Lean Toolbox

CumminsConfidentialLeanToolbox精益工具箱002LeanToolbox-1LeanTools精益工具•VSM•TAKTtime•TPM•Setupreduction•Visualmanagement•PokaYoke•Kanban•5S•ELS•LeanMetrics•OEE•Kaizen•Heijunka•Cellularmanufacturing•Productionlinebalance•…•价值流程图•TAKT时间•全面生产维护•减少备工时间•可视管理•防错•看板•5S•经济生产批量•运营指标衡量法•总体设备利用率•改善•均衡化生产•细胞式生产•生产线平衡•…002LeanToolbox-2ValueStream&WasteElimination价值流和消除浪费什么是“价值流”？•“价值流”是为客户创造价值所需要的一系列行动。•包括增值和非增值步骤。什么是消除浪费？•在思考任何流程时－工厂、行政管理和工程，通常会发现总的流程交付时间中只有5％甚至更少的时间是增值时间。•传统思维使我们更关注如何加快这5％。•精益生产思维则通过消除浪费，而将注意力放在95％的机会上。我们是如何“浪费”的？•缺陷•过度生产•多余库存•过多的移动•过度处理•运输•等候002LeanToolbox-3ValueStreamMapping价值流图ValueStreamMappingisapowerfultechniquethatallowsustocreatea“BIGPICTURE”visualrepresentationof:价值流图是一种有效的分析工具,通过创造一张“大图表”直观表示:–Allthestepsintheprocess,workingbackfromcustomerdemandtorawmaterial从原材料到客户整个过程中的全部工步,–Theflowofbothmaterialandinformationandtheeffecttheyhaveoneachother物流和信息流相互之间的影响–Thedistinctionbetweenvalue-addedandnon-valueaddedactivity(WASTE)识别增值和非增值的活动–Theeffectalloftheabovehaveonmeetingthecustomer’srequirements以上是否满足客户的要求002LeanToolbox-41.Takt节拍•Theavailableoperatingtime/customerrequirements.可用到的运作时间/客户要求•Establishestheprocesspace.建立流程的步调。•Takttimeisusedtoresourcetheprocess.节拍时间用来分析流程的配备资源。2.Flow流动•‘Product’doesnotstopmovingoncelaunchedintheprocess.“产品”一旦进入流程就不再停留•Interruptionstoin-processworkareminimized.减少在制品在流程中的工作中断。•Vigorouslyrespondtoflowstoppageswithdedicatedsupport.明确支持，积极应对流程中的停顿。3.Pull拉动•Productdoesnotstartuntilimmediatedemandiscommunicated.在无客户需求时不进行生产。•In-processworkdoesnotmoveuntilneededbythenextstep.在制品不流入下一道无需求的流程。4.Improve改进•Continuouslyevaluateandstudytheprocess.不断评估和研究流程。•Everyincrementalimprovementuncoversthenextopportunity.发现下一个不断改进的机会。FourElementsToMakeValueFlow创造价值流的四个要素002LeanToolbox-5TAKTtime节拍时间TAKTtimeisthepaceofproductionneededtomeetcustomerdemand节拍时间—满足客户需求的速度AvailableTimeinWorkDay每天可利用的工作时间TAKTtime=CustomerDemandperDay每天客户的需求Cycletimeisthetimerequiredtocompleteonecycleofanoperation循环(周期)时间—完成一个操作的循环(周期)时间举例:•每天工作时间640´•休息-30´•打扫卫生-20’•吃饭-30’•每天可利用的工作时间560´客户需求•每月26,000units/month•每月工作天数20days/month•每天需求1,300units/dayTAKTTime=560’/1300=0.43’(分)002LeanToolbox-6快速评估当前状态:现有循环时间能满足’TAKT’吗?循环时间1不能满足’TAKT’节拍时间循环时间1能满足’TAKT’,但能力过剩易产生各种浪费节拍时间循环时间≈1OK节拍时间TAKTtime节拍时间问题:对TAKT的影响•设备利用率?•设备准备时间?•瓶颈工序?•…002LeanToolbox-7TAKTtime&Standardwork节拍时间和标准化工作Whentakttimeandstandardworkareknown,wecanclearlyunderstand:在了解了节拍时间和标准化工作之后，我们可以清楚地知道：•howmuchwehavetodo我们需要做多少•howlongtodoit需要多长时间•andbasedonthat,theamountofresources(peopleandequipment)necessarytosatisfyourcustomer.据此，了解满足客户所需要的必要资源有多少（员工和设备）。Wasteeliminationandflowimprovementopportunitiesareidentified.不断发现消除浪费和改进流程的机会。•Qualityisimproved.质量得到改进。•Lead-timeisreducedandpredictableandrepeatable.交付时间被缩短，变得可预测和稳定地重复。•Customersatisfactionisenhanced.客户满意度提高。002LeanToolbox-8TPMisthesystematicexecutionofmaintenancebyallemployeesthroughsmallgroupactivities全员参与的系统化维护ThefivegoalsofTPM5个目的•Improveequipmenteffectiveness改进设备效率•Achieveautonomousmaintenance达到自治化维护•Planmaintenance计划性维修•Trainallstaffinrelevantmaintenanceskills全员相关维护技能培训•Achieveearlyequipmentmanagement早期设备管理TPMworkstoeliminatelosses消除下列浪费•Downtimefrombreakdownandchangeovertimes故障和变换产品的停台时间•Speedlosses(whenequipmentfailstooperateatitsoptimumspeed)速率损失•Idlingandminorstoppagesduetotheabnormaloperationofsensors,blockageofworkonchutes,etc.由于控制电器不正常的运做造成的设备空运行和较小的中断•Processdefectsduetoscrapandqualitydefectstoberepaired为了消除由于废品和质量缺陷的维修而造成的过程损失•Reducedyieldintheperiodfrommachinestart-uptostableproduction减少设备从启动到稳定生产的变化TPM(TotalProductiveMaintenance)全面生产维护002LeanToolbox-9ReduceSetupTime减少准备时间InitialSetupTime原始调整时间Separatesetupintopreparation,andactualsetup,doingasmuchaspossiblewhilethemachine/processisrunning(save30minutes)作好前期的准备工作Movematerialcloserandimprovematerialhandling(save20minutes)就近原则和改进工位器具Standardizeandimprovetooling(save15minutes)标准化和改进工具90min60min45min25min15minUseone-touchsystemtoeliminateadjustments(save10mins)Trainingoperatorsandstandardizingworkprocedures(save2mins)Step1Step2Step3Step513minStep4002LeanToolbox-10Red-linestoppage红色--生产线中断Yellow-callforhelp黄色--寻求帮助Green-normaloperation绿色--运作正常VisualManagement目视管理002LeanToolbox-11Poka-Yokedetectsanerror,givesawarning,andcanshutsdowntheprocess.发现失误,给出警告,并中止流程Poka-Yoke防错WhatisPoke-yoke?什么是防错Amethodthatusessensororotherdevicesforcatchingerrorsthatmaypassbyoperatorsorassemblers.一种运用传感器或其他设备预防和发现错误的方法002LeanToolbox-12SevenGuidelinesofPoka-Yoke防错的7个指导方针1.QualityProcesses-Design“Robust”qualityprocessestoachievezerodefects.质量流程－设计“稳固”的质量流程达到零缺陷2.UtilizeTeamEnvironment-leveragetheteamsknowledge,experiencetoenhancetheimprovementefforts.利用团队的环境－平衡团队的知识，经验以加强改进的效果3.EliminationofErrors-Utilizearobustproblemsolvingmethodologytodrivedefectstowardszero.消除失误－运用一个强有效的解决问题的方法使缺陷趋向于零4.Eliminatethe“RootCause”ofTheErrors-Usethe5Why’sand2H’sapproach消除失误的“根本原因”－使用5W2H的方法5.DoItRightTheFirstTime-Utilizingresourcestoperformfunctionscorrectlythe“first”time.一次合格率－有效运用资源确保一次合格6.EliminateNon-ValueAddedDecisions-Don’tmakeexcuses-justdoit!消除不增值的决定－不要找借口－马上行动7.ImplementanIncrementalCont