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P.1„2I1I3I15I3I1000/500”D”500”T”26325131.534I5I5I2I2I=6C/O=20minC/T=150SC/O=2minC/T=501SC/O=0C/T=395SC/O=0C/T=60SC/O=0C/T=60SC/O=0=5C/O=15min6015050139514541.53LT=27.5VA=18.4min=0.14%P.2-+=75TAKT=132SC/O=07C/O5min=1+23C/T=120S=110120924111LT=3VA=17.6min=1.28%SAITC„——1/2„——1/3~1/2„——1/10„——1/2„——1/4„——3SAITC„„P.3SAITCHenryFord'sConceptofProductionSynchronizationandVerticalIntegrationDr.Deming'sConceptofQuality&LeadershipAlfredSloan'sConceptofMarketStairsteppingAmericanSupermarketConceptofReplenishmentToyotaProductionSystemLeanOrganizationSAITC„„„„„„SAITC„‹‹‹‹‹„„P.4SAITCSAITC1=-SAITC„=+„„—=„—=P.52••3Waste••1)WasteofCorrection2)WasteofOver-Production3)WasteofMotion4)WasteofMaterialSEVENTypesofWaste)Conveyance5)WasteofWaiting6)WasteofExcessInventory7)WasteofOverProcessingP.6EFFECTSOFWASTEONPEOPLECausesphysicalfatigueCausesemotionalfatiguegIncreasesfrustrationsIncreasesstressCausesyoutoblameothersStealsyourtime41010101001012010120=209100=518P.766SAITC00P.8TPM5SSAITC?JustInTime„RightMaterialRightTime„RightTime„RightQuantity„RightQuality„RightPlaceSAITCP.9SAITC„25SAITCSAITC„„P.10SAITC„//„„„/SAITC„„„„„„„/„„……SAITCP.11SAITC„„„„„„„„U”„SAITC——‹P.12SAITC——‹SAITCAAAAAAAAAAACCCCABBBBBBBBSAITCABABACABABACABAB„ABACABABACABABACP.13SAITC1000600400()Month1Month2Month3Month4CFM56CF6-6CF6-80CWeek1Week2Week3Week437250150100250150100250150100250150100503020503020503020503020()()Week1Week2Week3Week4CFM56CF6-6CF6-80CDay1Day2Day3Day4CFM56CF6-6CF6-80CSAITCABCaaaaaaaAAAAAABCABACAbbbccaaaaaaaaaBbbbbccbCCAAAAABBBCCABACAACABABABBSAITC„„„„.„.„„.„‹‹‹P.14SAITC„=100%=1-MaterialPullSystemAmethodofcontrollingtheflowofresourcesbyPullSignalsPullProcessDefinition:flowofresourcesbyreplacingonlywhathasbeenconsumed.MaterialAtOperatorManpowerWASTEMaterialPushSystemResourcesareprovidedtoDefinition:theconsumerbasedonforecastsorschedules.P.15SAITC„„FIFO50PullSignalsNUMBERQUANTITYWIDGETADDRESSEMPTY123456789SAITC““ABP.16••(FIFO)•••()()FIFOFIFO••••••••••P.17TPM5SSAITCSAITCP.18SAITCXXSAITCPoka-yoke„ShigeoShingoPoka-yokePoka-YokeShigeoShingoSAITCPoka-yoke„Poka-yoke„Poka-yoke1.2.P.19SAITCPoka-yokePoka-yokeSAITCCHECKSHEETxxxxxxxxxxxxxxxxxxxxxxxxxxxxABCDEPARETODIAGRAMHISTOGRAMFLOWCHARTLINEGRAPHCONTROLCHARTSCATTERDIAGRAM............TPM5SP.20••••••••••ContinuousImprovement“P.21‹‹‹••••••••••P.22••SHORTCONVEQUIPFULL54123EQUIPQ1Q2Q310131211FPSFPSFPSFPS2=5SOrganizationalDevelopment===ChangeInThinkingVIP#1TEAMMEMBER#1TeamMemberDirectorsManagersSupervisorsOperatorsMgrGroupLeaderTeamLeaderTeamMemberP.23LeadershipMindChange80%20%20%80%&!!!EmployeeMindChange••••••!TeamWorkTeamWorkP.24TPM5STPM5S5S3--Seiso2--Seiton1--Seiri5--Shitsuke4--Seiketsu5S/P.25••55SS••••TPMTPM••••••••••••,•••••••P.26123457667891011126666VisualManagementVisualManagement‹Thefollowingstepsarenecessaryforimplementingvisualmanagement:1)Definetheneed1)Definetheneed2)Decidetypeofvisualization2)Decidetypeofvisualization))SetstandardsSetstandards))EasytounderstandEasytounderstand))EasytoseeEasytosee))ProvidesimportantinformationProvidesimportantinformation3)Implementandfollow3)Implementandfollow--upupP.27••55SS••••TPMTPM••••••••••••TTotalotalPProductiveroductiveMMaintenanceaintenance„:,TPMTPMTPMPreventivePredictiveCorrectiveBreakdownMaintenancePreventionP.28PreventiveMaintenancePreventiveMaintenance„¾¾¾¾PreventiveMaintenance(PM)PreventiveMaintenance(PM)„„PMPM¾¾¾,,,)())PreventiveMaintenancePreventiveMaintenance„„PMPM,„,P.29MaintenancePreventionDesignMaintenancePreventionDesign„(MP)„„,,//MPMTBFMPPMPredictiveMaintenancePredictiveMaintenance‹¾¾¾¾¾¾,,PredictiveToolsP.30‹99,,,,CorrectiveMaintenanceCorrectiveMaintenance„¾¾,¾BreakdownMaintenanceBreakdownMaintenance„P.31••,••••,••••••••••••TPMTPMABCCP.325:O.E.E.=0.87x0.50x0.98x100=42.6%OOverallEEquipmentEEffectiveness=/Availability=AvailableTime-Downtimex100AvailableTimeAvailability=460minutes-60minutesx100=87%460minutesExample:PerformanceRate=IdealCycleTimexProcessAmountx100OperatingTimeExample:PerformanceRate=0.5minutes/unitx400unitsx100=50%400minutesQualityRate=ProcessedAmount-DefectAmountx100ProcessedAmountExample:QualityRate=400units-8unitsx100=98%400minutesOEE1.6.5.3.4.2.&/P.331.2.103.90%95%4.5.(100ppm)6.99%0.90X0.95X0.99X100=85+%982134567&&&&•––––•P.34•–––•„¾¾()¾¾¾...•••••••••P.35••––AnnualPMPlanPM-AutonomousMaintenance..................P.36••55SS••••TPMTPM••••••••••••)))),,P.37••StandardizedWork•–»»»P.38SAITCTaktTime„„„112-,TaktTime=()SAITCCycleTime=231171152318446+11314T.T.=133A.T.T.=12011711820175123SAITCActualTaktTimeTime8060T.T.76C.T.A.T.T.70A6040200Non-valueaddedValueaddedP.39StandardizedWorkStandardizedWorkABCDEFG)),,ABCDEFGHIJKLMNStaticSOS-CombinationTable11223-34455SW-ON68.074.7P.40JISJOBINSTRUCTIONSHEET„„„„„„„ATT=577045B30A3035B30C30DEΣOCT===ATT572103.7P.41T.T.ATT5156395439ABCDA.T.T.A.T.T.??135246A.T.T.„„„100%P.42••55SS••••TPMTPM••••••••••••SAITC„„„„„„7P.43AttachReleaseWorkpiecePlateCAMSPRINGSTOPSpring-loadedcheckpinstopsinsidediameterClampFastenPEAR-SHAPEDTOOLING“insidediameteroftoolingAttach&RemoveU-SLOTCOLLARStoptopreventcollarfromrotatingU-sl

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