们需要-培训员工-下达明确的目标-指导任务的执行-控制结果我们希望着重管理-客户-持续改善-利用有效的工具三点理由:我们需要工作我们希望我们的工作能为客户创造价值LeanLeadershipDevelopmentProgramAllrightsreserved15leaninitiativesummary.MOSintroductionnextsteps让我们的所有工厂都融入到这些标准化中去,并扩展我们的精益生产管理操作系统MOSKPI8StepsTeamCornerActionPlanDelegationofresponsibilitiesTargetsAreaTeamTransparencyMeasureKPIPlantheactionsLinkactionstocostTrackresultsMacroImprovementPlanMIPVisualPe